As artificial intelligence workloads drive unprecedented compute density, the U.S. data center industry faces a formidable challenge: modernizing aging facilities that were never designed to support today’s high-density AI servers. In a recent Data Center Frontier podcast, Steven Carlini, Vice President of Innovation and Data Centers at Schneider Electric, shared his insights on how operators are confronting these transformative pressures. “Many of these data centers were built with the expectation they would go through three, four, five IT refresh cycles,” Carlini explains. “Back then, growth in rack density was moderate. Facilities were designed for 10, 12 kilowatts per rack. Now with systems like Nvidia’s Blackwell, we’re seeing 132 kilowatts per rack, and each rack can weigh 5,000 pounds.” The implications are seismic. Legacy racks, floor layouts, power distribution systems, and cooling infrastructure were simply not engineered for such extreme densities. “With densification, a lot of the power distribution, cooling systems, even the rack systems — the new servers don’t fit in those racks. You need more room behind the racks for power and cooling. Almost everything needs to be changed,” Carlini notes. For operators, the first questions are inevitably about power availability. At 132 kilowatts per rack, even a single cluster can challenge the limits of older infrastructure. Many facilities are conducting rigorous evaluations to decide whether retrofitting is feasible or whether building new sites is the more practical solution. Carlini adds, “You may have transformers spaced every hundred yards, twenty of them. Now, one larger transformer can replace that footprint, and power distribution units feed busways that supply each accelerated compute rack. The scale and complexity are unlike anything we’ve seen before.” Safety considerations also intensify with these densifications. “At 132 kilowatts, maintenance is still feasible,” Carlini says, “but as voltages rise, data centers are moving toward environments where