Achieving 8MW Hybrid Cooling Capacity: Malaysia's Modular Data Center Retrofit Case

A major industrial client in Malaysia transformed a section of their existing single-story high-bay factory into a cutting-edge server testing environment. The 3,500 m² retrofit supports production validation for air-cooled, cold-plate liquid-cooled servers, and full rack-scale systems. With 8MW of planned IT capacity across eight modular server rooms, the facility demanded a thermal management solution capable of handling extreme heat densities while ensuring rapid deployment and future scalability.

Innovative Cooling Solution

Prefabricated Containerized Cooling Plant:

• Four 2,000kW stainless steel (SUS304) water-cooled centrifugal chillers deployed in skid-mounted, factory-integrated modules.

• Chillers housed in weatherproof outdoor containerized cold stations, minimizing onsite construction time and maximizing space efficiency.

Optimized Coolant Distribution:

• Primary/secondary piping system with main headers routed horizontally along perimeter walls.
• Branch circuits installed at floor level for direct connectivity to server racks, reducing overhead clutter and simplifying  maintenance.

• Fully prefabricated distribution modules—including valves, pumps, and manifolds—assembled on galvanized steel frames for plug-and-play installation.

Implementation Highlights

• Space-Efficient Retrofit: Adapted an operational factory floor into a high-performance testing hub without structural modifications.
• Modular Scalability: Eight identical server room modules allow phased capacity expansion and isolated testing environments.
• Accelerated Deployment: Pre-engineered coolant distribution subassemblies reduced onsite installation time versus traditional methods.

• Future-Proof Materials: Corrosion-resistant stainless steel piping ensures longevity in Malaysia's tropical climate.

Results

• Achieved 8MW cooling capacity with highly uptime reliability during stress testing.
• Enabled validation of hybrid cooling (air + liquid) server architectures under production loads.
• Reduced operational risks through segregated cooling zones and standardized modular design.

• Set a benchmark for sustainable retrofits by reusing industrial infrastructure.

"This project demonstrates how prefabricated liquid cooling solutions can rapidly transform conventional spaces into high-compute environments. The modular approach delivered enterprise-grade thermal management while future-proofing the client's testing capabilities."
— Engineering Team Lead