As digital demand rises, data centers are under pressure to increase efficiency while reducing their environmental footprint. These facilities power cloud computing, streaming, and countless online services, however, their high energy and water consumption, especially for cooling, raises sustainability concerns. Traditional cooling methods are often energy-intensive, driving up costs and carbon emissions. 

To address these challenges, developers of new data centers are looking for more efficient cooling strategies like cold and hot aisle containment. This airflow management system improves cooling by preventing hot and cold air from mixing. By containing airflow, data centers can reduce energy waste, lower cooling costs, and improve overall system reliability. Integrating polycarbonate panels of twinwall and multiwall sheets into these containment systems further enhances thermal efficiency, helping facilities achieve significant energy savings while improving sustainability. 

Improving Airflow with Hot Aisle Containment 

Cooling systems account for nearly 40% of a data center’s total energy consumption, making them a major contributor to operational costs and environmental impact. Because servers generate considerable heat during continuous operation, effective cooling is essential for maintaining performance and preventing downtime. 

Cold and hot aisle containment systems specifically improve thermal management within these environments. They do so by organizing the data center racks into alternating rows of hot air exhaust and cold air intakes. This structured configuration enables targeted temperature control by directing cooler air to server inlets while segregating warmer exhaust air from the cooling zone. 

By improving airflow efficiency, aisle containment systems help reduce cooling demands and overall energy usage. These systems offer key advantages, including: 

• Improved thermal regulation 
• Reduced energy usage and operational costs 
• Increased equipment reliability 
• Support sustainability goals 

As one of the largest expenses for data centers, reducing energy use not only supports environmental goals but also frees up resources for other investments like infrastructure upgrades or emerging technologies. 

Comparing Different Types of Containment Systems

Legacy data centers often rely on less efficient cooling setups, leading to higher energy usage. In these configurations, rows of servers typically face the same direction with their fronts aligned. Cooling system fans pull heat generated at the front of the servers and expel it as exhaust air. This heated air then circulates into the next aisle, where it mixes with cooler intake air, raising the overall temperature and forcing the cooling system to work harder to maintain stable conditions. 

Hot and cold aisle containment addresses this inefficiency by organizing server racks to control airflow more effectively. In this setup, the backs of servers, which expel hot air, face each other to create a “hot aisle,” while the fronts of servers face each other to form a “cold aisle.” Cool air flows into the cold aisles and servers draw it directly into their front panels. Heated exhaust air from the hot aisle is isolated and directed back to the cooling system without mixing with the cool intake air, reducing the overall cooling load. 

Enhancing Efficiency Through Innovative Hot and Cold Aisle Containment Techniques 

At the core of cold and hot aisle containment is the use of physical barriers that prevent the mixing of hot and cold air. The use of advanced materials like polycarbonate sheet has taken these systems to the next level. Polycarbonate, known for its excellent insulation and fire resistance, is seeing increased use in containment structures to improve airflow control and thermal efficiency. 

Many data centers also use raised flooring systems to further improve airflow. In these setups, computer room air conditioning (CRAC) units push cooled air into the subfloor. This air then rises through perforated floor tiles into the cold aisles, where the servers draw it in. Hot air expelled into the hot aisle rises to the ceiling and flows back to the CRAC units for re-cooling. This closed-loop system helps keep stable temperatures, reduce energy waste, and improve cooling precision. 

Considerations Before Implementing Cold and Hot Aisle Containment 

While cold and hot aisle containment is well-suited for most new data center construction and expansions, converting an existing facility can be more complex and costly. Reconfiguring server racks may require downtime, and realigning power pathways could require the expertise of an electrician. Additionally, the new airflow dynamics will require adjustments to the data center's HVAC system to ensure balanced cooling. 

By managing airflow more effectively and minimizing temperature fluctuations, hot and cold aisle containment systems help data centers reduce energy consumption, improve performance, and lower operational costs. These improvements align closely with broader sustainability efforts aimed at minimizing the environmental footprint of digital infrastructure.

In fact, the Department of Energy estimates that using polycarbonate twinwall for containment can result in 20% to 25% energy savings – a significant reduction in both cooling costs and environmental impact. 

The Need for Superior Climate Control Between Data Center Aisles 

Effective thermal insulation is essential for maintaining separation between hot and cold aisles. Without proper insulation, hot air can leak into cold aisles, undermining cooling efficiency and forcing the system to work harder to maintain stable temperatures. 

Twinwall and multiwall polycarbonate panels excel in this area due to their hollow flute structure, which traps air and reduces heat transfer between the hot and cold aisles. This natural insulation enhances cooling efficiency, stabilizes intake temperatures, and reduces the overall cooling load, leading to lower energy consumption and improved system reliability. 

The Critical Role of Safety and Visibility Standards in Data Center Operations 

In data centers, safety is essential – not only for protecting equipment but also for ensuring the well-being of maintenance personnel. With the constant heat and electrical activity from running servers, materials used in containment systems must meet stringent fire resistance and visibility standards. 

Polycarbonate multiwall panels address both concerns effectively. They are Class A fire-rated, meaning they slow the spread of smoke and flames in case of a fire. Unlike materials that may ignite or allow flames to spread, polycarbonate melts rather than burns, reducing the risk of fire damage to equipment. 

In addition to fire resistance, polycarbonate panels also improve visibility. Unlike solid materials that create dark enclosures, polycarbonate allows light to pass through while diffusing it evenly. This improves visibility for maintenance personnel, making it easier to perform inspections and repairs without added lighting. 

Prioritizing Durability and Maintenance: Key Strategies for Long-Term Data Center Reliability 

Data centers run around the clock, meaning any downtime for maintenance or repairs can lead to costly disruptions. Choosing materials that minimize maintenance while offering long-term reliability is essential for sustaining high performance and reducing operating costs. 

Polycarbonate multiwall panels offer a clear advantage when it comes to durability and low maintenance. Unlike glass or acrylic, which are prone to cracking and shattering, polycarbonate is virtually unbreakable. Its impact resistance ensures that panels keep their structural integrity even in high-stress environments, reducing the need for frequent replacements. 

Polycarbonate’s natural resistance to moisture and UV exposure also makes it well-suited for long-term use. Unlike other materials that may warp or degrade over time, polycarbonate panels remain stable under varying environmental conditions, preserving the integrity of the containment system. 

Scaling Success: How Polycarbonate Sheets Empower Data Center Expansion 

As data centers scale to meet growing digital demands, adaptability becomes an essential factor in material selection. Containment barriers must be easy to modify, expand, and reconfigure without requiring extensive downtime or high costs. 

Polycarbonate multiwall panels offer excellent scalability and ease of installation. Lightweight yet durable, they are easy to cut, shape, and customize to fit evolving infrastructure needs. Their modular design allows for quick assembly and disassembly, supporting efficient layout changes. 

Specialized profiles like H-profiles connect panels by snapping them together to cover large areas. U-profiles cap the tops of the panels, helping to seal them and prevent moisture from entering and becoming trapped. Installers commonly use aluminum brackets to securely fasten the panels to walls, ensuring stability. This modular design makes polycarbonate a cost-effective and flexible solution that supports the growth and evolution of data centers over time. 

The Sustainability Impact 

Efficient airflow management and high-performance materials are key to reducing the environmental footprint of data centers. Polycarbonate twinwall and multiwall panels play a pivotal role in this shift by improving thermal performance and supporting long-term sustainability goals. 

Polycarbonate panels minimize heat transfer between hot and cold aisles, allowing cooling systems to run at lower power levels. This reduces energy costs, cuts reliance on non-renewable sources, and lowers carbon emissions. 

In addition to their energy-saving benefits, polycarbonate panels contribute to sustainability through their recyclability. At the end of their service life, these panels can be repurposed or recycled, helping data centers align with circular economy principles and reduce waste sent to landfills. 

Durability also plays a key role in environmental impact. Unlike alternative materials that may crack, warp, or degrade under long-term use, polycarbonate panels last for extended periods. Their long service life reduces the need for frequent replacements, minimizing both material waste and the emissions associated with manufacturing and transportation of new components. 

By combining energy efficiency, recyclability, and durability, polycarbonate multiwall panels support a more sustainable approach to data center design and operation – one that balances performance demands with environmental responsibility. 

The Future of Data Center Cooling: Smarter, More Sustainable Solutions 

As server density increases and computing demands grow, effective cooling is more essential than ever. Hot and cold aisle containment combined with high-performance materials like polycarbonate provides a practical path toward greater data center efficiency and sustainability. 

Polycarbonate twinwall and multiwall panels provide a cost-effective, durable solution for modern data centers looking to enhance cooling performance and sustainability. At thyssenkrupp Engineered Plastics, we offer a range of polycarbonate solutions tailored to the unique demands of data centers. Our plastics experts can help you find the best materials for your applications, ensuring your data center runs at peak efficiency. 

Polycarbonate isn’t the only high-performance plastic that supports data center sustainability. GPO, a key material used in data center infrastructure, also offers valuable performance and environmental benefits. Read more about how GPO contributes to efficient data center operations. 

Contact us today to learn more about how polycarbonate panels can enhance your data center’s cooling performance and sustainability goals. 

Have Questions? We’re Here to Help

Need more details about the materials, products, or services on this page? Fill out the form below, and one of our experts will provide the answers you’re looking for. Whether you need a custom quote or guidance on the right material for your project, we’re ready to assist.