01 / New build
Flow & return header sets
Matched flow and return mains with branch pairs on a set pitch, capped and prepared for connection to rack manifolds.
- 50–200 mm main bore
- Branch pairs to suit rack pitch
- Capped and pressure-tested
Custom copper cooling manifolds · East-coast Australia
Large-bore copper headers for liquid-cooled data centres.
Design, fabrication, supply, installation and rack connection. Brazed copper flow and return headers for direct-to-chip and rear-door cooling — hydrostatically tested, built to your floor plan rather than a catalogue.
Why liquid cooling
Air has run out of headroom.
Rack densities have climbed past the point air can carry the heat away. Liquid cooling is now the default for high-density and AI infrastructure — and it only works if the water reaches the rack.
A single AI training rack can draw 40, 80, even past 100 kilowatts. No practical volume of moving air carries that away quietly or cheaply. Direct-to-chip cold plates and rear-door heat exchangers move the heat into water instead — and water carries roughly three thousand times the heat of the same volume of air.
That shift is what makes high-density data centre cooling viable. But the cold plates and rear doors are only half of it. They perform only if water arrives at every rack at the right flow and the right pressure, which is the job of the header set feeding the floor.
Density
More compute per rack, per aisle, per hall. Liquid lets operators run high-density racks where an air-cooled hall would have to spread the load thin.
Energy
Water moves heat with far less parasitic power than air. Lower PUE, lower running cost, and chillers that can run warmer — or be shed.
Reuse & retrofit
Captured heat leaves as warm water that can be reused rather than dumped. And liquid can be brought into halls originally built for air, circuit by circuit.
We design, fabricate, test and install copper header sets across Australia's east coast — Melbourne, Sydney, Canberra and Brisbane — and connect them to the racks. One trade, one accountability, one set of drawings.
What we build
Header sets, built to the drawing
Every set is fabricated to the specific aisle, load and tie-in point. Nothing is a stock item.
02 / Non-standard
Custom configurations
Odd circuit counts, mixed bore, offset branches, tight ceiling voids, awkward tie-ins. Drawn in CAD, agreed before a single joint is brazed.
- Any circuit count
- Mixed-bore branch runs
- CAD drawings supplied
03 / Existing halls
Retrofit & tie-in
Adding liquid to a hall that was built for air. Survey, design around what's already there, fabricate off-site, install in the window you've got.
- Site survey and measure
- Off-site fabrication
- Staged cut-in and connection
How it runs
Supply. Install. Connect.
A sequence, not a menu. You can stop at supply — most clients don't.
Step 01
Supply
Design and fabrication from your layout or ours. Header sets arrive capped, labelled and hydrostatically tested, with drawings.
Step 02
Install
Set in place, supported, aligned and tied into the plant loop by the same people who fabricated it.
Step 03
Connect
Branch pairs run out and connected to the server boxes. Flushed, filled and pressure-proved on site.
Specification
The envelope
Standard capability. Outside these numbers, ask — most of it is a fabrication question, not a limit.
| Main pipe bore | 50 mm – 200 mm — copper tube |
|---|---|
| Branch bore | Sized to circuit load. 50 mm typical. |
| Circuits per set | 4, 6 or 8 as standard. Custom counts on request. |
| Configuration | Flow and return pairs, branch pitch to suit rack layout. |
| Joining | Oxy-brazing and silver soldering. |
| Testing | Hydrostatic pressure test on every set. ✓ Certificate supplied |
| Documentation | CAD drawings and as-built dimensions issued with each set. |
| Installation | Licensed plumber and gasfitter. Install and connection across the east coast. |
| Lead time | Issued on enquiry |
| Pricing | Issued on enquiry |
In-house
Everything under one roof
Design
CAD & drawings
Header sets modelled in Fusion 360 and signed off before fabrication starts.
Fabrication
Brazing & solder
Oxy-brazing and silver solder by a trade-qualified hand, not sub-contracted.
Assurance
Hydrostatic testing
Every set proved under pressure on the bench before it ships.
Site
Install & tie-in
Set, support, align and connect to the plant loop.
Site
Rack connection
Branch pairs run out and connected to the server boxes.
Licensing
Plumber & gasfitter
Licensed trade. Work handed over documented and compliant.
Enquiries
Tell us what you're cooling
Enquiries are read and answered by the person who builds the headers. Expect a reply within two business days.