Zinc whiskers in data centres are tiny metallic filaments that form on zinc-coated surfaces, such as electroplated steel and zinc-coated floor tiles. These whiskers are created due to internal stresses within the zinc coating and environmental factors like temperature fluctuations and high humidity. If not remediated on time, they can become airborne contaminants, posing a significant risk to equipment by causing electrical short circuits, malfunctions, and costly downtime. Effective remediation involves identifying and containing affected areas, replacing zinc-coated materials with non-zinc alternatives, and thoroughly cleaning with HEPA-filtered vacuums.
Regular monitoring, preventive maintenance, and staff training are also crucial to minimise the risk and impact of zinc whiskers, thereby ensuring the protection and reliability of data centre operations.
How Zinc Whiskers Form in Data Centres
In data centres, zinc whiskers are created through a combination of factors related to the zinc-coated materials used in the infrastructure and the environmental conditions within the facility. Here’s a detailed overview of how zinc whiskers form in this context:
1. Zinc Coating and Electroplating
Electroplating Process: Zinc coatings are often applied to metal surfaces (such as steel) in data centres through electroplating. This process involves depositing a thin layer of zinc onto the metal substrate to provide corrosion resistance.
Thin Coatings: The zinc coating is typically thin and may be prone to internal stresses due to its application method and the nature of the substrate.
2. Internal Stresses
Mechanical Stresses: The zinc coating and the underlying metal may experience differing rates of expansion and contraction due to temperature changes or mechanical impacts. These stresses can contribute to the formation of whiskers.
Thermal Stresses: Fluctuations in temperature within the data centre can create thermal stresses in the zinc coating, further contributing to whisker formation.
3. Formation of Whiskers
Deformation of Coating: Internal stresses cause the zinc coating to deform at a microscopic level. This deformation can lead to the formation of tiny, hair-like structures known as whiskers.
Nucleation and Growth: Once nucleated, these whiskers can grow in length. The process is influenced by the inherent properties of the zinc coating and the environmental conditions within the data centre.
4. Environmental Conditions
Humidity and Temperature: High humidity and fluctuating temperatures in data centres can exacerbate the stress within the zinc coating. These environmental factors can accelerate the formation and growth of zinc whiskers.
Airflow and Dust: The movement of air and the presence of dust in the data centre can also affect the growth and dispersion of zinc whiskers.
5. Detachment and Contamination
Airborne Contaminants: Over time, zinc whiskers may detach from their original surface. Once airborne, they can spread throughout the data centre, settling on sensitive equipment and contributing to potential issues.
Risk to Equipment: As whiskers settle on electronic components, they can cause short circuits, malfunctions, and other problems, impacting the performance and reliability of data centre operations.
How Zinc Whiskers Impact Data Centres and Equipment
Electrical Short Circuits: Zinc whiskers can cause short circuits when they settle on exposed electrical contacts, circuit boards, or other sensitive components inside servers and networking equipment. Their conductive nature allows them to bridge electrical connections inadvertently, leading to equipment failure.
Equipment Malfunctions and Failures: When zinc whiskers enter cooling fans, power supplies, or other electronic components, they can cause malfunctions, unexpected reboots, and even permanent damage. This can result in unplanned downtime and costly repairs or replacements.
Intermittent Performance Issues: Zinc whiskers can cause difficult-to-diagnose intermittent issues, such as system crashes, data corruption, or degraded performance. These sporadic problems are often challenging to trace directly to zinc whiskers, complicating troubleshooting efforts.
Contamination of Airflow Systems: Whiskers can be drawn into air filtration and cooling systems, where they can accumulate and circulate, spreading contamination throughout the data centre. This increases the risk of whiskers reaching sensitive areas, including inside servers and other IT equipment.
Increased Maintenance Costs: The presence of zinc whiskers can lead to frequent maintenance and cleaning requirements, elevating operational costs. Regular cleaning without addressing the root cause only temporarily reduces the risk, as whiskers continue to form and shed.
Remediation of Zinc Whiskers
Addressing zinc whiskers requires a comprehensive approach to identification, containment, and remediation to protect data centre operations. Below are the key steps for zinc whisker remediation:
1) Identification and Inspection:
Visual Inspection: Conduct thorough visual inspections under magnification to identify areas where zinc whiskers are present. Common sources include raised floor tiles, server racks, and other zinc-coated surfaces.
Environmental Testing: Use specialised equipment like microscopes or ion counters to detect whiskers in the air and assess the extent of contamination.
2) Containment:
Isolate Affected Areas: Limit access to areas where zinc whiskers are identified to minimise the risk of further spreading. Isolating affected equipment can prevent whiskers from contaminating the broader environment.
Positive Air Pressure: Implement positive air pressure systems to prevent contaminated air from flowing into clean areas of the data centre.
3) Replacement of Contaminated Materials:
Replace Zinc-Coated Floor Tiles: The most effective long-term solution is to replace zinc-coated raised floor tiles with non-zinc-coated alternatives, such as aluminium or epoxy-coated tiles, which do not produce whiskers.
Upgrade Zinc-Coated Components: Replace other zinc-coated parts, such as server racks or cable trays, with non-zinc materials or components specifically designed to resist whisker formation.
4) Cleaning and Removal:
HEPA Vacuuming: Use high-efficiency particulate air (HEPA) filtered vacuums to remove zinc whiskers from contaminated surfaces without reintroducing them into the environment. HEPA vacuums are essential because they capture even the smallest particles, including whiskers, preventing their dispersal.
Wipe Surfaces with Antistatic Cloths: Clean surfaces with antistatic wipes to remove loose whiskers and reduce the risk of electrostatic discharge (ESD), which can cause further equipment issues.
Controlled Airflow Cleaning: Carefully clean airflow systems, including filters, ducts, and fans, to prevent whiskers from circulating within the data centre.
5) Preventive Measures:
Regular Monitoring and Maintenance: Establish a regular inspection and maintenance schedule to monitor for zinc whiskers and address potential sources promptly.
Use Non-Zinc Materials: Where possible, select equipment and components made from non-zinc-coated materials, reducing the potential for future whisker formation.
Environmental Controls: Maintain stable temperature and humidity levels to minimise the stress that can contribute to whisker growth.
6) Training and Awareness:
Staff Training: Train data centre personnel on the risks associated with zinc whiskers, how to identify them, and the correct procedures for handling and remediation.
Contractor Awareness: Ensure contractors working in the data centre are aware of zinc whisker risks and adhere to protocols that minimise the disturbance of contaminated areas.
Conclusion
Zinc whiskers pose a significant threat to data centre operations due to their ability to cause equipment failures, electrical shorts, and ongoing contamination issues. Effective management includes identifying affected areas, containing and removing whiskers, replacing zinc-coated components, and implementing preventive measures to protect sensitive IT infrastructure. By addressing zinc whiskers proactively, data centres can minimise downtime, reduce maintenance costs, and safeguard the performance and reliability of their critical equipment.
Tailored Zinc Whisker Decontamination Solutions
Each data centre has distinct requirements shaped by its design, size, and operational needs. We employ advanced whisker remediation solutions, including sophisticated air filtration systems, comprehensive cleaning protocols, and continuous monitoring, to effectively manage zinc whisker contamination. By tailoring our approach to the specific conditions of your data centre, we ensure optimal protection for your sensitive equipment and infrastructure, maintaining a reliable and contamination-free environment.
Contact Us
Protect your IT infrastructure from the risks of airborne contaminants with our specialised decontamination services. Reach out to us today to discuss how we can tailor our solutions to meet the unique needs of your data centre. Partner with us to enhance equipment reliability, improve operational efficiency, and maintain a pristine environment.
