You must have had some way in the lab to generate 100K synthetic concurrent HTTP requests to determine your scaling needs May I know what tools you used to generate that load?
When I mean "concurrent" I am asking for concurrency at the server at a granularity of a second (the generating client concurrency is a different issue). A quick way to check this is your access log on a microsecond time scale and the number of loglines for a given second should be close 100,000.
http://www.metabrew.com/article/a-million-user-comet-applica...