AI Data Centers: Why polymer piping matters in direct liquid cooling

Cooling infrastructure under pressure

Liquid cooling is rapidly gaining momentum because liquids can transfer heat far more effectively than air. In fact, water has a thermal capacity roughly 3,500 times greater than air, enabling reliable cooling for rack densities exceeding 100 kW.

However, the efficiency of a DLC system depends not only on cold plates and Coolant Distribution Units, but also on the infrastructure transporting the coolant.  The piping system directly influences:

• coolant purity and contamination risks
• hydraulic performance and pressure loss
• system reliability and leak prevention
• installation time and operational sustainability

Cold plate microchannels are incredibly small and sensitive, maintaining high coolant purity is essential. Microscopic particles can clog these channels and compromise cooling performance, or worse, damage chips or cause downtime.

Why polymers are gaining ground

The paper examines the evolution of piping materials in data centers, from copper to stainless steel and now increasingly to high-performance polymers. Unlike metal piping, polymer systems offer inherent corrosion resistance, preventing the release of particles into the coolant loop over time. Their exceptionally smooth internal surfaces also reduce friction losses and minimize biofilm formation, helping maintain stable hydraulic performance throughout the system’s lifetime.

Cleaner welding, faster commissioning

Connections are critical points in piping systems. The study therefore looks closely at infrared (IR) welding technology, a non-contact process used to create highly reliable polymer joints. Infrared welding enables homogeneous molecular bonding without filler materials or welding gases, eliminating contamination risks inside the piping loop. According to GF’s data from millions of welds performed annually, the technology achieves extremely high reliability with automated process control and digital traceability. Another advantage: polymer systems typically require significantly less flushing during commissioning compared with metal pipework, helping accelerate project timelines.

Sustainability benefits beyond the cooling loop

With energy consumption and carbon emissions under increasing scrutiny, the material choice for data center infrastructure also affects environmental performance. The white paper notes that polymer piping can significantly reduce embodied carbon compared to stainless steel systems while also lowering system weight. Lightweight piping simplifies logistics, enables larger prefabricated modules, and can shorten installation time on site. Lower thermal conductivity is another advantage, helping keep heat inside the cooling loop where it can potentially be recovered and reused, for example in district heating networks.

From theory to implementation

Beyond material science, the paper also examines how system design, pre-fabrication, and engineering services contribute to reliable DLC deployment. With more than three decades of experience in mission-critical piping environments such as microelectronics manufacturing, GF applies the same principles of purity, reliability, and process control to data center cooling infrastructure.

Download the full document

For data center designers, operators, and engineering partners evaluating the next generation of cooling technologies, the white paper provides a detailed look at the material, engineering, and sustainability considerations behind modern DLC systems.

Download the full white paper: The role of polymer piping in direct liquid cooling.