Vertiv: Expanding Manufacturing for AI Data Centres

Vertiv is scaling its manufacturing operations across the Americas in response to surging demand for high-density data centre infrastructure. The company has announced four new or expanded production facilities designed to increase output of power systems, integrated cabinets and infrastructure solutions deployed in AI-driven data centre environments.

The expansion reflects mounting pressure on manufacturers to deliver scalable production capacity while shortening lead times for complex systems.

As AI workloads accelerate infrastructure requirements, manufacturing operations must support the integration of power, cooling and IT systems into cohesive production lines capable of delivering high-performance computing environments.

Manufacturing footprint across the Americas

The new and expanded facilities span locations across the US and Mexico, with each site dedicated to specific production lines within the data centre infrastructure portfolio.

In South Carolina, two additional manufacturing sites will concentrate on infrastructure solutions engineered to accelerate deployment timelines. Once these facilities reach full operational capacity, regional production output could increase by approximately seven times.

The facilities will manufacture Vertiv's integrated power modules and prefabricated infrastructure systems. Integrated power modules consolidate key electrical components into single production units, enabling operators to deploy power systems more rapidly than conventional builds. According to Vertiv, these manufacturing approaches can reduce deployment time by up to 50%.

The company's SmartRun solution represents a manufactured system that combines multiple infrastructure elements into a unified production output. This includes busway for power distribution, liquid cooling piping to manage thermal loads, networking components and containment systems that control airflow within data centre white space.

By delivering these components as prefabricated manufacturing units, SmartRun can reduce on-site installation time by up to 85% compared with traditional methods, allowing operators to bring capacity online faster.

Production capacity for high-density systems

In Pennsylvania, Vertiv has opened an additional manufacturing facility focused on racks and containment systems. These cabinets are produced with integrated cooling capabilities, allowing them to support high-density AI applications where thermal output is substantially higher than in traditional workloads.

The integrated cabinet production line simplifies deployment by reducing the need for on-site assembly and configuration. This manufacturing approach supports repeatable designs, which could become increasingly important as operators roll out standardised data centre environments at scale.

A facility expansion in Mexicali, Mexico will increase manufacturing capacity for power conversion, conditioning and distribution technologies by approximately 45%. These systems ensure stable and efficient power delivery to IT equipment, which is critical for maintaining uptime in environments handling AI and cloud workloads.

The Pennsylvania facility's production capacity represents a strategic response to the growing demand for rack-level infrastructure that can accommodate liquid cooling systems alongside traditional air-cooled configurations. This dual-capability manufacturing approach enables operators to deploy hybrid cooling strategies within the same data centre environment.

"Vertiv sees AI as a long-term, secular trend, and we are accelerating our capacity expansions to anticipate the continued growth in demand," says Giordano Albertazzi, CEO of Vertiv, in a statement.

"Today's announcement represents the most recent steps in our continuous capacity planning and deployment approach, as we further increase our regional and global footprint.

"We remain committed to our strategy of delivering future-ready, high-density solutions that enable our customers to plan confidently for multiple generations of compute ahead."

Supply chain strategy and production integration

Vertiv's manufacturing expansion reflects an industry shift towards fully integrated production systems that combine power, cooling and IT into a single manufacturing architecture. This approach supports the increasing density and complexity of AI workloads, which require coordinated production of energy management and thermal control systems.

The company positions its manufacturing portfolio as spanning the full infrastructure stack, from grid connection components through to chip-level cooling and heat reuse systems. This end-to-end production model allows operators to deploy systems that function as a unified platform rather than a collection of separately manufactured components.

As data centre operators look to reduce time to deployment while preparing for future compute demands, manufacturing scale and supply chain readiness have become central considerations in facility planning and operations strategy.

Vertiv's expanded manufacturing footprint is designed to address these requirements by enabling faster production cycles and delivery of critical infrastructure components. The strategic placement of facilities across the Americas could support regional supply chain resilience while reducing logistics complexity for customers requiring rapid deployment of high-density infrastructure systems.

The geographical distribution of manufacturing sites across multiple states and countries provides operational redundancy whilst enabling proximity to key customer markets. This regionalised production model supports faster response times to customer requirements and reduces dependency on single-location manufacturing operations.