Server Rack Installation made easy

When a leading U.S. data center needed to maneuver and install a long, heavy server rack into a tight and technically complex space, traditional lifting methods such as cranes or forklifts proved unworkable. The installation demanded extreme precision, limited floor loading, and vertical lifting up to 16 feet—all without damaging the utilities embedded beneath the concrete floor.

To overcome these challenges, Aerofilm Systems’ U.S. partner Farley & Associates Inc. developed a tailor-made air pallet solution that combined precision mobility with stable lifting performance.

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Impact

The air pallets with guide wheels provided smooth, straight-line movement for perfect positioning within tight floor space.

Air film technology distributed weight evenly, preventing point loading and protecting floor utilities.

The dual-lift system offered both movement and elevation within minimal floor space—ideal for data center environments.

Two connected scissor lifts ensured even elevation, stability, and full operator safety.

The challenge

The data center had to install a long, heavy server rack directly below its designated mounting point, then lift it to a height of 16 feet. Space constraints and sensitive floor utilities ruled out conventional equipment.

Cranes could not be used indoors, forklifts lacked maneuverability, and any point-loaded system risked damaging the infrastructure below. The customer required a solution capable of both horizontal precision and vertical lift—without downtime or risk to surrounding systems.

“Farley & Associates brought Aerofilm’s technology to life in this project—combining precision, creativity, and practical engineering to achieve what traditional equipment simply couldn’t.”

Michiel – Technical Application Specialist at Aerofilm

Our approach

Farley & Associates Inc. developed an integrated transport and lift solution. Two robust scissor lift tables were each mounted on an Aerofilm Air pallet equipped with guide wheels. This design allowed the heavy load to float smoothly across the floor on a thin film of air.

Each air pallet could handle up to 20,000 pounds—more than enough to support the combined weight of the lift table and the server rack. The guide wheels ensured straight, controlled movement. The two lift tables were linked via a single air hose, allowing synchronized operation and perfect balance during the lift. Once in position, the air supply was shut off and the scissor lifts raised the rack to its final installation height of 16 feet.

The result

The innovative combination of scissor lift tables and Aerofilm air pallets provided the precision, stability, and floor protection needed for this highly specialized installation. Within a confined space, Farley & Associates successfully positioned and elevated the server rack—without downtime, risk, or structural impact.

This project showcases how Aerofilm’s technology, implemented by trusted partners like Farley & Associates Inc., enables advanced, site-specific solutions for complex industrial and data center environments. The collaboration demonstrates the strength of combining local expertise with proven air caster engineering.