Artificial intelligence (AI) is driving one of the largest infrastructure investment booms the United States has seen in decades. Hyperscale operators are rapidly expanding data center capacity, investing in facilities that demand dense compute, advanced cooling, and resilient power systems. The scale and speed of this expansion are placing new pressures on the manufacturers supplying that infrastructure.
For US manufacturers of cooling systems and power storage, the race is on.
Orders are growing, unit sizes are increasing, and delivery timelines are tightening. The manufacturers pulling ahead aren’t overhauling their factories; they’re simply finding smart ways to get more out of their existing facilities.
AI workloads change the demands on data center infrastructure. Higher rack densities and sustained compute loads are pushing cooling systems to new extremes. Larger chillers, more advanced HVAC systems, and liquid cooling distribution units are becoming standard, and they’re significantly larger and heavier than many factories were designed to accommodate.
Power infrastructure is following the same pattern. Generator sets and modular power enclosures are growing in size and complexity as data center operators plan for contingencies and grid instability, ensuring they have sufficient power available in an emergency.
Most manufacturers already have the technical capability to build this equipment. The real challenge is how efficiently it moves through production.
Finished or near-finished units such as chillers, CDUs, HDUs, and gensets now commonly weigh tens of thousands of pounds, with some reaching as much as 190,000 lbs. As these units move between assembly, testing, and final dispatch, efficiency and flow become critical.
Businesses building equipment to support the 'AI boom' are often reliant on forklift trucks to pulse units through production stages. Forklifts remain essential, but they were never designed for high-throughput, high-precision movement of large equipment in congested layouts. As volumes rise, many manufacturers find that material movement is becoming the bottleneck.
This approach presents several issues:
For many facilities, there is no efficient way to move large, heavy units laterally or rotate them precisely using existing infrastructure or equipment. The result of using traditional material handling systems is often a stop-start process, resulting in lost throughput even when labor and production capacity are available.
The equipment required in modern data centers is expensive, custom-engineered, and often built to order. Combine that with tight factory layouts, heavy loads, and limited handling options, and the result is a perfect storm of material handling challenges. Large units need to be carefully positioned for final assembly or testing. Small misalignments that result in damage can lead to unnecessary rework and delays.
Safety is equally critical. Moving tens of thousands of pounds through busy production areas demands controlled, accurate movement. Methods that rely on manual guidance or lifting increase risk for both operators and equipment.
Many factories are still using handling methods designed for smaller loads and lower volumes. As unit sizes and demand increase, internal inefficiencies become more costly.
AI infrastructure projects move quickly, and customers are increasingly sensitive to delivery timelines. Manufacturers that maintain smooth internal production flow gain a clear advantage. Those constrained by handling bottlenecks risk falling behind, regardless of technical capability.
To keep pace with rising demand, manufacturers need a different approach to material handling. MasterMover’s PowerSteered range of industrial electric tuggers are designed precisely to meet this challenge.
PowerSteered tuggers are heavy-duty, electric machines built to move large, high-value equipment safely and precisely across the factory floor. They provide a flexible alternative to forklifts, helping manufacturers increase throughput without changing layouts or overhauling fixed infrastructure. Individual machines can move loads up to 154,000 lbs, with even greater capacity available through MultiLink technology.
PowerSteered tuggers connect directly to loads mounted on skates, carts, or wheeled frames and move them without lifting. Operators can control movement via remote control, maintaining clear sightlines while guiding loads through tight or congested spaces.
For larger equipment or applications requiring omnidirectional movement, MultiLink technology allows multiple tuggers to work together as a single, coordinated system. This enables smooth, controlled movement of very large loads while maintaining full control over direction and speed. When not linked, individual machines can be redeployed elsewhere, increasing utilization.
The PowerSteered range of electric tuggers addresses the key challenges faced by manufacturers, including:
Many manufacturers across the United States have already deployed the PowerSteered range to help them get ahead in the AI infrastructure race. Whether it’s moving large, industrial HVAC units with precision or creating a staged production process for gensets, leading brands are meeting rising demand with MasterMover.
AI-driven data center projects are moving fast. Internal delays aren’t visible to customers but missed delivery dates are. If large equipment is waiting on forklifts, or being inched into position with workarounds, throughput is already being lost. The manufacturers keeping pace aren’t adding space. They’re fixing how loads move through their factory.
If you’re building large cooling or power systems to support AI infrastructure, now is the time to take a closer look at internal material flow.
Download our guide to explore how controlled, flexible handling can remove bottlenecks and increase throughput.