Data center logistics: How does the AI infrastructure get to where it’s needed?

Every AI query, every access to the cloud, and every streaming request ultimately ends up in a data center. The expansion of these facilities has accelerated significantly in recent years, as has a branch of logistics largely overlooked outside the industry. Servers worth millions must be transported across continents, delivered on time, and installed with millimeter precision.

This article explains how the supply chain for data center construction works, the requirements involved, and the role of road freight in the process.

What is data center logistics?

Data center logistics (DCL) refers to the planning and execution of all transport and handling processes related to setting up, operating, and dismantling data centers. The term encompasses more than just transport: it extends from pickup at the manufacturer, to temporary storage, delivery, and installation of the hardware onsite.

DCL differs from traditional IT logistics primarily in terms of scale and fault tolerance. Rather than involving just individual devices, it deals with entire racks, cooling systems, power supplies, and network infrastructure for sites that cannot tolerate any downtime during operation.

Three terms keep coming up in this context:

• Hyperscaler: These are the operators of large, multi-site, distributed data centers. They are usually cloud or platform providers who are rapidly expanding their capacity.
• Data hall: The protected area of a data center where racks and servers are set up and made operational.
• White-glove service: Specially trained teams deliver and set up the equipment, unpacking, positioning, aligning, and connecting it.

Why is the market currently growing so quickly?

The primary driver is the increased demand for capacity generated by AI applications. Training models and performing inferences require significantly more computing power than previous cloud workloads, and this demand can only be met by adding physical locations. Anyone looking to sell computing capacity must first deploy hardware.

This has a direct impact on logistics volume. The data center logistics market was estimated to be worth approximately $23 billion in 2025 and is expected to reach at least $35 billion by 2030. Growth is spread across the globe. Europe, India, Australia, Indonesia, and the Middle East are actively expanding their infrastructure in addition to the U.S.

There is also a second, often overlooked effect: hardware replacement cycles are becoming shorter. Therefore, data centers are not one-time construction projects, but rather generate recurring logistical needs throughout their entire lifespan.

What does a data center’s supply chain entail?

The supply chain begins with the manufacturer and only ends when the equipment is dismantled. The equipment typically goes through six stages, five of which involve road transport.

1. Collection and supplier management: Coordination of pickups from the factory, which often involves multiple suppliers working simultaneously within coordinated time slots. Transport to the port or airport is almost always by truck.
2. Main leg: For intercontinental shipments, sea and air freight come into play. For particularly time-sensitive shipments, this also includes charter flights. The situation is different within Europe: if the hardware originates from a European factory or port, the main part of the journey is by road.
3. Staging and Storage: Temporary storage near the final destination which often includes pre-configuration, quality inspection and order picking according to construction phases.
4. Delivery to site: Delivery to the data centre comes with increased security requirements and must be closely coordinated with the construction schedule. Depending on the component, this can range from semitrailers to special transports requiring official permits.
5. Installation in the data hall: Positioning and aligning the racks, grounding the systems, and connecting the cabling are all tasks that require technical expertise and great care.
6. Lifecycle support: Supply of spare parts during ongoing operations, as well as the removal, refurbishment, or relocation of hardware at the end of its utilization cycle.

Each of these stages has its own documentation, security and traceability requirements. Handovers between different service providers are critical points because accountability and transparency can be lost at these junctures.

Therefore, road freight is not just the final step at the end of the chain; it is the vital link connecting all the other stages.

What makes the transport so challenging?

The most obvious factor is the value of the goods. Prior to the AI boom, the typical price of a server ranged from $100,000 to $250,000 per unit. Today, it is not uncommon to see prices ranging from $1 million to $3 million, as these servers incorporate specialized processors and sophisticated cooling technology.

This also increases the demands of physical handling. Modern server racks are heavier and bulkier than earlier generations. Once they reach a certain size, air transport is no longer an option. This shifts the focus to sea and land transport, which extends lead times. Additionally, this technology is sensitive to vibration, humidity, and temperature fluctuations.

The third aspect is security. High-quality IT hardware is a prime target for theft. Losing only one item can delay an entire construction phase. Thus, a seamless chain of custody – that is, a documented chain of transfer from pickup to installation –, secure vehicles, and vetted personnel are standard practice.

What role does road freight play?

In data center logistics, road freight handles the legs of the journey that no other mode of transport can cover. It connects seaports and airports with interim storage facilities and ultimately delivers the equipment to the construction site – often to locations far from major metropolitan areas, because data centers are built where sufficient space and network connectivity are available.

Data center shipments have three particularly characteristic requirements:

• Time window instead of delivery day: At active construction sites, deliveries can disrupt the schedule. Early deliveries tie up space, and late deliveries delay installation crews.
• Bulky and heavy cargo: Cooling units, transformers, and generators often exceed standard dimensions, necessitating special transport arrangements and permits.
• In-house spare parts logistics: Once a data center is up and running, every hour counts when components fail. Direct runs that can be arranged at a moment’s notice are essential.

For shippers, this means road freight in this particular sector is not merely an interchangeable add-on at the end of the supply chain. Rather, it determines whether the entire project stays on schedule.

Why does speed decide who wins a contract?

Response times in this market are significantly shorter than the industry average. Clients expect price quotes for air freight within two to four hours and for ocean freight within 24 hours for short-notice shipments. For standard freight operations, 24 to 72 hours is typical.

The reason for this is the operators’ cost accounting. If the commissioning of a data hall is delayed, costs arise that far exceed transport costs. For predictable, recurring shipments, price certainly matters, but for short-term needs, availability and reliability take precedence.

For logistics service providers, this means that the pace of quotation processes, capacity checks, and scheduling must be on par with that of the shipments themselves.

What happens after go-live?

The logistics task does not end with commissioning. Since hardware generations have shorter lifespans than in the past, every installation is predictably followed by dismantling. Servers and racks are removed and transported securely to be refurbished, reused at other locations, or recycled.

In this case, returns management is logistically more challenging than it initially appears. Removed hardware typically contains data and must be handled in a way that ensures proper security and documentation. At the same time, undamaged hardware retains considerable residual value.

From a resource perspective, this is a significant asset. Each component returned to service instead of being discarded replaces the production of a new one. This benefit can be quantified on a per-project basis, provided that refurbishment and reuse are factored into the initial planning.

How does DHL position itself in the data center logistics sector?

DHL coordinates data center operations across divisions as the One DHL Network. A dedicated group of regional teams in Asia-Pacific, Europe, the U.S., Latin America, and the Middle East and Africa manage operations, and a global Center of Excellence supports them by overseeing operational standards, partner networks, and solution design. DHL Global Forwarding takes the lead, while DHL Freight serves as the road freight provider. DHL Supply Chain is responsible for warehouse and facility capacities, among other things.

DHL’s offerings are based on three pillars.

• End-to-end handling with global coverage: A consistent approach from the factory to the data hall, with a dedicated contact person throughout all project phases rather than shifting responsibilities for each phase.
• Reliability for business-critical processes: Standardized, safety-tested processes at all locations, designed to identify and mitigate risks to operational readiness at an early stage.
• An integrated network: Integration of air, sea, and land transport, warehousing, and installation into a coordinated process – rather than a string of individually contracted providers with inefficiencies at the interfaces.

This is complemented by specialized handling of high-value infrastructure, specially trained teams working in the data hall, and digital shipment tracking that provides real-time status updates.

The need for these services is well-documented. According to their own statements, around 85% of hyperscalers would prefer to work with a single end-to-end partner. However, only 43% currently consider themselves positioned to do so. Precisely this gap is addressed by the cross-divisional approach.

Conclusion: How quickly is the logistics sector developing AI infrastructure?

The expansion of data centers has become a driving force of the digital economy. Currently, it depends just as much on the supply chain as on the technology itself whether a new cloud region or an AI service will be available by the planned deadline. In these projects, logistics is not just a downstream cost factor; it is an integral part of the planning process.

Logistics service providers must adapt to these changing requirements. They need quick response times, robust security standards, experience with high-value and bulky cargo, and the ability to integrate all modes of transport and dismantling into a seamless process.

Road freight plays a particularly visible role here, on the final leg, when it becomes clear whether the schedule will be met. Those who plan transport early in such projects can avoid delays and ensure successful commissioning. If you are looking for a partner for this – please feel free to contact us.

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