Large-Scale Heat Load Testing

Stress-testing infrastructure for the AI and HPC revolution. KES provides large-scale heat load testing to simulate real-world thermal stress using advanced air and liquid load banks. Our methods support the extreme densities required for AI and high-performance computing, giving owners confidence before live IT load is introduced.

Essential validation for data centres

Staged thermal testing proves cooling and power paths under controlled load—without risking production equipment.

Design intent verification — Confirms the cooling system can handle maximum designed thermal load before servers are installed.
Real-world simulation — Heater banks mimic heat output and airflow patterns of high-density racks.
Hotspot identification — Highlights stagnant air or insufficient cooling so floor tiles and containment can be adjusted.
Redundancy testing — Verifies remaining plant maintains setpoint during simulated mechanical failure.
Electrical stress testing — Confirms UPS, generators, and distribution remain stable at full load.
Performance baselines — Delivers data to support SLAs for uptime and operational acceptance.

Deployment and capacity

We manage the full test environment—from load bank positioning and sensor integration to incremental load steps that map the cooling response curve.

Thermal stress is applied in stages (typically 25%, 50%, 75%, and 100% of target load) so engineers can observe plant response, adjust controls, and sign off each milestone before the next increment. Real-time monitoring captures temperatures, flows, and alarms throughout.

In-house capacity

KES maintains significant in-house heater and boiler capacity, with turnkey distribution, cabling, controls, and site labour.

500 kW boilers — 25 MW in-house capacity
200 kW heaters — 28 MW in-house capacity
100 kW heaters — 8 MW in-house capacity

15 kW heaters — 16 MW in-house capacity
Distribution panels, cabling, and controls supplied by KES
Experienced teams for multi-megawatt hall deployments