The surge in AI data center construction brings with it some unusual demands for industrial electrical connectors, according to a manufacturer of the components.
OAKWOOD, Ga.—The global push for artificial intelligence infrastructure has moved into concrete and steel. Private investment in U.S. data centers hit a record high in 2024, according to a release from Mencom Corporation, a manufacturer of custom-made industrial electrical connectors.
U.S. grid-power demand was forecast to grow 22 percent in 2025 and electric utility capital expenditure projected to rise to approximately $212 billion across 47 utilities, driven largely by data center load growth, the release said. Similar surges are currently underway across Europe and the Middle East.
“What makes this wave different is load density. AI racks require 30 to over 100 kilowatts, three to ten times the load of traditional server racks (7 to 10 kilowatts),” the release stated. “This gap changes every assumption about how a facility is powered, cooled, and wired.”
The wiring problem nobody talks about
While the industry focuses on chips and power contracts, less attention goes to field-level electrical work—control panels for cooling units, sensor networks, and the thousands of connections tying mechanical systems together.
According to Mencom, standard IT cabling falls short in these environments. Data center construction now looks like industrial plant engineering, requiring components that can survive harsh, high-EMI conditions.
Bridging the specification gap
The release identified three categories of industrial interconnects that are becoming essential for AI uptime, according to Mencom.
Industrial Circular Connectors: M8 and M12 connectors are widely used in thermal management to collect temperature, flow rate, and pressure data from cold plates and coolant distribution units (CDUs). Network connectors maintain industrial Ethernet communication for rack monitoring without compromising environmental sealing.
M23 and MIN Series connectors deliver high-amperage power to dense server power distribution units (PDUs). Shielded and armored variants protect against physical damage, moisture, and electromagnetic interference (EMI) in liquid-cooled environments while maintaining grounding continuity and signal integrity. The IP67/69 rating ensures resistance to high-pressure washdowns and exposure to dielectric fluids or glycol mixtures.
Heavy-Duty Rectangular Connectors: For modular power blocks and liquid-cooling skids, rectangular connectors offer a superior, vibration-proof alternative to traditional hard-wiring. Their plug-and-play modular inserts combine high-current power and signal in one housing, drastically accelerating the deployment of high-density PDUs, UPS battery banks, and containerized data centers required for GPU clusters.
Panel Interface Connectors (PICs): PICs provide safe, external access to liquid-cooling and power control panels managing high-density GPU clusters. Using IP65 housings, they offer pass-through connections for RJ45, USB, power receptacles, and D-sub ports.
“This allows technicians to perform diagnostics or firmware updates without opening the enclosure, maintaining environmental seals and reducing arc-flash risks in high-voltage AI environments,” the release stated.
A specification gap worth closing
According to Mencom, procurement teams on large data center projects often discover this mismatch late in design, when mechanical contractors and controls engineers arrive with component assumptions that differ from those of the IT infrastructure team. Addressing it at the specification stage reduces rework and supports the phased expansion schedules that most hyperscale facilities follow, the company said.
“The interconnect solutions that survive in industrial environments, high ingress protection ratings, robust mating cycles, and verified environmental compliance, are what keep these massive investments running reliably when they matter most,” the release stated.
AI data center racks require 30 to over 100 kilowatts, three to ten times the load of traditional server racks, according to Mencom. (Image courtesy of Mencom Corporation)