Aflex delivers for Melbourne's hyperscale data centre
Australia’s data centre sector is experiencing unprecedented growth, driven by artificial intelligence, cloud computing and the increasing demand for secure, high-performance digital infrastructure. With more than $26 billion in forecast investment by 2030 to support AI infrastructure and economic growth, data centres represent one of the most exciting and rapidly expanding markets in the country.
Contributing a critical piece of infrastructure to this transformation, ASSDA Member and Accredited Fabricator Aflex designed, manufactured and supplied stainless steel expansion joints for a major hyperscale data centre in Melbourne. While compact in scale compared to the overall facility, these precision-engineered components play a vital role in ensuring the efficiency, reliability, and long-term performance of the centre’s high-purity cooling systems.
Engineering for hyperscale performance
A hyperscale data centre is engineered for extreme scalability, supporting large-scale workloads through optimised network infrastructure, streamlined connectivity and minimised latency.
With that power comes significant energy demand. Cooling systems are critical to performance, reliability and efficiency. Even small improvements in hydraulic design can deliver substantial energy savings across a facility of this scale.
Rethinking expansion in high-purity cooling systems
Traditionally, water lines with low thermal growth rely on pipe loops to accommodate expansion. Aflex demonstrated innovation by applying compact stainless steel bellows in high-purity cooling water systems, an approach not typically used in this setting.
Expansion joints are engineered connectors designed to absorb movement through their flexible and convoluted design. They manage thermal expansion, vibration, and mechanical movement in pipelines and vessels. Each assembly typically comprises one or more bellows, end connections and tie rods depending on the application.
For this project, compact grade 316 stainless steel bellows were installed in straight pipe runs. The result?
- Reduced pumping energy
- Improved cooling efficiency
- Significant space savings
- Simplified installation.
By outperforming conventional pipe loops, Aflex’s solution delivered measurable gains in operations efficiency while maintaining the integrity of ultra-pure cooling systems.
Why stainless steel was critical
More than 10 tonnes of grade 316 stainless steel pipe, sheet, and flanges were used across the project, supplied by ASSDA Members Stirlings Performance Steels, Vulcan, and Midway Metals. Materials were provided in 2B finish, machined surfaces and mill finish to suit specific application requirements.
The bellows were formed from fully annealed 316 stainless steel sheet and electropolished using a TIG brush. This ensured compatibility with ultra-pure cooling water – which in data centres is often cleaner than everyday drinking water – while delivering long-term corrosion resistance and durability.
In this critical infrastructure environment, stainless steel offers:
- Exceptional corrosion resistance in high-purity water systems
- Strength and flexibility to withstand thermal cycling
- Resilience to building settlement and seismic movement
- Long service life with minimal maintenance
- 100% recyclability and reduced life cycle costs
Stainless steel sets the foundation for efficient, resilient and high-performance infrastructure. In modern data centres, it is the material of choice for mission-critical applications.
Quality, traceability and local capability
Manufactured under ISO 9001 certification, Aflex’s expansion joints were produced with full traceability and rigorous inspection. Quality assurance extended to accredited standards ISO 9002 and ISO 45001, advanced welding practices and comprehensive testing protocols.
Each assembly was supplied with a detailed Manufacturer’s Data Report (MDR), including bellows calculations, material certificates, weld procedures and weld records.
Further reinforcing its leadership, Aflex is commissioning a cycle testing and spring rate testing machine to become Australia’s first bellows company compliant with EMJA (Expansion Joint Manufacturers Association) cycle testing requirements. Cycle testing demonstrates stainless steel’s superior resilience under stress, proving its ability to flex reliably over thousands of movements.
Award-winning innovation
In recognition of its excellence in design, engineering and fabrication, Aflex was awarded the 2025 Australian Industry Stainless Steel Fabricator Project of the Year Award in the Small Project, Big Impact category.
As Australia accelerates investment in digital infrastructure, this project highlights how local expertise, advanced fabrication and the intelligent application of stainless steel are enabling the next generation of high-performance facilities.
This article was featured in Australian Stainless Magazine Issue 84.
Photo credit: Aflex.
