PVC & CPVC Piping for Data Centers: Enhancing Safety and Durability in Cooling Systems

More data also means a higher demand for cooling solutions that enable peak performance. Performance is critical to meeting sustainability goals, an essential metric for data center providers, and improving sustainability. Achieving these goals requires a more efficient cooling medium, which is making legacy air cooling solutions obsolete. As data centers push toward higher density and performance, the new cooling systems are liquid-cooled - either by single or two-phase immersion cooling in most cases.

The data center industry is heavily regulated, so engineers and operators are turning towards enhanced thermoplastic materials like PVC and CPVC (Polyvinyl Chloride and Chlorinated Polyvinyl Chloride) for liquid handling to meet stringent building codes and guard against material corrosion to protect the equipment.

With CPVC, the chlorination process used in resin production enhances material properties to improve the material's resistance to heat and chemicals, improving its chemical stability.

Heating and cooling systems are essential components of modern buildings, providing a comfortable indoor environment for occupants. These systems cooperate to regulate temperature, humidity, and air quality, ensuring a healthy space. Heating and cooling systems can be categorized into various types:

• Heating, ventilation, and air conditioning (HVAC)
• Evaporative cooling systems

Each type has its unique characteristics, advantages, and applications. Understanding the basics of heating and cooling systems is crucial for selecting the right fluid-handling material suite for a specific building or application.

Historically, metal piping systems have dominated data center cooling infrastructure. But these traditional solutions come with critical drawbacks:

Condensation and Corrosion: carbon steel and stainless-steel metal pipes, due to their high thermal conductivity vs. thermoplastics, are susceptible to condensation. This characteristic increases the risks of corrosion and interior blockages (corrosion rate is dependent on water quality). Over time, corrosion can result in system inefficiency, higher maintenance costs, or even catastrophic system failures or safety events if the piping is not insulated sufficiently. Metal piping is susceptible to corrosion, while thermoplastic piping is not.

Metal valves can use an epoxy coating to guard against corrosion, but if the coating chips off or is insufficiently thick, the metal valve can rust once they are insulated.

Figure 2 below illustrates examples of metal material corrosive degradation after only a year or two of use. Corrosion can occur on the disc of a metal valve, rendering it unable to be opened or closed.

Cost & weight: metal pipes often need to be lined and insulated to guard against condensation and material corrosion, adding cost to the system. Metal piping also requires additional support due to weight. The excessive metal weight also contributes to higher transport costs, increasing indirect carbon emissions as well due to increased fuel consumption to transport the heavier material.

In addition to the insulation, corrosion resistance, and higher transport costs, metal piping also carries added handling costs compared with thermoplastic during installation. For example, metal valves may require a crane for placement, while an equivalent-sized thermoplastic valve may only require manual handling by an operator for positioning. Also, due to weight differences, a 3- or 4-person crew may be required to handle metal products during installation compared with 1 or 2 crewmembers to install thermoplastic, for example.

International supply: Metal valves are fabricated out of carbon steel or cast and ductile iron, most of which are imported, increasing lead times, transport costs, tariff costs, and supply chain disruption risk.

Longevity: Thermoplastic water handling applications operate for 20 years or more without meaningful component failures, while metal systems and components require more frequent maintenance and replacement due to sensitivity to corrosion.

PVC and CPVC piping offers numerous benefits tailored specifically to withstand the demanding environments of data centers:

1. Superior Chemical Resistance: PVC and CPVC offers best-in-class resistance to corrosion from cooling, hot water, additives, and other chemicals typically found in water treatment systems, significantly reducing maintenance demands and extending piping life. While metal ductile valves last only a year or two before corroding, PVC or CPVC piping and valves can last over 25 years, improving sustainability and lowering the total cost of ownership.
2. Enhanced Safety: With significantly lower thermal conductivity compared to metal, PVC and CPVC dramatically reduces condensation issues, creating a safer operational and production environment. Both materials help maintain the desired temperature of chilled water while preventing energy loss due to reduced temperature loss from the metal’s thermal conductivity.
   PVC and CPVC pipes provide superior electrical insulation, reducing electrical safety hazards and making them an excellent choice for environments sensitive to high temperatures and electrical interference, such as data centers. CPVC's heat resistance, enhanced by the chlorination process, allows it to withstand high temperatures, making it ideal for hot water applications.
   CPVC is popular for data center applications due to the plenum space codes. The plenum spaces facilitate the movement of conditioned air (in air-cooled systems) throughout the building. Plenum and smoke codes were written to reduce risk of a fire spreading. CPVC material aids in meeting these codes with a robust flame speed rating and flame spread performance.
3. Cost & weight: Just as metal pipe and valve material can bring higher transport and lifetime material cost, both PVC and CPVC outperforms metal from a sustainability, energy, and total cost of ownership perspective. Maintenance is also reduced as thermoplastic can be more durable than metal  due to its properties. Improved durability and lower handling costs due to lighter weight and small installation crews reduce the TCO of thermoplastics over metal in many cases.
4. Domestic supply: Data center system designers can source BABAA-compliant PVC and CPVC piping and valves to sharply reduce lead times (from months to weeks) and ensure their components bring the highest quality construction to the system to maintain uptime.
5. No need for chemical additives: Thermoplastic piping systems require minimal (if any) use of biocides, descalers, and other chemical additives that are commonly used to protect metal piping systems from corrosion, pitting, biological buildup in the system, and scale buildup in evaporative cooling applications.
6. Retrofit metal piping applications: PVC and CPVC products, such as valves, can be used in metal piping systems as long as installers employ sufficient transition piping. Thermoplastic butterfly valves with ANSI/ASME B16.10 face-to-face dimensions can be directly interchanged with metal butterfly valves with no changes to the piping system.

PVC and CPVC piping systems can last decades when properly installed and maintained, substantially outlasting traditional metal systems in data center cooling applications (25+ years vs. 2). And when compared with traditional thermoplastics like polyethylene and polypropylene, both PVC and CPVC offers superior durability, strength, and heat resistance, improving maintenance, longevity, and overall life cycle performance.

However, overtightening fittings or failure to account for the material’s thermal expansion properties are common installation errors, leading to premature failure. Proper education, equipment and training guard against these risks, but they also can create the perception of a less durable material. It is essential to educate the market to handle and install PVC and CPVC correctly to realize the benefits.

Regular maintenance and repair are essential to ensure the optimal performance and longevity of PVC and CPVC piping systems. Maintenance tasks include inspecting the system for signs of wear and tear, checking for leaks, and replacing worn-out components. Repair tasks include fixing leaks, replacing damaged pipes and fittings, and cleaning the system to prevent clogging and contamination.

To fully leverage these materials' benefits, proper installation process and maintenance procedures must be followed:

• Avoid Overtightening: PVC and CPVC requires less torque than metal (15-20 ft-lb vs. 15-100), and overtightening fittings can lead to premature failure.
• Manage Thermal Expansion: Engineers must account for PVC and CPVC’s higher thermal expansion compared to metals (32 μin/in/°F vs. 6 µin/in/°F) by allowing adequate spacing and supports to absorb expansion growth.
• Training: Ensure that contractors and installation teams receive training in best practices specific to thermoplastics to eliminate user-error-driven issues.

Selecting the right piping material is crucial, particularly in high-performance and industrial environments, where reliability and resistance to harsh conditions are critical.

Hayward Flow Control leads the industry with:

• High-quality PVC and CPVC Products: Engineered specifically for data centers and challenging environments.
• Made in America: BABAA-compliant to ensure short lead times and high reliability.
• Global 3-Year Warranty: Demonstrating the confidence and commitment Hayward has in the performance and longevity of their PVC and CPVC solutions.
• Extensive Technical Support and Training: Providing essential resources and education (“Thermoplastics 101”) for engineers, contractors, and end users to make informed decisions and installations confidently.

Selecting the right piping material is crucial, particularly in high-performance and industrial environments, where reliability and resistance to harsh conditions are critical. PVC and CPVC products are well suited to meet durability, sustainability, and cost targets of data center cooling system projects.

Contact Hayward to talk with materials consultation that can guide you through material selection for your data center project.

1. Why is PVC and CPVC ideal for data center cooling systems? Both materials' piping systems are highly resistant to corrosion, minimize condensation issues, and enhance safety through non-conductivity, making them ideal for data centers. CPVC is advantaged to comply with plenum and smoke building codes.
2. Are PVC and CPVC pipes durable enough for data centers? Yes, properly installed PVC and CPVC systems are highly durable, and can substantially last 12x longer than traditional metal piping.
3. How does PVC and CPVC affect energy efficiency in cooling systems? Both PVC and CPVC’s lower thermal conductivity reduces condensation, leading to fewer cooling inefficiencies and energy savings. PVC and CPVC also exhibits a reduced friction factor compared with metal pipe. This advantage results in lower head loss across the pipe, boosting energy efficiency for the same fluid volume transported.
4. Does PVC and CPVC cost more than metal piping? While initial costs are comparable, PVC and CPVC typically offers lower total cost of ownership due to reduced maintenance and enhanced performance with enhance corrosion resistance over metal.
5. Are PVC and CPVC compliant with current regulations? Yes, PVC and CPVC systems can comply with regulatory requirements, and Hayward’s PVC valves with UHMWHDPE seats are designed specifically to lower PFAS content.
6. What are best practices for PVC and CPVC installation in data centers? Best practices include avoiding overtightening, accounting for thermal expansion, and ensuring installation teams are trained in PVC and CPVC-specific material handling.