• • • EDITOR'S CHOICE • • •
Balancing uptime and upgrades Perhaps the most significant challenge in any retrofit project is protecting live operations. Data centres don’t get the luxury of downtime, even during major overhaul works. For engineers, that means walking a tightrope: upgrading mission-critical systems without breaching resilience thresholds.
Success depends on early-stage planning, strong communication and phased execution. Key best practices include: • Temporary systems to maintain cooling and power while permanent systems are replaced. • Integrated systems testing (IST) conducted in phases to validate each system under operational conditions.
• Laser scanning and 3D modelling to pre-empt spatial and structural constraints.
• Pre-construction surveys and risk mapping to identify interdependencies and mitigation needs.
In one of our projects, we installed bespoke chiller gantries across several sites in London, Birmingham and Guildford. Working with constrained footprints, the team used laser scanning and off-site fabrication to reduce time on site and eliminate disruption to operations. Another retrofit, delivered within a fully occupied data centre, involved installing a new 380V DC system to achieve 96.2 per cent efficiency, alongside hot aisle containment to increase thermal performance. The result? A 136-cabinet fit- out, six more than originally specified, completed without interrupting business-as-usual operations. Whether it’s extending backup power, delivering futureproofed cooling, or relocating grey space to unlock white space, these projects rely on detailed sequencing and cross-disciplinary collaboration.
Engineering in action Retrofit strategies are most compelling when backed by tangible results. EMCOR UK has delivered several retrofit projects that demonstrate what’s possible with the right engineering expertise and planning rigour.
Case study 1: Fibre roll-out in a former call centre A large telecoms customer needed to deploy 50kW of capacity in a 300m² footprint to support fibre roll-out in a disused call centre. Within 12 weeks, we reconstructed the
facility, comprising of power and cooling systems delivered to the required resilience strategy. The build also facilitated bespoke cabinet and fibre connectivity that allowed for the day one solution and was scalable to cover the future growth deployment phases. Despite limited initial power availability, the project met its energy and resilience requirements, and handed over on time.
Case study 2: Supporting TfL’s 5G rollout Transport for London needed additional resilience and capacity to enable its Underground network’s digital upgrade. Working on a live site, we delivered a 154-cabinet white space extension, installed a new rooftop CRAC plant, and the deployment and relocation of a new DNO service, without disrupting the facility’s existing Tier 3 infrastructure. The works were completed ahead of schedule in just 38 weeks.
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When retrofit makes most sense Retrofit is no longer just a tactical option; it’s a strategic enabler. But that doesn’t mean it’s the right solution for every scenario. The key is understanding when a retrofit is the best tool for the job.
Typical triggers include: • End-of-life plant or M&E systems reaching critical failure risk.
• Rising maintenance costs or frequent reactive repairs.
• New technologies exceeding existing capacity. • Sustainability mandates requiring carbon reduction and efficiency gains. • Customer SLAs or resilience thresholds that are at risk of being breached.
• Available power or space on-site that could be re-optimised rather than replaced.
Operators and facilities managers can build a robust business case by conducting asset condition surveys, lifecycle costing and energy audits. Understanding PUE performance, energy consumption per rack, or cooling system inefficiencies can all inform whether retrofit presents a viable, and more sustainable, path to performance. Strategically, retrofit offers faster time to value. Compared to a new build, which can take two to three years to come online, retrofits can often deliver within 6 – 18 months, depending on scope. They also tend to require less upfront capital and enable phased investment aligned with organisational goals.
Why it’s a long-term play,
not a short-term fix Perhaps the biggest misconception about retrofitting is that it’s reactive. Today’s most
successful retrofit programmes are proactive, future-focused and aligned to long-term business needs.
Modern facilities need to support higher rack densities, lower PUE, smart systems integration, and tight uptime SLAs. All of this can be achieved through a structured retrofit roadmap, especially when supported by partners with self-delivery capabilities and experience operating in live environments. Retrofits also help meet increasingly complex compliance and ESG reporting requirements. Upgraded plants support more granular energy monitoring, simplifies Scope 1 and 2 emissions tracking, and avoids the embodied carbon associated with new construction. For organisations aiming to meet Net Zero targets, retrofit can be a more practical and impactful option.
Future-ready, retrofit-first The data centre sector is at a crossroads. On one side lies soaring demand, limited supply and an urgent need to reduce environmental impact. On the other lies a stock of ageing infrastructure, much of it under-optimised and nearing its design limits. Retrofitting bridges the gap. It offers a faster, more flexible and more sustainable route to growth, enabling operators to modernise their estates, enhance resilience and prepare for the demands of next-generation technologies like AI and edge computing.
In an environment where time, carbon and capital are all under scrutiny, retrofit is no longer a compromise. It’s a competitive advantage. And increasingly, it’s the only realistic path
forward.
https://www.emcoruk.com ELECTRICAL ENGINEERING • OCTOBER 2025 43
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