Your Protective Packaging Strategies Checklist for the AI Data Center Boom
As AI adoption accelerates, the physical infrastructure powering it is racing to keep up. Data center construction is booming across the U.S., with billions in investment pouring into regions like Virginia, Texas, and Arizona. Global data center capacity could triple by 2030, driven largely by the explosive growth of generative AI– with all that equipment and building material shipping from location to location, protective packaging strategies need to evolve just as fast (Lee et al., 2025).
From HVAC systems to prefabricated wall panels, the components that make up these massive facilities are at risk of damage during manufacturing, in transit or on-site. For manufacturers and distributors supplying the build, every shipment is mission-critical. A damaged enclosure or compromised finish could mean costly project delays, missed installation windows, or failed performance specs, making packaging choices more important than ever.
To help you stay ahead of the curve, we’ve pulled together a quick checklist of packaging to-dos built for the pace and pressure of AI-driven construction.
1. Identify risks and choose the right protection
Before packaging can do its job, you need to understand what exactly it’s protecting—and what it’s protecting against. From polished finishes, such as aluminium or stainless steel, to oversized components, each item presents different risks across shipping, staging, and installation.
Once those needs are clear, align them with proven protective solutions:
- Surface-sensitive materials: Stainless steel cooling towers or painted metal roofing benefit from temporary protective films that guard against scratches and abrasions – without leaving residue.
- Heavy or irregular shapes: Computer Room Air Conditioners (CRAC) or metal server racking require block and brace cushioning, like fabricated foam plank.
- High-value electronics: Server components require superior shock-absorbing materials. Pregis foam-in-place materials are engineered to conform to exact dimensions, helping to minimize impact and prevent shifting during transport.
2. Consider environmental and logistical factors
Construction sites are dynamic environments with constantly shifting conditions. Your packaging needs to be just as agile—ready to protect sensitive materials no matter where or when they’re handled:
- Temperature swings and moisture can degrade certain materials; ensure packaging is rated for job site conditions.
- UV exposure can discolor or damage finished surfaces, making temporary protective films an effective safeguard.
- Footprint and stackability matter when staging materials for phased installs.
- On-site waste handling: Right-sized packaging reduces excess material and simplifies cleanup.
3. Integrate packaging into the construction workflow
Packaging should not be an afterthought—especially when every delay, rework, or material mishandling can ripple across a tightly choreographed construction schedule. A well-defined packaging strategy from the outset allows you to certify that every component arrives intact, on time, and ready for installation:
- Coordinate with installers to ensure packaging can be removed quickly without damaging the enclosed material.
- Align with shipping timelines and sequences to avoid staging delays.
- Think holistically—packaging should perform across every phase of the value chain. From heat resistance during manufacturing, to cushioning in transit, to moisture and UV protection on-site, each stage presents unique demands that packaging must be designed to handle.
4. Partner with experienced packaging suppliers
Smarter packaging isn’t just a nice-to-have—it’s how you keep your timeline tight, your materials protected, and your crew moving. From damage reduction to faster installs and cleaner staging, the right strategies can make a measurable difference on every build. Which is why choosing the right packaging partner matters. Pregis brings deep expertise in industrial applications, with consultative support and customizable solutions that scale with demand—plus design and testing capabilities through Pregis IQ to ensure packaging performs in real-world building environments.
Whether your customers are manufacturing for their first data center or ramping up production for the next wave, we can help you craft a packaging strategy that fits their timelines, protects their components, and supports their crews. Connect with a Pregis representative today to start planning smarter.
1. Lee, V., Seshadri, P., O’Niell, C., Choudhary, A., Holstege, B., & Deutscher, S. A. (2025, February 5). Breaking barriers to data center growth. BCG Global. https://www.bcg.com/publications/2025/breaking-barriers-data-center-growth
