Hyper scale AI Data Center:
Rack/Stack and Structured Cabling
Client Overview
Brainotech IT Solutions delivered a high‑density
GPU cluster with a strong emphasis on disciplined
rack‑and‑stack, resilient UPS/PDU design, and
production‑grade cabling (fiber and Cat6A). Scope
covered fabric‑ready structured cabling, dual‑feed
power architecture, and formal cable certification
using Fluke test instruments.
Business Challenge
The pilot rack exhibited intermittent link
errors and lacked structured, fabric‑ready
cabling. The new build required:
- Clean, repeatable rack‑and‑stack at scale.
- 2×100G fabric readiness with clear
separation between fabric & management. - Resilient dual‑feed power via UPS and
intelligent PDUs. - End‑to‑end copper and fiber certification
– without extending time to production.
Outcome
- Production‑ready in 8 business days.
62% decrease in CRC/errored frames after
structured cabling and certification. - Predictable single‑feed failover with ≤5%
performance deviation under test. - Delivered a complete runbook with rack
elevations and certification reports.
Solutions
1. Rack & Stack and Fabric Readiness
- Racked eight high‑density cabinets with GPU
servers, storage, and spine/leaf switches. - Implemented standardized elevations, and labelled
RU plans to streamline access. - Layered cabling by function (fabric & management)
with defined pathways
2. Cabling (Fiber and Cat6A)
- Structured cabling with pre‑terminated trunks and
modular panels; labelling ports, panels, and trunks. - Fiber: OM4; MPO trunks with Type‑B polarity for
100G. - Copper: Cat6A for management and storage
control paths; short, color‑coded patch leads
3. Power Architecture: UPS & PDUs
- Dual independent power feeds per rack via the
UPS, each landing on intelligent three‑phase PDUs
with per‑outlet metering.
Exercised failover across fabric and storage tiers to
validate resilience and recovery behaviour.
Color‑coded armored power cords and locking IEC
connectors; end‑to‑end power chain documentation
down to the outlet.
4. Cable Testing & Certification
- Copper (Cat6A):
4. Cable Testing & Certification
Certified Permanent Links with Fluke Networks
DSX‑8000 CableAnalyzer
Verified ACR‑F, return loss, propagation delay,
and length; saved results to LinkWare and
provided PDF to customer. - Fiber: Tier 1 (Basic) certification using Fluke CertiFiber
Pro OLTS.
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