Server rack design for military and national security deployments

Reliable IT hardware is crucial in modern military and national security / intelligence operations.  From a military perspective, IT hardware may be used in harsh battlefield environments or onboard Naval vessels.  From a national security and intelligence perspective, agents may transport classified data on commercial aircraft.  These types of environments are subject to shock, vibration, and water ingress.  In these scenarios, ensuring the integrity of critical IT infrastructure is vital, and rugged cases can help protect servers, switches, and other devices.  Case design is key and can influence field performance.

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Fit-for-purpose

In military and national security deployments, any equipment must withstand intense vibrations during transport, sudden shocks from accidental drops, and exposure to water and dust in open or hostile terrains.  Standard IT hardware is not built to withstand this stress, making robust protective measures necessary.

Rugged cases can help by incorporating advanced shock and vibration-dampening systems, and feature waterproof and dustproof seals that protect sensitive components, maintaining operational reliability regardless of the environment.  Protection from water and dust ingress is key and can help the case become IP65-67 rated as well as other Mil-Std 810 environmental qualifications.

There are also logistical and operational constraints.  Tactical deployments require quick and reliable transport of IT equipment, often in high-stakes situations.  Rugged cases offer practicality, usually including integrated handles and wheels for rapid portability.  These features allow military and security personnel to carry and deploy heavy cases with minimal effort, so the mission can proceed without delays.

The shift to the field

As military and national security operations increasingly depend on real-time data processing and secure commissions, IT hardware has become more important.  There is increasing demand for edge computing solutions — deployable IT hardware that processes data locally, without reliance on remote servers or satellite connections.  This shift has enabled faster decision-making, enhanced data security, and provided greater control over mission-critical systems, particularly in remote or contested areas.

Adapting IT hardware for the field has brought its challenges.  Servers and switches, for example, are traditionally suited to data centres and may not have the necessary structural integrity to weather, vibrations, or harsh temperatures.  However, providing the design is suitable, these cases can ensure such devices are field-ready.  Custom mounting brackets, blade retention systems, and shock-absorbing features are just some solutions that can help commercial-off-the-shelf (COTS) equipment comply with stringent military standards.

Design features

When designing mobile cases and enclosures, such as Ultralife’s EL8000-MCS, durability is one of the main considerations.  Aluminum is a common material choice because it is lightweight yet robust.  Unlike plastics, which can crack or degrade under extreme conditions, it can also withstand impacts and be formed back into shape.  As well as extending the case’s lifespan and reducing repair costs, it minimizes waste — a key consideration in the drive towards sustainability.

As previously mentioned, shock and vibration dampening are also important.  Cases such as the EL8000-MCS feature a suspended internal frame that absorbs impacts and vibrations during transportation.  Consequently, the user can be confident that the hardware will function as normal, even after enduring the rigors of the field.

Although the cases must be durable and rugged, they must be easy to move around.  Integrated handles on both the front and rear of the case enable two-person lift, distributing weight evenly while minimizing strain on the handlers.  Handles at the front and back of the case are especially invaluable onboard vessels where there is insufficient room for two people and a case side-by-side.  In some cases, wheels are added onto the rear, allowing users to roll the case over short distances without lifting it.

With the EL8000-MCS, Ultralife has also made accommodations for lid storage.  In field operations, the end user can often misplace the lid, which leads to unnecessary delays and equipment exposure.  To prevent this, Ultralife’s case comes with two 2” interchangeable lids and quarter-turn latches, which can replace mismatched rack-mount lids and knuckle-busting latches.  It might seem like a small detail, but it can make a huge difference in keeping the IT hardware protected and deployable.

With regards to national security agents transporting confidential information by air, Ultralife has designed a carry-aboard case (the EL8000-CA) that meets airline compliant sizing requirements and can fit into the overhead space or under the seat of some aircraft.  An integrated telescoping pull handle and roller bearing wheels help users to transport the case through the airport terminal as they would a suitcase.

Compliance and customization

For defense applications, the case design must comply with stringent military requirements, especially those that relate to reducing electromagnetic interference that could compromise the IT hardware or other nearby electronic devices.  Electrical bonding is crucial here, adding as many bonding points in the case as required to meet Military Standard 461 (MIL-STD-461) – the military’s standard for EMI interference.

Additionally, security and advanced locking mechanisms can help prevent unauthorised access to the IT hardware inside the cases.

For example, government-approved padlocks can be combined with wire latches, safeguarding against tampering.  Designing this level of security into the case is crucial, especially for servers that contain sensitive or confidential data that is critical to national security.

Rugged cases are not just protective enclosures, they are tailored solutions designed to meet the needs of specific IT hardware and applications.  Ultralife have designed and installed blade retention brackets and custom mounting hardware for our cases to help secure our customers’ servers and other IT components, even during intense shock & vibrations and movements.  Usually, mounting hardware is unique to each customer, so a tailored solution is required.  There is not an industry standard for mounting and servers are unique to each manufacturer, so we approach this on a case-by-case basis.

If a custom solution is required, it is important to work with a partner that can support the entire integration process.  For example, Ultralife sells cases directly, but can also receive the customer’s hardware and integrate it into a custom solution before shipping it back to their facility.

Rugged cases help to keep IT hardware protected and ready for the demands of military and field deployments.  These cases combine durability, portability and a tailored design, transforming standard equipment into mission-critical solutions.  Whether it is for military or another high-stake application, a well-designed rugged case can help keep its contents secure and functional.

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