Vertiv unveils double-stack busway for AI data centres

Vertiv has expanded its PowerBar Track busway range with a double-stack design aimed at data centres facing tighter space constraints and rising power-density demands linked to AI roll-outs.

The new configuration uses a compact, vertically stacked layout for overhead power distribution in colocation and hyperscale facilities. Vertiv positions it as a way to increase capacity while preserving white space on the data centre floor.

Higher ratings

The double-stack system is available in configurations rated up to 2000A under UL 857 and up to 2500A under IEC 61439-6. Customers can specify copper or aluminium conductors, depending on project requirements.

Busway systems are drawing renewed attention as operators rework power distribution for higher rack densities. AI training and inference deployments are driving demand for larger electrical feeds, alongside closer monitoring of utilisation and headroom. In many facilities, this is increasing interest in overhead distribution that avoids additional floor-standing equipment and reduces the need for disruptive reconfiguration.

PowerBar Track uses an open-track architecture that allows operators to install or relocate tap-off boxes along the busway while the system remains live, according to Vertiv. The company says this can avoid planned downtime during layout changes, a critical consideration in multi-tenant sites and hyperscale campuses.

The system includes mechanical and electrical interlocks at each connection point, designed to improve operator safety during installation and changes. Optional integrated metering provides real-time visibility of power usage and can feed into capacity planning and energy management.

Layout flexibility

The double-stack arrangement increases the number of connections per tap-off box, according to Vertiv, and scales vertically. This gives facilities another option for adding feeds while keeping clearances and service access within design constraints.

Kyle Keeper, Senior Vice President of Vertiv's Power Business Unit, said the launch addresses the pressures operators face as they adapt power systems for AI workloads.

"Power distribution must keep pace with the scale and density of modern AI and high-performance computing environments," said Kyle Keeper, Senior Vice President of the Power Business Unit at Vertiv. "As customers navigate increasing power demands, tighter space constraints, and rapidly evolving infrastructure requirements, they need solutions that provide flexibility. Vertiv PowerBar Track double stack is designed to address these challenges by enabling compact yet scalable expansion, supporting live changes, and delivering the reliability required in mission-critical data centre environments."

Vertiv says the busway integrates with other parts of its power portfolio, including PowerBoard switchgear, uninterruptible power supply systems, and racks. It also links the system to its 360AI line-up, described as power distribution, protection, and management technologies aimed at AI-ready deployments.

For operators, integration between busway, switchgear, and UPS equipment can affect project design choices and maintenance practices. Standardised interfaces and consistent monitoring can reduce complexity in mixed estates, although most large operators run multi-vendor environments and rely on internal standards that specify acceptable configurations.

The company also says PowerBar Track integrates with OneCore, its prefabricated data centre infrastructure offering, and SmartRun, its modular overhead IT infrastructure system. Vertiv describes this as a cohesive approach to modular data centre design, which is increasingly used to support repeatable deployment patterns across new halls and campuses, with shorter build cycles and defined upgrade paths.

As electrical loads rise, serviceability remains a central concern. Vertiv says the system can be configured to simplify maintenance and reduce maintenance-related downtime. The company also points to its global manufacturing and service network, which it says supports faster deployment for customers expanding rapidly.

The launch comes as data centre developers and operators reassess power distribution choices across new builds and retrofits. Higher power densities can require changes in electrical topologies, protection schemes, and physical routes. Overhead busway designs are often evaluated alongside alternatives such as underfloor distribution and direct cable drops, with each option shaped by building constraints, safety policies, and the operating model for moves, adds, and changes.

Vertiv says the double-stack design is intended for modern compute environments where operators expect ongoing shifts in layouts and electrical demand as AI projects evolve.