Mission-critical reliability to the core: Engineered flow solutions for better system performance

GF Piping Systems, founded in 1802 by Georg Fischer in Switzerland, has a legacy of innovation and precision engineering. For over six decades, the company has specialized in polymer piping systems, positioning itself as a global leader in developing advanced jointing technologies, including contact-free infrared fusion for polymer piping systems.

Mark Stuart, data center sales director EMEA at GF Piping Systems, explains:

“We not only manufacture the piping systems and all the equipment around it, we manufacture all the jointing tools as well, providing a complete, end-to-end system of solutions.”

From microchips to megawatts

GF’s experience in mission-critical infrastructure began with microelectronics, where its high-performance polymer piping systems are integral to processes like chip manufacturing for Intel and TSMC.

This expertise naturally transitioned into the world of data centers, where efficient, high-performance cooling infrastructure is increasingly vital. The expansion started 25 years ago, particularly as data center activity boomed in Dublin, one of the now key FLAP-D (Frankfurt, London, Amsterdam, Paris, Dublin) markets.

“A lot of the contractors we worked with in microelectronics moved into the data center market, especially in and around Dublin. We moved with them as they expanded right across Europe,” said Stuart.

Specialized solutions for data centers

GF’s expertise lies primarily on the cooling side of data center operations, whether it’s facility water for cooling data halls, or newer liquid cooling systems within thermal control systems (TCS) that bring fluid right to the server racks.

“Again, we used our experience in microelectronics in the data center market, from cooling and microelectronic space to the full cooling system within a data center now.”

GF offers different piping systems tailored to individual applications, such as connections to chillers, cooling towers, dry coolers, and CRAH units. For facility water systems, Stuart explains that polyethylene is generally the preferred choice due to its proven performance, speed of installation, and adaptability:

“One of the key advantages of polyethylene is its flexibility, which makes installation significantly faster and easier. It’s also well-suited to handle thermal movement – making it ideal for systems that experience frequent temperature changes, as it accommodates expansion and contraction effectively.”

Polymer piping is up to 70 percent lighter in weight compared with metal systems,as deduced via GF’s carbon calculator, reducing the need for heavy equipment and several hands on deck to install. The use of polymer also allows for prefabrication off-site without compromising on performance standards.

GF provides engineering support to help customers adapt traditional metal piping designs to polymer-based systems. This includes hydraulic analysis, pipe stress analysis for appropriate bracketing, and detailed design of pipe spools to enable off-site prefabrication:

“In some cases, we even deliver the system pre-mounted into racks, ready to be dropped straight into the data hall,” explains Stuart.

Dispelling myths about polymers

The biggest challenge GF encounters is not general unfamiliarity with piping systems – many data center professionals are well-versed in carbon or stainless steel piping. Rather, it’s the skepticism about the viability of polymer systems.

These systems, made from materials such as cross-linked polyethylene (PEX) and polypropylene homopolymer (PPH), are sometimes mistakenly associated with plastic drainage pipes used in residential settings. Stuart explains:

“Our piping systems are pressure-rated and specifically engineered for performance in industrial applications. We use advanced technologies like infrared welding to fuse the pipes, creating a reliable and robust connection that’s more sophisticated than many assume.”

Over time, GF has worked hard to shift these perceptions by getting GF systems within the specifications of many of the largest hyperscalers and co-location providers, as Stuart states:

“Today, we are included in the specifications for many of the biggest players in the industry – a testament to the reliability and performance of our systems.”

The Plastics: The not-so-mean girls in sustainability

Understandably, when people hear “polymer” or “plastic,” their first question is often, “How can plastic be sustainable?”

Digging a little deeper, Stuart explains that the lower embodied carbon of polymer piping systems stems primarily from the production and transport phases. Polymers such as polypropylene or polyethylene require significantly less energy to manufacture due to their lower melting points compared with metals. Additionally, their lighter weight makes transport less carbon-intensive than for metal piping systems:

“In fact, the embodied carbon of polymer piping is often less than half that of stainless steel, and lower than carbon steel as well, making it a more sustainable choice in many applications,” Stuart notes.

To support transparent decision-making and help customers meet relevant building standards, GF provides life cycle assessments (LCAs) and environmental product declarations (EPDs) for most of its piping systems.

For those interested in evaluating their own systems, GF developed its carbon calculator on its data center portal, where users can input the specifications of their piping system and instantly compare the embodied carbon footprint of polymer piping with traditional metal options.

Of course, sustainability claims around polymers also depend on end-of-life recycling. Metals currently have the advantage in that area, but polymer recycling is improving. According to Stuart, GF is actively working to advance this progress:

“Sustainability is not just about manufacturing. We invest heavily in recycling – not only within our own production facilities but also across the entire supply chain. We’re actively exploring ways to recycle and repurpose products at the end of their life cycle.”

Cooling down downtime

In any mission-critical environment, even brief system downtime can be detrimental. If maintenance or modifications are needed on a specific rack, even minimal disruption can have a broader impact across the entire system.

GF offers specialized valving solutions that enable isolation at the rack or row level, allowing maintenance to be carried out on a specific section without affecting the operation of the wider system.

Stuart illustrates that GF’s patented dual ball valve design includes a built-in safety mechanism, meaning that when the valves are in the open position, the system cannot be split. To disconnect the valve safely, both sides must be fully closed. Once closed, the connection can then be separated.

Conversely, if the valve is in flow position, it remains locked and cannot be detached – an important safeguard to prevent accidental decoupling resulting in a fluid release, especially in sensitive environments like data halls.

“There’s also a patented safety pin inside the valve that prevents it from being opened when it’s not properly secured. It’s a small but crucial feature designed to avoid unintentional disconnections or spills,” adds Stuart.

While metallic alternatives to this type of valve are available, they are 55 percent heavier, based on in-house testing. In large-scale data centers where thousands of these valves may be installed, the weight and cost advantages of polymer systems offer a significant advantage.

Training and consistency across global projects

GF provides installation training as a core part of its support throughout the construction process, benefiting both internal teams and on-site contractors.

While GF doesn’t carry out contracting work itself, it adds value as a product manufacturer by prefabricating its systems into piping spools or modular units and training installers to ensure correct, consistent execution, particularly where installation quality varies across regions. Stuart explains how GF takes a proactive role in maintaining high standards across all of its projects:

“Whether on metal systems or polymer ones, some hyperscalers experience problems with installation. What we’re trying to do is to upscale the quality by doing training for each of the projects to make sure that people are installing products following the correct processes.”

Keep the receipts

Data-backed insights are key to confirming installation quality and system design. As is now industry standard across much of today’s technical equipment, all of GF’s welding products keep digital records of their activity, documenting what was done, when, and how. These electronic logs are given to the end user upon project completion, offering full traceability and assurance.

As part of its complete system, GF’s product range includes a plethora of integrated sensors to monitor key metrics, such as pressure, flow, temperature, and conductivity – especially useful for tracking water quality in cooling systems.

“The team at GF is always working on something new, whether it’s a new application, piece of equipment, AI-enabled capabilities, or novel uses of polymers – there’s always something new coming out. We work closely with our customers and partners like the Open Compute Project (OCP) to push the boundaries of what’s possible,” says Stuart.

Adapting to climate extremes from the Middle East to the Nordics

Climate can also significantly influence how systems should be installed. In hot, dry regions like the Middle East, or cold, wet climates like the Nordics, product performance must remain consistent year-round. Speaking to these environmental challenges, Stuart notes:

“It doesn’t change the performance of the system, but it does mean you need to be mindful of how it’s installed.”

Because polymer piping systems expand and contract more than their metal counterparts, correct installation is critical. Though the performance of the material remains stable, its physical behavior does differ. For example, in the Middle East, pipes exposed to intense sunlight may expand considerably, while in Nordic winters, contraction can become a major concern.

To address this, GF leverages the expertise of its advanced engineering team to thoroughly review every installation plan:

“We evaluate the installation design to ensure the piping is properly supported and bracketed, allowing for thermal movement without introducing stress or strain on the system.”

At its independently-accredited, proprietary laboratory in Switzerland, GF conducts rigorous testing across a range of environmental conditions, including extreme heat and cold, as well as bushfire and impact testing, to ensure its polymer solutions are application-ready.

Ultimately, success comes down to informed design – making sure each project is engineered to accommodate thermal dynamics so the system performs reliably under all conditions.

Mission-critical in the Middle East

With extreme environmental conditions, cooling and chemical processing systems in the Middle East demand the utmost performance and reliability. The resilience of GF’s systems was a key discussion point at DCD>Connect MENA, a debut event hosted in Dubai this April.

With growing interest in the Middle East market, GF is showcasing the durability of its systems through local manufacturing and rapid deployment:

“We’ve actually got our own manufacturing plant and prefabrication shops in Abu Dhabi, so that really helps with the coordination, meaning we can prefabricate for two or three big projects at the same time and deliver locally without having to transport and wait six to 12 weeks for shipping.”

Helping you find your flow, globally

Sustainability practices vary greatly by region. For instance, in the Nordics, the infrastructure for recycling plastics is highly advanced, even more so than in locations like the UK. On the other hand, in parts of the Middle East or North Africa, local recycling capabilities can be more limited.

Each region has its own infrastructure, policies, and limitations. This is where GF’s regional teams step in to support customers locally, helping them navigate these differences and build sustainability into their operations. That might mean researching local recycling options, advising on end-of-life planning, or helping develop an operational sustainability strategy that fits their region.

“Their role is to provide full project support – from the initial design phase right through to post-installation. In fact, on large-scale projects, we often stay involved well after completion, supporting maintenance, system upgrades, or adjustments. The key is ensuring there’s always someone local to help our customers manage ongoing needs and changes.”

In a rapidly changing market, speed and responsiveness are critical. GF’s priority is staying close to its customers, offering fast, flexible support through product innovation, prefabrication, and expert on-site assistance.

Find out more about GF Piping Systems here.