Blog

Every rack and cabinet that leaves Vertiv carries more than just steel. It carries a story of precision, craftsmanship, and innovation. Each year, our facility processes over 500,000 pounds of U.S. sourced steel, turning raw material into the high-performance enclosures that support data centers, broadband networks, and critical IT systems around the world.  Take a tour with our video or read on for a step-by-step breakdown of our process.

 

 

Step 1: Locally Sourced Metal

The process begins with shipments of different metals, aluminum, and stainless steel, all sourced locally from Ohio. From here, the material is distributed across three laser cutters and two punch presses.

 

Step 2: Cutting with Precision

Our laser cutting capabilities range from a 3,000-watt cutting 300 inches per minute to an 8,000-watt fiber laser capable of 1,400 inches per minute. 

For complex stamping, we rely on a 32 ton, 56 station punch press equipped with forming tools, stamps, knockouts, and louvers. Making it possible to create details that lasers can’t. 

Step 3: Storage and Material Handling 

Once cut or punched, parts are organized by our Night Train storage system, which automatically stores and retrieves materials until they’re needed for the next operation. This automation improves efficiency, reduces downtime, and helps us manage large volumes of production with speed and accuracy. 

Step 4: Forming the Shape

Flat sheets become functional components in our forming department. From hydraulic press brakes to robotic arms and semi-automatic forming machines, our team uses the latest technology to bend, fold, and shape every piece to each specification. 

Software-driven programs guide the machines, while operators provide oversight and craftsmanship, ensuring flexibility for high-volume runs and custom parts. 

Step 5: Welding and Surface Prep

Next, parts move into our welding shop, where skilled operators use spot welding and precision welding tables to assemble doors, and enclosures. From there, surfaces are smoothed to create a great finish before coating. 

Step 6: Powder Coating with Complete Coverage

Durability begins with our five-stage wash system, which cleans, rinses, and applies protective treatments before parts enter the powder booth. 

Our automated powder coating line uses a scanning system to ensure 100% coverage, even in hard-to-reach corners. Reclaim systems recycle powder for maximum efficiency and sustainability. After coating, parts are baked at 350°F for 35 minutes, locking in a durable finish that resists corrosion and wear.  

Step 7: Assembly, Testing, and Quality Inspection

Once finished, components move to final assembly. Here, every door, panel, and accessory is fitted to meet customer specifications. Each product goes to a final inspection by quality managers, ensuring nothing leaves our floor without meeting Great Lakes’ high standards.  

From Start to Finish

At Great Lakes, every process is designed with one goal: delivering racks and cabinets that perform reliably for years to come.