Cumulus Quality https://cumulusquality.com Work Done Right™ Thu, 12 Feb 2026 14:23:47 +0000 en-US hourly 1 https://i0.wp.com/cumulusquality.com/wp-content/uploads/2023/01/cropped-Cumulus-Logo-Black-copy.png?fit=32%2C32&ssl=1 Cumulus Quality https://cumulusquality.com 32 32 202253790 500,000 Workers Short: Why Construction’s Real Risk Is Execution Capacity https://cumulusquality.com/500000-workers-short-why-constructions-real-risk-is-execution-capacity/?utm_source=rss&utm_medium=rss&utm_campaign=500000-workers-short-why-constructions-real-risk-is-execution-capacity Thu, 12 Feb 2026 14:23:47 +0000 https://cumulusquality.com/?p=16146 The U.S. construction industry is facing a reality it can no longer postpone. According to a recent Fortune article, the...

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The U.S. construction industry is facing a reality it can no longer postpone.

According to a recent Fortune article, the industry will need half a million new workers next year just to keep pace with demand. On its surface, this sounds like a hiring challenge. In practice, it signals something far more consequential.

This is not a temporary labor dip or a short-term training gap. It is a structural constraint colliding with rising project complexity, compressed schedules, and unprecedented capital investment.

When labor availability tightens, the first thing lost isn’t productivity — it’s tolerance for error.

Fewer workers mean:

  • Less inspection coverage
  • Fewer experienced eyes on critical work
  • More handoffs without context
  • Greater risk that issues surface late, when correction is most expensive

Historically, quality has been treated as a downstream function — something to verify once work is complete. That approach assumes abundant labor, time for rework, and margin for recovery.

Those assumptions no longer hold.

In today’s environment, quality must operate upstream. It must surface issues early, preserve institutional knowledge, and reduce reliance on heroics and tribal memory. When people are scarce, systems must absorb variability — not amplify it.

Execution capacity is no longer defined by headcount. It is defined by the ability to:

  • Capture reality as work happens
  • Detect deviation before it compounds
  • Create feedback loops that improve outcomes across projects

For owners and operators, the risk isn’t simply schedule or cost overruns. It’s whether delivery systems are designed for the conditions that actually exist — not the ones we hope will return.

The industry’s labor challenge is real.

But the more important question is this:

Are our quality systems built for abundance — or for scarcity?

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Water impact needs better measurement. https://cumulusquality.com/water-impact-needs-better-measurement/?utm_source=rss&utm_medium=rss&utm_campaign=water-impact-needs-better-measurement Tue, 03 Feb 2026 21:47:02 +0000 https://cumulusquality.com/?p=16124 As we’ve spent more time looking at water infrastructure, one theme keeps coming up in conversations with operators, utilities, and...

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As we’ve spent more time looking at water infrastructure, one theme keeps coming up in conversations with operators, utilities, and investors: people don’t trust many of the existing water-impact claims.

And it’s not because the intentions are bad. It’s because the underlying measurement often isn’t strong enough to support real financial decisions.

Many traditional water offsets were built for philanthropic or ESG reporting purposes, not for infrastructure financing. They rely heavily on modeled estimates, assumptions about user behavior, or generalized basin-wide metrics. For community projects, that may be fine. But for large industrial water users, utilities, or investors, that level of uncertainty becomes a non-starter.

If you’re going to put hundreds of millions of dollars into a new plant, change siting plans for a data center, or rely on a third party to offset a meaningful portion of your water footprint, you need deterministic, metered, auditable data, not probability curves.

This is exactly the problem the World Bank highlights when discussing why private capital avoids the water sector: investors don’t have the confidence that promised outcomes will actually materialize. Without reliable measurement and verification, the risk is simply too high, and the returns are too low to compensate for it. That’s how you end up with a $7 trillion global funding gap that public budgets can’t fill.

The technical requirements are not complicated in principle, but they matter enormously in practice:

  • Direct metering instead of models
  • Clear baselines tied to actual historical usage
  • Continuous monitoring—not one-time estimates
  • Third-party verification
  • No double counting
  • Clear, auditable ownership of environmental attributes
  • Outcomes backed by contractual and insurance protections

These ideas appear in most credible standards, including the Blu Diamond Water Standard, which requires deterministic measurement, third-party audits, insurance-backed assurance, and strict rules against modeled or probabilistic claims.

The point here isn’t about any single program. It’s about the evolution of water markets.

If water is going to become a real part of corporate and infrastructure decision-making, whether for AI, manufacturing, semiconductors, or municipal supply, its impact accounting has to reach the same level of rigor as energy markets.

For infrastructure operators, this isn’t academic. Without reliable measurement, you can’t plan. Without verification, you can’t invest. Without trust, you can’t scale.

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Key Regions for Data Center Construction in the U.S. https://cumulusquality.com/key-regions-for-data-center-construction/?utm_source=rss&utm_medium=rss&utm_campaign=key-regions-for-data-center-construction Thu, 16 Oct 2025 17:11:23 +0000 https://cumulusquality.com/?p=14518 With the data center industry evolving at a rapid pace, it’s no surprise that current location trends for new data...

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With the data center industry evolving at a rapid pace, it’s no surprise that current location trends for new data center construction are different than last year. Key states like Virginia and Texas continue to experience strong activity, however, the industry is also seeing an expansion of emerging markets outside of the established data center hubs.

Key Regions for Data Center Construction in the U.S.

  • Virginia
  • Texas
  • Midwest
  • Arizona
  • Louisiana
  • North Dakota
What’s Driving Regional Trends?

It’s important to note that site selection still heavily depends on the following criteria:

  1. Power Supply and Grid Capacity
  2. Land Availability and Cost
  3. Network Connectivity
  4. Cooling and Climate
  5. Regulatory Environment
  6. Proximity to Demand

Primary markets for data center construction (i.e. Silicon Valley, Hillsboro), are becoming saturated and hyperscalers are increasingly looking to secondary markets that balance all these factors.

Midwest on the Map

One of the fastest-growing hotspots of data center construction is the Midwest. The city of Columbus, Ohio, and Chicago remain the region’s primary data center markets, however major data center development is occurring from Kansas to Michigan and to other Great Lakes states as well.

The Midwest is an attractive area for data center developers as it offers relatively low land cost, access to multiple power grids, and redundancy across regions. The cooler temperatures also reduce the need for energy-intensive cooling.

Looking to Louisiana

One of the major hyperscalers in the U.S. has officially broken ground on what will be the largest data center in the Western Hemisphere, and this is happening in Richland Parish, Louisiana.

While this build may be the region’s first data center, it probably won’t be the last as companies are increasingly eyeing Louisiana for data center projects. Developers require large, continuous plots of land and access to natural gas and transmission lines, making the Pelican State a prime location for future construction.

Relay to coastal data routes, relatively lower land costs, and strategic location for serving both U.S. and Gulf-coast network path, also make it a very attractive region for further development.

Challenges in Data Center Construction Remain

The industry continues to face many challenges to keep up with demand. Power availability is the most critical issue, as grid capacity and upgrade timelines often lag behind development needs.

On top of this, escalating construction costs, supply chain bottlenecks, and skilled labor shortages further complicate timelines and budgets while developers try to maintain speed to market in an intensely competitive landscape.

Hyperscalers and developers are establishing solutions to mitigate constraints, where possible. For example, in response to the skilled labor shortage, builders are using technology like the Cumulus Quality Execution platform to upskill and guide workers step-by-step through operating procedures to guarantee quality in and eliminate rework.

Data center construction faces complex challenges, but the industry is notorious for problem-solving and will continue to do so by adopting smarter planning, technology, and collaboration strategies.

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The Myth of the Triple Constraint: Achieving Cost, Schedule & Quality Goals in Data Center Construction https://cumulusquality.com/the-myth-of-the-triple-constraint-achieving-cost-schedule-quality-goals-in-data-center-construction/?utm_source=rss&utm_medium=rss&utm_campaign=the-myth-of-the-triple-constraint-achieving-cost-schedule-quality-goals-in-data-center-construction Mon, 06 Oct 2025 23:10:32 +0000 https://cumulusquality.com/?p=14422 Yes, Developers can have it all. But how? Many forces are creating persistent pressure to build data centers (and build...

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Yes, Developers can have it all. But how?

Many forces are creating persistent pressure to build data centers (and build them quickly) right now.  Key drivers of the current data center boom include explosive growth in computational demand, digital transformation of business and consumer services and strategic geopolitical security motivations. Data centers are truly the backbone of our current and future world infrastructure and that is what makes them so important.

This accelerated rate of delivery has historically caused developers to make trade-offs between three goals of data center projects. Cost, schedule and quality are all equally important for data center execution, however in the past one of these priorities would often be sacrificed for the others.

Nowadays the data center industry is evolving at an unprecedented pace, and these trade-offs aren’t occurring as often. Stakeholders in new data center builds now demand to achieve all three goals without compromise – and they have figured out how to do so.

Precon Activities are Key

Developers are focusing on preconstruction (precon) activities as one of the most critical phases in data center delivery because it helps avoid the triple constraint trade-offs between cost, schedule, and quality. Here’s how it guarantees builders don’t have to compromise:

Cost Control

By establishing accurate budgets and estimates based on design documents, vendor input, and market pricing (all done before construction) developers prevent financial surprises during execution.

Through value engineering, stakeholders can review designs early and identify cost-saving alternatives—such as material substitutions or modular construction methods—without compromising performance. 

In addition, a proactive procurement strategy ensures that major equipment and materials are secured in advance, protecting the project from price volatility and long lead times that could otherwise escalate costs.

Schedule Assurance

Preconstruction activities provide a strong foundation for schedule reliability by identifying risks and potential bottlenecks early, such as permitting challenges, utility connections, or long-lead equipment.

By mapping out phasing and sequencing strategies, the team creates a realistic construction timeline that accounts for dependencies and allows for parallel workflows where possible. Decisions made during precon, like the use of prefabrication or modularization, further streamline execution by shifting work off-site and compressing the overall project schedule.

Quality Assurance

QA/QC is critical in ensuring the success of capital projects in high-stakes environments like data centers. Compromising quality, even unintentionally, often leads to safety risks, schedule delays, and increased costs. Quality must be considered in the precon stage and should be proactive, not reactive to avoid these unfavorable project outcomes.

Fortunately, there are tools and platforms, like the Cumulus Quality Execution System that provide real-time quality tracking and documentation and are essential for lifecycle traceability and operational readiness.

The Cumulus software uses Bluetooth-enabled tools (e.g., torque wrenches) to capture real-time data, replacing paper-based reports with automated, cloud-based records. By guiding workers through digitized Standard Operating Procedures (SOPs) and verifying compliance in real time, Cumulus prevents errors that lead to costly rework, which can account for up to 12% of project costs. 

Contractors also report never losing QA/QC documentation, eliminating rework due to lost paperwork. Cumulus provides QA/QC visibility, as users gain a single dashboard view of work progress and quality, enabling proactive issue resolution and serving as a proxy for project completion milestones, accelerating project delivery and guaranteeing safety.

Conclusion

Precon planning gives builders clarity on scope, integrates design and procurement, and plans for risks up front. It also unites all teams involved in construction and commissioning to align together for seamless execution. This allows projects to hit cost, schedule, and quality targets simultaneously—rather than having to trade one for the other mid-construction.

Quality assurance (QA/QC) must also be discussed early in the data center lifecycle and must be treated as a core value if builders want to avoid the “iron triangle” trade-offs between cost, schedule and quality.

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Not Just a Requirement: The Value of Torque Logs In Data Center Construction https://cumulusquality.com/not-just-a-requirement-the-value-of-torque-logs-in-data-center-construction/?utm_source=rss&utm_medium=rss&utm_campaign=not-just-a-requirement-the-value-of-torque-logs-in-data-center-construction Mon, 08 Sep 2025 13:55:45 +0000 https://cumulusquality.com/?p=14239 At a time when speed to market is being measured as the ultimate goal in data center construction, many vital...

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At a time when speed to market is being measured as the ultimate goal in data center construction, many vital factors in the process are often overlooked. One of those is the proper recording and reporting of torque logs.

However, torque logs can no longer be perceived as just “subcontractor paperwork.” These logs have become a leading indicator of data center reliability and operation, to the extent that operators are now specifying torque logging in their construction standards.

It is now crucial that all parties involved in data center construction, especially general contractors, prioritize this key step.

Beyond a Checklist Item

Torque logs are critical QA/QC tools that protect the general contractor’s reputation, reduce liability, and ensure the data center will meet the owner’s uptime and safety expectations. There are several reasons why torque logs should be a focus in data center construction:

1. Quality Control & Documentation

General contractors are ultimately responsible for ensuring that installations conform to engineering specifications and quality standards. Torque logs provide a documented trail proving that every critical bolt or connector was tightened to the correct specification—vital for commissioning and client handover.

2. Risk Mitigation & Liability Protection

In a facility where reliability is king and downtime is extraordinarily costly, general contractors benefit from torque logs as tangible proof that installation procedures were rigorously followed. This documentation becomes crucial in defending against post-construction claims or failures.

3. Subcontractor Oversight

Multiple subcontractors (electrical, mechanical, structural) may be responsible for torque-critical tasks. Torque logs enable general contractors to audit, verify, and sign off on each package of work in an organized manner, ensuring consistency and accountability.

4. Commissioning & Turnover Efficiency

During final commissioning, owners or commissioning agents will ask for traceable documentation. Torque logs are often part of the turnover deliverables, helping general contractors avoid delays during reviews or rework requests.

5. Safety Assurance

Loose or improperly torqued connections in critical systems (electrical busbars, grounding systems, mechanical flanges) can lead to overheating, mechanical failure, or even catastrophic incidents. Torque logs demonstrate proper fastening, reinforcing the safety integrity of the installation.

6. Corrective Action & Prevention

Torque logs aren’t just records—they can highlight anomalies such as trends of wrong torque values or tool miscalibrations. General contractors can use this data to mandate tool recalibration, retraining, or process tweaks before minor issues compound into major problems.

An Outdated Paper Process

As data center projects continue to expand without a hint of slowing down, the industry cannot keep up with demand. This imbalance has highlighted many opportunities to streamline delivery, though. One such opportunity is improving the torque logging and reporting practice that hasn’t changed since torque tools were first invented.

Traditional QA/QC processes rely on people, paper, and poor visibility, requiring extensive manual effort. This approach is error-prone, time-consuming, and inconsistent across contractors, leading to rework, delays, and audit failures. Fortunately, there is now a better way to capture this information and accelerate construction with quality assurance.

The Digital Way to Document Torque

Construction technology like the Cumulus Quality Execution System addresses the challenges of a paper process by automating data capture and standardizing digital reporting across all contractors. This software replaces cumbersome manual processes with a seamless, digital workflow that saves thousands of man hours, reduces rework and eliminates the need for paper torque logs.

As data center construction continues to accelerate, the need for reliable, safe, and compliant infrastructure (which includes torque activities), has never been more critical. Cumulus revolutionizes the creation of torque reports, automating data capture, standardizing processes, and delivering real-time quality assurance.

Conclusion

Torque logs are critical quality and reliability tools that are becoming an industry expectation and a differentiator for general contractors. Digital solutions like Cumulus, modernize torque documentation, ensuring compliance, safety, and efficiency while protecting reputations and reducing risk.  Cumulus provides digital torque guidance and automated QA/QC documentation, streamlining data center construction and delivering unmatched efficiency and quality.

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Scaling Data Center Capacity Amid Resource Constraints https://cumulusquality.com/scaling-data-center-capacity-amid-resource-constraints/?utm_source=rss&utm_medium=rss&utm_campaign=scaling-data-center-capacity-amid-resource-constraints Fri, 22 Aug 2025 17:06:43 +0000 https://cumulusquality.com/?p=14136 Scaling Data Center Capacity Amid Resource Constraints There’s no debating that demand is outpacing supply in the data center industry...

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Scaling Data Center Capacity Amid Resource Constraints

There’s no debating that demand is outpacing supply in the data center industry for a variety of reasons. The difficulty of scaling capacity in the industry comes from limits to the infrastructure that supports its construction. Power availability continues to keep developers up at night, but now the labor shortage, increasing permit delays and a backlogged supply chain contribute to the limitations as well.

As AI and cloud grow exponentially, the pressure to build amidst these challenges has only increased and this accelerated construction can cause numerous issues in early stages of building. Rework rates in the industry are significantly higher than other mission critical fields and rushing through the construction phase can pose safety concerns further down the line.

The Solution: Adopting a Systems Approach

Fortunately, there’s a way to address these concerns. Developers can meet this pressure head on by:

  1. Prioritizing QA/QC in Construction
  2. Leveraging Modularization
  3. Addressing Labor Shortage with Innovation
  4. Engaging the Supply Chain Early

This systems approach reduces rework, increases certainty, and ensures projects are safe, reliable, cost-effective, and sustainable.

Prioritizing Quality in Construction

Quality assurance and control in the construction phase of a data center must be a proactive discipline and not an afterthought, as it so often becomes. When developers rush to build, they often sacrifice this key performance indicator which can delay startups, trigger safety incidents, or erode trust with hyperscalers. Time-to-market drives value, but speed alone cannot come at the expense of quality.

A way to ensure this doesn’t occur is by maintaining digital QA/QC records to provide traceability and smoother and faster turnover to operations. The Cumulus Quality Execution System does just that.

Cumulus delivers 100% traceable, digital QA/QC documentation standardized across all contractors and projects, simplifying audits and ensuring compliance with hyperscaler requirements. This accelerates commissioning and testing by providing actionable QA/QC data instead of manual paperwork reviews.

By ensuring critical work in data center construction is completed correctly the first time, Cumulus reduces the risk of rework-related delays, keeping projects on schedule for hyperscaler occupancy.

Leverage Modularization and Offsite Construction

Modularization is one of the biggest levers for scaling data centers quickly despite constraints in the market. This strategy makes builds faster, safer, more predictable, and less dependent on scarce labor and delayed permits. It turns bottlenecks (power, people, permitting, supply chain) into parallelizable activities, unlocking speed to market without sacrificing quality or safety:

  • Prefabricated, factory-built modules provide higher safety, quality, and schedule certainty than stick-built projects.
  • Offsite construction mitigates constraints such as power delays, permitting bottlenecks, and skilled labor shortages.
  • Modular racks and MEP systems are increasingly necessary as AI-driven rack densities push to 500–600 kW, requiring precision manufacturing in controlled environments.

Because of the many advantages it provides against traditional construction, modularization will become a primary strategy for hyperscalers to scale (if it’s not one already).

Addressing Labor Shortage with Innovation

The U.S. alone is short millions of skilled craft workers such as electricians, welders, and pipefitters. Data centers specifically require specialized electrical and MEP installations that aren’t easily replaced with general construction labor. Add to this that younger generations are less likely to enter the trades and the pipeline of available labor is shrinking while demand skyrockets. Even with modularization, crews are still needed to install, connect, and commission, so what’s the answer?

Upskilling workers with digital tools bridges the gap in environments with accelerated schedules and aggressive milestones. Using construction technology like the Cumulus Execution System is one example of this.

Cumulus provides digital task guidance with embedding step-by-step instructions, visuals, and validation into daily work. Using structured workflows reduces cognitive load and improves consistency, capturing performance data to refine training and identify knowledge gaps.

This smart tool helps offset labor shortage pressures through fool-proof guidance in real-time, making scaling feasible despite constraints.

Engaging the Supply Chain Early

Early and frequent supply chain engagement is undervalued but critical to scale data center capacity rapidly. Switchgear, transformers, chillers, and generators all have lead times stretching 12–24 months due to global shortages. Because of this, suppliers should be treated as value partners, not just cost centers.

Early involvement and alignment of suppliers improves certainty on materials, equipment, and delivery schedules. Collaboration reduces risks of rework, warranty issues, and compliance failures, further adding to speed-to-market.

Conclusion

To scale data center capacity rapidly in a constrained market, leaders must treat speed as part of an integrated system—not as the only goal. This multi-dimensional challenge can be solved by using a systems approach that involves proactive QA/QC, a smart modularization strategy, collaborative effort to supply chain bottlenecks and using technology to address specialized labor shortages.

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Building Leaders to Build the Future: Kirk Offel on Data Centers, AI, and Purpose-Driven Teams https://cumulusquality.com/building-leaders-to-build-the-future-kirk-offel-on-data-centers-ai-and-purpose-driven-teams/?utm_source=rss&utm_medium=rss&utm_campaign=building-leaders-to-build-the-future-kirk-offel-on-data-centers-ai-and-purpose-driven-teams Thu, 31 Jul 2025 17:00:37 +0000 https://cumulusquality.com/?p=13979 In this episode of the Work Done Right podcast, Kirk Offel delivers a powerful message: Now is the best time...

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In this episode of the Work Done Right podcast, Kirk Offel delivers a powerful message: Now is the best time to become a builder.

Kirk emphasizes how the industry is at a transformational moment comparable to the early days of automobiles, now fueled by AI, requiring both skilled labor and forward-thinking leadership. Whether you’re a veteran, tradesperson, or someone looking for a meaningful, future-proof career, the data center industry—powered by AI and cloud growth—is full of opportunity. 

About Kirk

Kirk is the CEO of Overwatch Mission Critical, a service-disabled veteran-owned small business that combines strategic consulting with full service owner representation for the data center and telecom industries. His mission is clear: build a company that lasts by investing in people and culture and help customers unlock emerging technologies that improve lives everywhere.

Kirk’s leadership journey began at the U.S. Navy aboard the fast attack submarine USS Memphis, setting the foundation for more than two decades of experience delivering some of the industry’s most demanding projects. He’s also the founder of DCAC, an anti-conference known for its SXSW style energy designed to shake up how our industry shares ideas. 

Kirk is a passionate advocate for veteran transition, industry education, and pushing our field to evolve.

Top 3 episode takeaways

1. Building a Workforce for a Rapidly Evolving Industry

The data center industry, accelerated by AI adoption, is evolving monthly and faces a major labor shortage—currently 500,000 workers short worldwide. Overwatch Mission Critical focuses on recruiting adaptable people (veterans, tradespeople, those with high emotional range) and giving them purpose-driven careers that don’t require prior experience, but rather a willingness to learn and adapt quickly.

2. Overwatch University: Leadership First, Technical Next

Kirk emphasizes starting with leadership training to develop self-leading and team-leading skills before layering on technical certifications like EPI data center credentials and AI-driven tools training. The program focuses on human performance, standardized processes, and emotional resilience to ensure new hires can thrive in high-pressure, ever-changing environments.

3. Data Centers as the “AI Factories” of the Future

The demand for data centers is now likened to the auto industry boom of the 1920s—a foundational shift supporting emerging AI technologies. These projects offer career opportunities that can rebuild the middle class, as hands-on construction and technical roles cannot be replaced by AI or automation. 

Episode Transcript

Wes

 

Today’s guest is Kirk Offel. Kirk is the CEO of Overwatch Mission Critical, a service-disabled veteran-owned small business that combines strategic consulting with full service owner representation for the data center and telecom industries. His mission is clear. Build a company that lasts by investing in people and culture and help customers unlock emerging technologies that improve lives everywhere. 

Kirk’s leadership journey began at the U.S. Navy aboard the fast attack submarine USS Memphis, setting the foundation for more than two decades of experience delivering some of the industry’s most demanding projects. He’s also the founder of DCAC, an anti-conference known for its South by Southwest style energy designed to shake up how our industry shares ideas. 

Kirk is a passionate advocate for veteran transition, industry education, and pushing our field to evolve. Kirk, welcome to the show.

 

 

Kirk Offel

Nice to be here, Wes. It’s a privilege to be here. Thank you for having me.

 

Wes

 

Yeah, so you have quite the background. I’d to dive in a little bit more. That way everybody understands a bit more about who it is that we’re talking with here. So with that, how did you get started? What prompted you to join the Navy? And just really tell me a bit more about your career and background.

 

 

Kirk Offel

Yeah, you got it. I appreciate that. So I am the youngest of a couple boys. My father was career military, turned 18, learned bombs on F-4s in Southeast Asia, came out of the military 24 years later with a bachelor’s in Boise State, a master’s from OU, and thousands of hours in the cockpit of multiple different platforms that he flew. And he was a big proponent in believing that Uncle Sam could help pay for our college too, right? So all of my brothers joined the military.

I myself stumbled in the only direction away from what they did and the only branch left was the Navy. And I watched a lot of movies about submarines, which inspired me. So I just thought it would be a really cool, I thought it was a special thing to do in the Navy was to be on a submarine. I still feel like it was. I feel like it had some of the most advanced training and I was exposed to some of the most advanced weapons, machinery and technology you can imagine. 

The schools that we had to go to were very, very challenging and the deployments that we did were very, complicated and challenging, but they were incredibly worth it. So I was a wrestler my whole life. And I believe that being a wrestler helped prepare me to be in a better sailor. Right. And it was critical that I was prepared to be a strong sailor because there was a, you know, another challenge in my life as I got out of the military. 

So I got out of the Navy in 2000, right around the end of the third industrial revolution or what’s also known as the dotcom bust, which was the bookmark between the end of the third industrial revolution, which began in 1969 and the beginning of the fourth industrial revolution, which ended right around the same time as COVID.

So in that time, I got out the military and put myself back through school as a UPS service engineer carrying a tool bag. And I ended up getting this job in Silicon Valley right around the same time that dot-com bust. And the beauty was, is I had a front row seat in emerging technologies. So if you remember what was happening during that time was, one industry was closing and then it was really the birth of web 2.0, which was the precursor to what’s known as the internet of things. 

So the worldwide web, which led to e-commerce and cloud technologies. And here we are today at AI. So I started my career in Silicon Valley after I got out of the military, sitting front row watching the development of this thing that’s now called the data center industry or the mission critical vertical. And back then it was very niche, very small.

It was emerging. I try to say that you know, today in 2025, now as we build AI and people are much more aware of what we’re building now with the announcement of programs that we’re, and we get to be involved with like Stargate and others that are like them of equal magnitude. We’re building the AI factories, we’re building the sky for the cloud and we get to build a home for AI. And, and, and everything that I got to do has been involved in an industry that is just now emerging into the mainstream.

So everything I did as a wrestler prepared me for my career in the military. My career in the military prepared me to get into a world of technology that really was reinventing itself on a monthly basis. So as a consumer, think about the way that we absorb and process and utilize technology and data today and how much different is that today than we did a year ago. And then try to imagine how much more different it’s going to be in a year from now.

So I get to be a part of this growing technology stack where we, the consumers that are demanding all the eyeball content and video cache, we’re also the same ones that get to deliver the product that allows that technology capability to exist.

 

 

Wes

 

Yeah, it does. And that’s awesome as well. You know, that grew up as a wrestler as well. So I would also say even beyond just preparing you for the military. Now, as a business leader and owner, I would say it’s great because it gives you a level of grit that most other really most of the sports don’t give you. But most other experiences don’t give you as well. Like, this, this internal, this mantra that I’m not necessarily relying on other folks, I’ll work as a team, but I can do this. I’m to face the difficult situation kind of head on and take in a strategic manner. Love it.

 

Kirk Offel

 

And I’m pretty proud of the fact that after World War II, 55 % of all new business that were started in the United States were started by a veteran. Today, that number’s less than 10 percentage points. When I started my company in 2019, that was about 5%. Now that number is trending closer to seven or eight. But if you look at the demographic, one in five members of the US workforce today are former military. So we are making an impact to industry and we’re making an impact to society in the way that we deliver our capabilities.

And when we get into building, I found that wrestlers and veterans and people that come from the trades that just otherwise didn’t want to go to college to earn it. What is now almost a college degree is the equivalency of a taxi medallion in two to three years from now, considering the fact that one out of four kids will graduate from college in the next two years with a degree that’s already been made obsolete because of technology. Right?

So we’re really looking for as we build this guy for the cloud and the home for AI, where can we find a strong, robust labor force, the trades coming out of the military. And, vocationally, we still find people coming out the college that can contribute, but we’re really looking more for people that have craftsmen tendencies, the ability to deliver professional skills, and we could grow and mentor them to build data centers.

 

 

Wes

 

 

Yeah, no, that’s all excellent. Touching on the just I mean, obviously, for anybody listening, they can they can definitely glean that you have a passion for for getting folks into the industry. And I know that you have a lot like you touched on a focus around really pulling veterans into this this gigantic boom that we’re in now with data center construction. Can you tell me a little more about the outreach that you’re doing there and what you’re doing to help get folks ready to join this labor force and this massive opportunity that we have here?

 

 

Kirk Offel

 

Yeah, no, it’s a good question. And I’ll kind of zoom out a little bit before we talk about veterans, because there’s, mean, I have a company that’s a service disabled veteran owned business, but only 40 % of my workforce are former military. The other 60 % have a paramilitary type mindset. There are civilian counterparts and you have to remember less than one half of 1 % of the US population at any one time is in the uniform, meaning where there’s not a large population of those that go out and take the oath. 

So it’s a small pool to recruit from and what we look for in the military and what we can translate that into the civilian community or the civilian fleet would simply look like this. The reason why we like and we value military transitioning veterans is one, it does not matter what you did because this industry that we work in, the data center industry is technically considered what’s called the mission critical vertical. So all of you are listening that want to build, you know, there’s commercial and residential and there’s hospitals and semiconductor fabrication plants and high tech.

Things that are heavy in density on the MEP side are always fun to build, but there’s nothing more exciting than building a data center. That’s almost the punk rock version of construction because the way that we build data centers evolves every month. So why we like veterans isn’t because veterans are exposed to the most advanced weapons, machinery and technology, but the military as a whole is an incubator for leadership training. This industry that I work in is called data centers. We’re building AI.

It is not absent of genius or intelligence, but it is absent of leadership capabilities and the courage to be a strong leader. People in the military are in the left seat, right seat cockpit mentality from jump. As soon as they report to duty, their jobs to learn the job of the person above them while simultaneously teaching the job of the person below them. 

The entire military is predicated on an on the job training. It’s immersion training. It’s not unusual for people to just be thrown a list of things to go get done and go get accomplished with the minimum guidance and minimum resources with the only message was simply says, just go figure it out. And people that have the ability to learn at what I consider the most insane learning curve tend to have the most emotional range. People that come from the military are also mission critical, but they don’t measure it in downtime. They measure it in their own mortality. So mission critical as an industry on the commercial segment is relatively more like this.

For any business that could quantify the loss of revenue that they would create by $1 million per one second of downtime, that’s a mission critical company. So think about e-commerce businesses, companies that are just cloud businesses without brick and mortars. Those people cannot afford to go down. The other aspect of mission critical is life or death. Building FAA towers is an example, building hospitals that are capable of withstanding storm surges in the middle of open heart or open brain surgery.

Those are types of mission critical environments that we started from as an industry. And today we’re building AI isn’t even close to what we built when we were building cloud and building cloud isn’t even close to we were building to when we building the worldwide web or the internet of things. So the skills that are necessary to be successful in this industry are a large emotional range and the ability to learn at an insane learning curve. And if people have that ability, we could train them. 

We know that most people in the military have that because that’s the minimum standard, the stress inoculation, the pressure testing we go into having served in the military. We all know what the minimum standard is. There’s no institution on earth that could redefine the constitution of a human being better than the US military. We’ve all said people go off to boot camp or basic training and come back and they’re completely different people. And we know that that testing is that insane learning curve rate that they’re being introduced to and forced to. Like when you’re in the military, when you’re not in the military, you think that your potential is this. 

Once you get in the military, you realize that this is your potential because there’s someone there to guide you to pull it out of you. We actually don’t build data centers. When people ask us what we build, I’m like, we just build leaders. And if we could build strong leaders, those leaders will build teams. And if we have strong teams, those teams will build data centers. And those data centers are what service this guy for the cloud and the home for AI. 

So it doesn’t have to be a veteran. We know that there’s a minimum profile or category that you come from. The optics how we view you is very homogenous because all of us that have taken the oath know what that pressure testing looks like. In the civilian community, it’s harder to identify that, but those people definitely exist. Like I said, 60 % of my own workforce are not former military, but they thrive in this environment because they love things and they love a purpose.

They understand that we have a call to action as a business. are creating a movement to create a more sustainable and scalable labor force and people that believe in what we believe in want to come be a part of what we get to build. And that’s how we recruit and train. So military people are great. Wrestlers are fantastic. 

People that have been in challenging situations or stressful situations in their lives, they are the best from the civilian community at acclimating into a culture like this that has to build something that reinvents itself every month. This industry changes because of what you and I as consumers demand of our technology. The demand changes every month and the need for building the product that we have changes every month alongside of.

 

Wes

 

No, very well said. So, so you’re, what I’m hearing is you’re looking for people who are highly adaptable effectively. So whether that’s again, through that, that expedited learning curve, whether that’s the, the changing of specifications or requirements on a month to month basis, or even just the general idea of we’re going to be doing something new today as opposed to what we’re doing tomorrow. So let’s just focus on the new mission and execute going forward. And then having that element of the attributes of leadership to where it is, yes, can educate the people underneath me while also guiding them to follow the orders of the person above me. that generally the profile they’re looking for?

 

 

Kirk Offel

Not only are you a spot on and that’s what we’re looking for. Let me inspire them, I hope, with a statement that simply says, we don’t need experience. There will be people here that say you have to have some sort of experience, but there’s not. Experience here is only good for a year or two, three tops, because after that, it’s so obsolete. Like if you’re a kid going to college your freshman year being exposed to this technology, by the time you graduate from college or senior year, that technology is already obsolete.

So experience in the way that we, the means and methods and how we deliver this product, it doesn’t matter as much in this industry. We’re not a homogenous construct that’s been around for a hundred years and we’re not building hospitals the same way we have been for years and years and years. This is a completely different product. 

The fabric of this product changes every month. So people that have experience, the only experience that matters is the emotional range, having the ability to sit in a very volatile environment and being able to acclimate and pressure. Well, look, it makes diamonds or it makes the splat marks, right? And it ain’t for everybody, but it is for everybody. This data center industry as it emerges is going to create so many building opportunities for millennials and Gen Z that these are the jobs that will literally build back the middle class because you don’t need a college degree to be a builder in the data center industry. You just need to know how to reinvent yourself every month. 

And you have to, you have to immerse yourself in an environment where people believe in that method so they can teach you because this is such a kinetic environment that it gives you the ability to be limitless in what your capabilities and limitations are. A lot of the people that are building these major programs, they don’t have any formal training experience outside of what they learned on the job training by working their way up through the ranks of one line item within a CSI breakdown to the other and within the construction constructs of what we build within.

You have no limits and you can’t look at this industry as though the soup’s done cooking because this industry is so new that what 2025 is for AI is what 1925 was for the automobile industry. And to put that into perspective, we were still building Model Ts until 1927. And that’s because the boom began in 1925 where we didn’t have auto mechanics. We were building cars.

But we didn’t have people that were trained. There was no school to send people off to to learn how to repair cars, because cars were being reintroduced to the world every year, multiple times a year, by multiple other brands that were emerging in the industry. So there was no workforce behind the automobile industry. And look at how far the automobile industry has gone today.

Our industry is getting pulled into the mainstream because the demand of energy that’s being required is putting us on the collision course with the oil and gas vertical. But that being said is we’re sitting right now in the data center industry amongst the Henry Fords of our generation. This industry will be not only more mainstream than the automobile industry that we’re building, but it’ll have a greater impact on society since powered flight and the automobile industry. Better, the biggest impact on humanity since the automobile industry.

And if you think about the automobile industry, Henry Ford didn’t create a car. He created a 40 hour work week with an entire sub economy underneath that of companies that just make tires and just make seat belts and windshields and et cetera. So there’s a whole ‘nother group of things that are coming behind this AI demand. And a lot of people, think are scared of AI. They need to see it as an opportunity. we parents, I mean, you said you have a little one. I got three in college next year. 

And I just told you that college is a taxi medallion, but when there’s a lot of network that comes out of these colleges still, but there there’s still nine different job domains that represent 285 different jobs within the data center industry. And the ability to build with your hands will never go away. The jobs that we’re offering people and the jobs that kids could steer themselves for in college will be the types of jobs that you will never be. They will never be lost to AI. Hiring humans is the only way to build AI.

And these opportunities right here require people like you and I to just have conversations and open up the aperture to people that want to build, people that have an appetite to build, but they don’t know how to really get started. I’m here to introduce how they could find the breadcrumbs that hopefully lead them back to the data center industry. Cause I work for a company who’s only has one purpose and that is to build the strongest teams that could build the best data centers. 

And our purpose is we know that we started it with a veteran in mind. And I’ll tell you, it’s because when I started my company, 22 veterans were killing themselves every day. That number is down below 19 now, but it’s still 19 too many. We’ve learned that the only way to try to imagine the transition from going into the military where you’re driving a multi-billion dollar war machine to transitioning. And now you don’t have something that you get to contribute to that you feel is as significant as what you were doing when you were part of a much larger team.

 

Wes

 

No sense of purpose.

 

 

Kirk Offel

 

Purpose is everything. It has to be about purpose. And here’s the beauty about what I’m talking about. The demand, the adoption rate of emerging technology, specifically driven because of the demand for AI, has made our ability, like right now, we’re building more capacity for data centers right now than we’ve done in the previous 20 years prior to that. 90 % of what we’ve already built or was under construction today is already occupied or pre-leased. We can’t keep up with demand because we can’t put labor forces together fast enough.

So right now there’s people that have a purpose and we’re trying to figure out how to give purpose to people because we’ve learned that in a human performance perspective, they have a higher level of output and productivity, which pencils out as a business. They bring more value to your clients when they have purpose behind what they’re doing. So we knew if we give someone purpose as they transition out the military, they’re less likely to hurt themselves. 

And the jobs that we’re offering them are the most significant jobs the middle class could ask for today because there is no greater man for build construction models at the volume that we’re building at than what we’re seeing in AI and the programs like Stargate that we’re building today. That’s the fifth, that’s the Manhattan project of the fifth industrial revolution. And that’s just the first part of it. Right? 

So there’s other programs that are going to come. The opportunity to build is going to be massive. We’re going to need leaders like with your background, your skill set that are amplifying and using your megaphone to reach more people so we can recruit people to bring back into this industry. to help build the sky for the cloud and the home for AI.

 

 

Wes

 

No, very well said. There are people that are out there that might think, is it all hyperbole? Is this just all something that we’re doing so that we can generate pictures of cats in space or something like that? But truly, as more of these technologies are coming out, the words that you’re saying as far as really that point in history likened to 1925 of where we are today, very well stated. 

At the time, the utilization of the car, the adoption or the commercialization are was nothing compared to this like it is today. And we’re at a very similar point where, you it was the early adopters the last couple of years who have been using things like AI, but it’s pervasive these days. So  everybody’s getting on board with it. 

It’s democratizing information to where we’re able to do more and more and more and make people much more capable. In that way, so absolutely, this is not just a farce. This is growing and with a significant purpose. 

And in that way, I’m curious, know, there are a couple of different things that are coming to mind, directions that we can go with the conversation. But one of the things you were saying is, we don’t need people with a lot of experience. We need people with the right attitude, the right personality, the right intent behind their actions. 

How is it that if you’re able to attract these people to you, you screen them, yes, these are the candidates that we are looking for. What do you do with them then? Can you tell me a bit about how it is that you’re getting people ready for this ever-changing environment and how it is that you can help them to succeed once you have them.

 

 

Kirk Offel

 

I’m glad you asked and I’m going to speak about Overwatch University in just a second. But before I did, just for the people that are listening to understand because you’re talking about data and you’re talking about, you know, how we’re using technology. People need to realize like every time you chat GPT one question, try to imagine the demand of energy that’s required to make an answer is the equivalency of charging your cell phone from zero to a hundred sixty times. And as people know, when you generate an exchange of electrons like that, you create heat.

The only way to reject that heat is typically with some sort of water. One Chat GPT question is the frequency of charge in your phone, zero to 160 times, and it requires about a 16 ounce bottle of water to reject that heat. That’s one Chad GPT question. So think about it at scale. We create more data on this planet every nine months than the history of the data before that. So data is now the most valuable commodity on earth.  

So when I talk about your question is, is how do we recruit, grow, train, and most importantly, retain this talent? And it’s, it’s through a program that we’ve launched one piece at a time. So I get to work for the one of the most sophisticated technology incubators for labor ever created. We’re a staff augmentation company for anybody that wants to go build data centers. They just come to us and they pull talent off the shelf. So how do they know what a transparent, predictable and reliable model looks like? Any different than you and I as a consumer at home? 

The fastest way to becoming a millionaire today is hands down through the trades, not through college. And the beauty about the industry that we’re in is you can’t go create curriculum and put it in a university today and teach people on this. Cause by the time you’re done writing the curriculum, it’s already outdated. By the time you’re teaching them, it’s already outdated. So the only way to train people is almost through a journeyman or an apprenticeship journeyman master program. 

So what we’ve created is last year, Overwatch Mission Critical acquired a company called the Talent War Group. Not sure if you heard of the Talent War Group, it was led by a very famous Navy SEAL who’s currently ranked number 9th in the world right now for leadership gurus. His name is Mike Cirelli and Mike Cirelli is a retired Navy SEAL King Commander. But he also wrote a book called The Everyday Warrior, which he hosts his podcast, The Men’s Journal and Sports Illustrated. But he also wrote a book called The Talent War, which is about what we’re talking about is

There’s this massive pent up demand for talent and we can’t get talent fast enough into this industry to build distributed natural gas generation plants, the four walls and the roof that house the data center infrastructure as well as all the technology that rolls in. And we have to figure out how to recruit for that. So when we started, we started with leaders. So we bought the talent word group last year and absorbed them and began implementing them into our business.

We teach leaders first. So when they come in, we try to introduce them to some homogenous constructs of leaderships, what the rules and engagement look like to be a leader, what the responsibilities and expectations are. And then when we’re done with that, we partnered with the most accredited global data center certification program in the world. 

And they’re referred to as EPI. They’ve been around since 1983. Microsoft and Amazon, two of the largest, Goliaths, when it comes to AI and cloud, only standardized on those certification programs. We as a business have signed a partnership with EPI to where once every employee has worked for us for at least six months, we will get them certified in data centers within the following six months. 

Typically, it comes in two different opportunities. DCF, Data Center Fundamentals or CDCP, which is a certified data center professional. So when people come to work for Overwatch, if they could stay here for six months and show what their value is, we invest into getting them certified. In that first six months, we’re definitely exposing the leadership training. In the second six months, we’re getting them certified through EPI, one of the most accredited global platforms in the world for data centers, and all of our workforce will be certified at data centers. 

So that way when people call and they’re like, I need this talent, could call us like they call the plumber or like they call the electrician. They’re not asking for the resume of that person. How long has that person been doing it? Where’d they get trained at? Where’d they come from? They just know they have a transparent, predictable and reliable resource that’s going to come up on scene and they’re certified at data centers and they can answer your questions and help solve your problems. So we are creating this incubator that we did just for our own business. We created it just for our own talent. We hire 20 people a month as we grow right now.

And I have to have a standardization before we optimize and scale this business. And training is where we optimize. We’re a former military group. We’re a paramilitary type culture. We love to train. So we’re going to train, train, then we’re going to train some again. And we’re going to give people the opportunity to do that. If they do that after one year, we’ll even go get them PMP or all the EIEIOs they want behind their name. But getting them certified in data centers is going to give them the confidence to walk into any construction site and not only know what they have to do for construction background, but they understand the components that they’re putting in the building.

What each thing is doing is it’s connected to the other. So this platform that we started just for us is something that we begin to offer our clients and our clients are beginning to send members of their team to us to get standardization training on leadership and then certifications and data centers. 

We just actually less than one hour ago, I just signed a lease for 14,000 square foot of class and office space to serve as Overwatch University and Overwatch University gets launched in about the next 60 days where we will officially have our classrooms up. Because right now we just do mobile training. And I think that that helps us – if we take care of training them, it takes care of retaining them. So we’re just really focused on investing everything we can into the people that we hire.

 

Wes

 

First off, congratulations on signing the lease.

 

Kirk Offel

 

Thank you.

 

Wes

 

That is a huge step for you for Overwatch and really for the industry, really for you guys, awesome. Congratulations.

 

Kirk Offel

 

Appreciate that, thank you.

 

Wes

 

So with that, interesting thing that I think that I heard is that you don’t start off necessarily getting overly industry specific whenever you start off with your training. I think I heard that you say that you focus on really leadership training to begin with and the core fundamentals of how it is that we’re going to work in a team network and then you focus on really specializing in kind of the bits and pieces of what it is that we’re building. Is that right?

 

Kirk Offel

 

Yeah, you have to look at it like this. There used to be a time where there were so many people lined up for the same opportunity that a company can afford to just rip out and replace him being like they would a bad spark plug on a car. Hey, this isn’t performing. They’re underperforming. Just rip out and replace it with another one. The problem is the data center industry today has 3.2 million people around the globe. We are 500,000 people short in this industry as of right now.

And ironically enough, since this industry, in many respects, people believe that the data center industry gave birth in 1994 when amazon.com went live. But imagine if that was true. It’s not, it started before that. But imagine that was true. That’s more than 30 years ago. So to put a few things into perspective, do you know how long it took before one in four Americans adopted electricity from the time that it was discovered in the second industrial revolution? One in four Americans putting in their home from the time that it was introduced to society as an option. It took 40, 46 years.

 

Wes

 

I would say 30 years. How long was it?

 

Kirk Offel

 

Forty-six years before one for Americans adopted electricity in their home from the time that it was introduced as an option. Connectivity which was the third utility it took 27 years before one for Americans put a copper wire in their homes So they could communicate with other people what I’m telling you is the adoption of emerging technology Can be very slow at first right televisions picked up faster. That was 13 years. You know radio was nine years. You could go to Facebook, which was five years you go to… You could probably go to TikTok, which is nine months and you go to chat GPT, which was five days. So we adopt technologies as they arrived to us faster than we used to, but it took a long time.

So we’re watching this polar shift take place in the way that people are functioning with their technology. We are in the fifth industrial revolution, which is designed for us as consumers and as humans to have a healthier and more harmonious relationship with machines and technology, which means that there’s going to be repatriation of cloud and regression of some capacities of technology demand, but it is going to trigger a shift in our global economy from an energy basis, because it’s untenable. 

We can’t scale the adapt rate of technology based on the limited capacity of energy that exists. And we can’t give up our dominance of AI because we can’t put energy online fast enough so that China could outflank us. So there’s going to be this massive shift that takes place in the next four to five years in this industry. And we’re building a schoolhouse around that to where people could come in and whatever evolutionary shifts are taking place in the field will be reintroduced into the classroom, both from a leadership perspective and a technology subject matter expertise perspective, because it all begins with leadership. 

Ninety percent of all the problems that exist within a team come down to communication because there’s no bad teams, there’s only bad leaders. And we train people. We in this technology industry, in this build industry, in the construct industry, we’re teaching everyone how to be professional subject matter experts. We’re not teach them not only one how to lead and grow and maintain teams, but we’re not teaching them how to lead them. And there’s a difference between managing them. Managing people is like managing a processor or protocol. Leading people requires a difference, and that word is called inspiration. 

If you can’t inspire, you can’t lead. If you can’t lead yourself, you definitely can’t lead others. So you have to, we have to teach people how to lead themselves first. Because there isn’t today 1,000 people standing in line for the same job. 

There are 500,000 people in this industry globally that we’re short on. And here’s the beauty. This industry started, let’s say 31 years ago then. If that’s the case, then more than half of our industry has been in this industry for more than 20 years. Meaning we’re facing what’s called the silver tsunami. Half of our industry that went through the growing apprenticeship or the birth of this industry together, that no world of bodies are buried and how we got here. They’re poised to retire. The only thing stopping them is maybe the de-escalation of a couple of wars between Israel or Ukraine, maybe some tension with China de-escalating or a global economy becoming more stabilized. 

But the minute that those things take place, we’ll see a massive wave of the silver tsunami of people that are going to be retiring. And we are already 500,000 people short in this industry right now. 

So everybody listening that wants to build, we’re building campuses of thousands of acres at a time. For every time we build a hundred megawatts, that’s on 40 acres, it takes 1400 people to build that. leave at least 100, we leave one person back per megawatt when we’re done building it, just to operate it when we’re done. There are so many jobs and these campuses aren’t a project like a Stargate type of program doesn’t last for one year or two years or three years. It lasts for five years, it lasts for seven years. Those are campuses that we’re building urban cities around. There’s so much change coming that if we don’t build stronger leaders, we won’t have a workforce.

We can’t recruit them and keep them in this industry long enough because we’ll burn them out because of the pace we grow at. So we need to find leaders who could build and grow strong, healthy teams and build and protect bulletproof cultures that we could build and talk subject matter experts around. And that’s how you scale an industry.

 

Wes

 

I think it’s the absolute right approach. There’s the age old, how to influence people. Dale Carnegie says it in there. Is it the best engineer that ends up becoming the engineering manager? No, it’s the engineer that works best with people. And really, why is that? Just like in engineering, just like in construction, it’s not like we have a bunch of robots that are going around out there and we get programmed the systems. It’s not like the dirt or the piping or the cable is going to move itself. Who does it?

People does it. not managing, like you’re saying, the operation. You’re leading and guiding and managing people. people are at the center of all of it. If you don’t know how to work with people and lead people, then you’re not going to be successful as a leader fundamentally.

 

Kirk Offel

 

Yeah, I’m really big on like, host this technology summit once a year in Austin, Texas called DCAC, it means data center anti-conference. And it’s just we’re David poking holes at Goliath. There’s four Goliaths in the world that run most data center conferences. They’re all about the same. They offer about the same. We, we focus not only on the energy and the technology of building data centers, but we focus one third of the conference on human performance. 

We’re getting to an age where we have never pushed our teams harder. I’m sure with all the teams and all the programs that you built, I don’t know how it works in your industry, but in our industry, there are three KPI, safety’s first, schedule’s second, cost is third. You can never compromise one thing for the other, but we build big programs and mega scales and they are dangerous. So getting ready go home at the end of the day, that’s the number one focus in this entire industry. 

But scaling this industry by training people how to maintain schedules is and the integrity of a budget, is the next hardest part. And we’re putting so much pressure on humans right now because the adoption rate of the consumer of technology that we just simply can’t deliver fast enough.

There is so much pressure on this industry right now that we can’t get more cowbell out of these people until we start really focusing, not just training them better as subject matter experts, but we have to equip them emotionally to be able to endure the challenges that come with an evolving industry that’s reaching the mainstream. Again, try to imagine living in the automobile industry before it became mainstream. There was no ethics, there were no regulations, just like our industry, it’s all self-imposed.

When industries become mainstream is when we start adopting ethics and more regulation and because AI is the forefront of everybody’s optics You’re gonna see this industry getting pulled into the mainstream faster. So it’s still blue sky. Experience isn’t really a factor that should anybody consider to hold them back from getting into this industry People should be looking at how they could bring their professional skills their craftman skills or trade skills to this industry to help advance it moving forward because it has the most volume and velocity of construction that you’re ever going to build.

 

Wes

 

Right. And then even just the infrastructure that you have to build around it to get ready to build the infrastructure to get ready to build the infrastructure is immense. Like it is, it is a huge undertaking. for anybody who’s ever built a LNG facility in North Dakota or something, it’s the same kind of thing.

 

Kirk Offel

 

There’s never been a better time to be a builder. There’s never been a better time to build, be a builder.

 

Wes

 

I couldn’t agree more. Taking out of all of these inputs that we’ve been talking about here and bringing them all together really back in, I think into Overwatch University, I’m curious, you’ve been in the industry around data centers for a couple of decades now.

 

Kirk Offel

 

Since 2000.

 

Wes

 

Yeah, that’s awesome. So you’ve seen change after change after change in design. So the full build out of it in the way that they’re getting executed. And now you’re in the middle of this gigantic boom that we’re behind on labor, but we need to accelerate schedule fundamentally. we’re, we’re needing to do more with likely fewer people. And one of the, one of the elements of that is it’s kind of augmenting technology. I think you touched on it earlier when you’re beginning of the conversation of even the tools that we’re using on a monthly basis or bi-monthly basis are changing. 

So I know with, believe anyway, with the work that you’re going to be doing with Overwatch University, that’s an element of it as well, is getting folks up to speed on some of the resources and tools that are out there to augment the labor experience. What are you seeing in that space? I guess, what sort of changes have you seen? What are you seeing maybe some solutions for now and where are still the big problems for people to tackle for, again, just making the industry better and expediting our schedules while maintaining safety.

 

Kirk Offel

 

Yeah, good. A lot of great questions. How at the end, well said, how do you never compromise the integrity of the safety element? All right. So Overwatch University is a static, I mean, a dynamic environment, not a static one. Well, there’ll always be components that our ecosystem will donate to the schoolhouse that people want to look at a UPS or a PDU or like those things will be there. But you have to think about the evolution of a labor force. Right. So we, we up until now, we didn’t have enough transparency and visibility into what was working. And when I say working, I say with a very broad stroke, because if you’re a leader of a team, you invest so much money into a team. If you’re not retaining that team, it’s hurting your bottom line.

So you’re going to be dealing with human nature.

So my thing is, we had to start with not just focusing on building a labor force with more subject matter expertise, we almost had to pause, collect our breath, and then focus on the human, the human aspect of our labor force. And that’s where we focused on the leadership side, teaching people how to lead themselves so that they can go lead others and they could go solve problems on teams and those teams could go deliver and have a higher level of output productivity. But we started with the leadership side. 

Then once they understood and had the strong leadership capability, the emotional range, capable of being on a project that’s highly kinetic, then we could teach them the subject matter expertise on how to function and be comfortable and operate on that campus or within this industry. 

Once that’s done, then we have to equip them with advanced AI resources. There are multiple companies that we’re talking with right now. Some have GoPros that will put on their helmets that can walk through a construction site. And I could, the barrier to entry or the introductory requirements to get into the market are lowered because I don’t need someone that has experience. I need someone that could follow a map and walk an entire construction site. And when they’re done, they hook that camera up to a SharePoint repository that feeds that information into another machine.

That is gonna build the entire construction project on a model and it’s gonna evaluate whether you’re on track or not. But those types of technologies we’re gonna be adopting and installing on our teams. There’s other technologies that start at the supply chain level where we will teach our teams, we will invite groups like Kaya AI, which are writing some of the most advanced procurement software platforms in the world. 

And what they’re able to do is aggregate the inputs of every contributor from an ecosystem supply chain, any vendor management inventory program, any OFCI schedule, and it could pull it all in. And then when there’s one disruption to the entire supply chain, it’s automated through AI. It’ll inform everybody. It’ll tell you what the impact is, what’s the critical path, what’s the long pole in the tent, and it’ll give you remediation plans if necessary. What I’m telling you is we start with leadership, then we make stronger, such matter experts.

We have to start with the human, okay? So we’re gonna have to focus heavy, heavy on the human side. That’s the leadership side, teaching people how to lead themselves so they can lead others. Building subject matter expertise.

We’ll never change. We will never not have an evolving level of curriculum that’s fed through based on what’s relevant in the field at that time. But then teaching them advanced techniques and advanced technologies is the third phase of the four phases. That third phase is getting them used to using AI, getting more things done to where we have clash coordination studies that are coming to us faster to make sure we’re not running trades into each other in the field. 

There’s so many ways that we’re going to adopt these technologies. And once we’re done, it turns out this week I also had conversations with Wade Vincent, who’s the chief data center architect for all of Nvidia. Nvidia is one of the largest contributors to robotics in the world right now. So groups like us are going to be talking to companies like Nvidia and other robotics companies to figure out how we can implement some robotics into our labor force. There will be things that weigh 2,000 pounds that don’t require human beings to move it. Maybe that’s the perfect job for a robot to pick up and move that thing around.

It could be a solar panel. It could be a load bank. Who knows? But there will be things. what we build, first of all, building and having the ability to be a builder at any trade level, at any general level, is the greatest job that you can have to secure a career throughout the birth and proliferation of AI. Everything that AI is doing that’s wiping out those white collar jobs will never replace what we will do on the blue collar side.

Emerging industry means the soup’s not done cooking. The way we do things today won’t be the same way we do them next month, next quarter or next year. And as long as there are people that like to go learn and grow,

This is blue sky country for those people, right?

But we’re going to start with leaders teaching humans how to take care of humans, teaching humans how to teach humans how to be better subject matter experts, teaching humans how to use advanced technologies, then teaching humans how to work alongside robots. They’re going to take away roles that were of the greatest risk to safety or the greatest risk to a human in general in terms of how they could injure themselves. Does that make sense?

 

Wes

 

Yeah, no, excellent. So those are your four phases. Focus on leadership, integrate technical understanding, then advanced technical understanding along with some of the resources that are available to them, the tools that you’ll deploy. And then the fourth phase is that integration and that kind of, you know, human robotic element and how you’re going to work alongside not just the digital AI or digital resources that are out there, but really the physical resources, the manifestation of that on project.

 

Kirk Offel

 

I would say 95% of all the work that’s required to build a data center will never be able to be solved by a robot. It has to use a human. And we won’t build anything in this country at a larger volume of velocity than what we’re doing right now, other than data centers. And to put it into perspective, there are let’s say 8,000 data centers on earth right now, depending on which AI robot you ask. 

Let’s say 5,426 of them are in the United States. That means if you add up every aid, every other data center outside of the United States, it’s still not even close to how many we have here. Because if you look at the largest drivers of cloud, which would be Facebook, Apple, Microsoft, Google, Amazon, Oracle, and SoftLayer, those seven groups represent 80% of the world internet traffic probably. 

So between them, we are the home of the most advanced technologies because we are deploying more of it. And we’re the only thing that we need to stay ahead of it on a national security basis as a stronger labor force. A bigger labor force that’ll allow us to build more power plants, distribute natural gas generation plants, renewable energy plants, more power plants to support the need for AI because AI is the most advanced weapon machine and tech ever built and we can’t let anybody else outflank us on.

 

Wes

 

No, you’re absolutely right there. And clearly this, you know, just getting effectively, you know, the workforce readied for this between the craft workers and the leaders, not that the craft workers aren’t individual leaders and contributors themselves, but is clearly a passion for you. I couldn’t agree with you more on the importance of it, the significance of it on a personal level for how it is that it can really revolutionize your life and entirely shift the paradigm and structure for how it is that you’re operating yourself and just the opportunities that are coming with it.

Totally right, now is the best time. If you’ve never done it before, built something, now’s the best time to start. Totally agree.

 

Kirk Offel

 

I agree, man. You know, I really respect what you’ve done with this podcast and I share your desire to help people. I share your desire to reach more people. I think that this is the greatest thing that we get to do. Building is the greatest job career you could ever have. If you look back deep enough, we’re all builders. just, the biggest project that we’re always building is ourselves. 

We’re just simply trying to get people like building themselves enough so we could their talent and their passion to help us build data centers. Because the jobs they may have if they came into this industry, two years from now those jobs don’t even exist yet, right? So there’s so much blue sky opportunity for anybody that wants to be a builder. And those building opportunities are the jobs that build back the middle class.

 

Wes

 

Absolutely. Couldn’t agree with you more. So Kirk, I do appreciate it. Thank you very much, sir. Can you tell us a little bit more? When is when is DCAC this year in Austin? How can people find it?

 

Kirk Offel

Yeah, thanks for asking. you could find information about about DCAC and just Googling DCAC live. DCAC live will come up and it’ll take you to our conference that has a landing page that talks about what we’re doing here on September 16th to the 18th. But we we rent out Austin city limits in downtown Austin for two days and we bring in some of the greatest rock stars around the world of data centers. Everybody’s been on that stage from Facebook, Apple, Microsoft, Google, Amazon, Tesla.

So I invite anybody that wants to shift or look into a career in data centers to visit us at dcaclive.com. then for the Overwatch side of what we do, our website’s simple. Weareoverwatch.com.

Again, we are Overwatch.com. And if you go to that, you’ll find trails and information that leads you to perhaps Overwatch University. if worse comes to worst, find me on LinkedIn. And I’ll put you in touch with the right people if someone’s interested in getting into the career field of the data center side.

 

Wes

 

Excellent, absolutely. Kirk, I do appreciate everything that you’re doing. Thanks for coming on this show and hope to talk again soon.

 

Kirk Offel

 

Thanks for having me, man. It’s an honor to be here. Thanks so much, I mean it.

The post Building Leaders to Build the Future: Kirk Offel on Data Centers, AI, and Purpose-Driven Teams appeared first on Cumulus Quality.]]>
13979
5 Reasons Why Quality Matters in Data Center Construction https://cumulusquality.com/5-reasons-why-quality-matters-in-data-center-construction/?utm_source=rss&utm_medium=rss&utm_campaign=5-reasons-why-quality-matters-in-data-center-construction Tue, 15 Jul 2025 17:45:56 +0000 https://cumulusquality.com/?p=13862 Quality plays such a critical role in data center construction, and it impacts every project phase, from planning and design...

The post 5 Reasons Why Quality Matters in Data Center Construction appeared first on Cumulus Quality.]]>

Quality plays such a critical role in data center construction, and it impacts every project phase, from planning and design to operations and maintenance. With the immense industrial pressure of speed-to-market, however, it often gets deprioritized in lieu of other project goals to accelerate delivery.

Treating quality as an afterthought though is incredibly risky and often ends up in rework down the line. Quality is a strategic lever in data center construction, not a ‘nice-to-have.’ Here’s a comprehensive breakdown of why it’s so vital:

1. Ensures Reliability and Uptime

Data centers are expected to deliver high levels of uptime, often with service-level agreements guaranteeing 99.999% availability. To achieve this, high-quality components (e.g., electrical systems, cooling infrastructure, servers) must be used and redundancy designs are implemented with rigorous quality control.

Construction must also adhere strictly to specifications to avoid latent defects that could lead to outages, since these mission-critical buildings serve as the digital backbone for nearly every modern business, service, and communication channel. When quality is compromised in the construction phase of a data center, the ripple effects can be severe, and uptime becomes impossible to guarantee.

2. Compliance and Standards

Quality data center construction ensures adherence to industry standards and regulatory compliance. Standards like TIA-942, Uptime Institute Tier Certifications, ASHRAE guidelines, and ISO/IEC 27001 require specific construction and operational benchmarks because data centers host sensitive data, support essential services, and require high levels of availability, security, safety, and performance.

Non-compliance due to poor quality work can result in legal penalties, failed inspections, or revoked certifications.

3. Cost Efficiency Over Lifecycle

While cutting corners in quality may lower upfront costs, it leads to:

  • Expensive rework or retrofits if issues arise later.
  • Increased maintenance costs due to premature equipment failures or inefficient layout/design.
  • Downtime penalties, reputational damage, or customer churn in case of service disruptions.

Conversely, high-quality construction reduces total cost of ownership since the data center will experience fewer failures and minimized risks.

4. Safety and Risk Mitigation

Data centers involve complex electrical systems, battery banks, HVAC units, and fire suppression systems, making safety and risk mitigation a critical concern. High-quality construction plays a key role in preventing incredibly dangerous accidents (like arc flashes), fires, and electrical hazards.

High-quality construction also ensures safe access for technicians and maintenance teams, reducing the risk of injury or service disruption during routine or emergency work. Moreover, durable and well-executed infrastructure supports robust disaster recovery planning, helping facilities remain resilient in the face of unexpected events.

5. Project Schedule and Delivery

Poor quality in data center construction often leads to significant setbacks, including construction delays, failed inspections, and disputes among stakeholders. These issues frequently require contractor rework, which disrupts schedules and inflates budgets, ultimately jeopardizing project timelines.

In contrast, implementing robust Quality Assurance and Quality Control (QA/QC) practices from the outset helps streamline project delivery by ensuring that work is completed correctly the first time, minimizing delays and keeping the project on track.

Companies like Cumulus for example are prioritizing quality by digitizing QA/QC workflows and eliminating rework via connected tools. This in turn accelerates construction by providing real-time data to prevent issues, not just detect them.

Conclusion

In data center construction, quality is not optional. Fortunately, the industry is taking note of this, and leading organizations are beginning to prioritize quality from the onset of construction.

By embedding quality into the construction phase, data center builders can prevent systemic errors, build trust with clients and partners, and deliver on time, on budget, and with confidence in long-term performance.

The post 5 Reasons Why Quality Matters in Data Center Construction appeared first on Cumulus Quality.]]>
13862
Building It Right: Training, Torque, and Quality in Hyperscale Data Center Delivery | Work Done Right with Dale Jennings https://cumulusquality.com/building-it-right-training-torque-and-quality-in-hyperscale-data-center-delivery-work-done-right-with-dale-jennings/?utm_source=rss&utm_medium=rss&utm_campaign=building-it-right-training-torque-and-quality-in-hyperscale-data-center-delivery-work-done-right-with-dale-jennings Mon, 14 Jul 2025 16:45:28 +0000 https://cumulusquality.com/?p=13782 In this episode, Dale Jennings, Executive Vice President at Fulcrum Reliability Systems, shares how his background in the nuclear Navy...

The post Building It Right: Training, Torque, and Quality in Hyperscale Data Center Delivery | Work Done Right with Dale Jennings appeared first on Cumulus Quality.]]>

In this episode, Dale Jennings, Executive Vice President at Fulcrum Reliability Systems, shares how his background in the nuclear Navy and commercial nuclear power shaped a career focused on quality assurance, commissioning, and operational discipline. Now at Fulcrum, Dale brings that mission-critical mindset to the fast-growing data center construction industry, helping ensure projects are delivered both fast and right.

Dale outlines how Fulcrum is addressing the modern construction environment’s biggest challenges: balancing speed and precision, bridging the workforce skills gap, and eliminating rework through training, culture, and smarter tools.

About Dale

Dale Jennings is the Executive Vice President at Fulcrum Reliability Systems. Dale has an extensive experience ranging from nuclear operations, mission critical training programs, and some of the most complex infrastructure projects in North America. 

Now at Fulcrum, Dale brings a true mission critical level of precision and discipline to hyperscale data center commissioning, refinery safety programs, and industrial controls. At Fulcrum, he’s helped build a culture centered on operational excellence technical rigor, and most importantly, people-first leadership. 

Top 3 episode takeaways

1. Proactive Training is Essential to Meet the Demands of Quality and Speed

Dale strongly emphasized that the youth and inexperience of today’s data center construction workforce necessitates deliberate and structured training. Fulcrum has built its identity around people-first leadership, focusing on targeted training programs rooted in proven methodologies (e.g., the SAT-ADDIE model) to teach fundamental skills such as:

  • Torque application and documentation
  • Understanding project specifications and site-specific standards
  • Effective communication and procedural compliance

Training is not only for Fulcrum’s personnel but also extended to contractors and site teams, filling a critical gap that many organizations overlook. 

2. Early-Stage Planning and Alignment (Pre-Con) are the Most Powerful Levers for Project Success

According to Dale, the greatest opportunity for improving quality and speed lies in thorough pre-construction planning. Unfortunately, he noted that this phase is often rushed or skipped due to contracting delays and pressure to start building. The result: teams enter job sites underprepared, discovering critical requirements midstream.

Key suggestions from Dale:

  • Dedicate three weeks to full-scope pre-construction alignment across electrical, mechanical, commissioning, and quality disciplines.
  • Use that time to standardize procedures, build work packages, scope cable energization strategies, and clarify client expectations.
  • Early engagement with all stakeholders (GCs, vendors, QA, commissioning agents) sets the foundation for smoother execution and avoids costly misalignment down the road.

Dale likened it to the nuclear power industry’s model, where years are spent planning 30-day outages—making the case that “a little time upfront pays dividends later.”

3. Quality is About Culture and Behavior, Not Just Tools or Checklists

While digital tools (like Cumulus, AutoLOTO, BIM, Procore, and CX Alloy) help streamline documentation and reduce administrative burden, Dale pointed out that behaviors, discipline, and oversight remain the most critical elements of quality assurance.

Cultural practices such as:

  • STAR (Stop, Think, Act, Review), borrowed from the nuclear world
  • Encouraging the use of AI (e.g., ChatGPT) for clearer issue documentation
  • Strict adherence to defined work packages and procedural language (e.g., “shall,” “should,” “may”)

…are all part of Fulcrum’s toolkit for instilling accountability and accuracy at every step.

Notably, Fulcrum now offers find-and-fix services during inspections, rather than waiting for vendors to rework issues—an innovation that directly addresses the inefficiencies of fragmented project cycles.

Episode Transcript

Wes 

Today’s guest is Dale Jennings, Executive Vice President at Fulcrum Reliability Systems. Dale has an extensive experience ranging from nuclear operations, mission critical training programs, and some of the most complex infrastructure projects in North America. 

Now at Fulcrum, Dale brings a true mission critical level of precision and discipline to hyperscale data center commissioning, refinery safety programs, and industrial controls. At Fulcrum, he’s helped build a culture centered on operational excellence technical rigor, and most importantly, people-first leadership. Dale, welcome to the show.

Dale


Thanks Wes, I appreciate being on.

Wes 

 

Yeah, great to talk with you! We’ve talked a couple of times in the past and you have a very interesting background to say the least. So I’d like to dive into that a little bit to begin with about how it is that you started in the industry and how you made your way into really what you’re doing now with Fulcrum working primarily in that mission critical space.

Dale


I think it’s a very similar probably background to a lot of the folks in the industry at the beginning of my career in that there are a lot of Navy Nukes and I started out as a Navy Nuke. But then I took a path that was that was a little bit different. I spent most of my adult life in the commercial nuclear industry and started our own, with some other principals, started our own nuclear training company to train across the country. And we exited that via an acquisition from a publicly held company in 2014. And I actually went on a non-compete for five years with nothing to do.

And so in 2019, I got a phone call for some folks in the industry asking if I could put together a small team and come up and provide some electrical quality inspections on some gear. And that’s how we got started in the industry.

Wes 


Oh wow! So you started, you were re-emerging into, effectively into the workforce after having a few years and…

Dale


Right, right, was actually planning until – I got the phone call – I was planning on going back to what I know, and never re-entered that workforce. Just blossomed as we came into this industry because it was such a target-rich environment.

Wes 


Well, yeah, especially right place, right time by the sounds of it. Also right on that kind of front end of this AI boom and data center boom that we’re all experiencing at the moment. So you really, so you started off nuclear submarines, right? With the Navy, you got out of the Navy, you worked around nukes for a while longer, right?

Dale


I did, I got my license at a nuclear plant in North Carolina. To have to operate a nuclear reactor, you have to be licensed by the Nuclear Regulatory Commission. And I got my license back in the early 90s at a nuclear plant in North Carolina. And, you know, I’d already spent so much, it’s called sitting in the box, just sitting there staring at things that aren’t supposed to move. What a pretty boring existence for me. You know, I couldn’t do it for a lifetime. 

But so then I transferred to the training environment and I got certified by the Institute for nuclear power operations to train. That just makes you kind of mobile within the industry because there’s requirements for training all over the place. Internal staffing generally doesn’t handle it many, many times. So there’s consulting and contract teaching is certainly a need in that industry. So I entered it and eventually started my own company to support that need. And then once again, exited it 10 years later. Yeah.

Wes 

Got it, that all makes sense. that brings us to now what you’re doing with Fulcrum. For those folks who might not be as familiar with Fulcrum, could you describe a little bit about what it is that y’all do, the markets that you serve, and kind of the approach that you’re taking there?

Dale


Sure, we provide quality and commissioning services. We generally are attached to the GC, but we work very often directly with the client. We work with the client generally at the integrator facilities, providing direct eyeballs on fasteners, essentially quality inspections.

And we perform that same task at the sites, the construction sites as well. And we like to take it all the way through the L3 process. And we like to get it energized and tested. And then we will assist the folks coming in, the client, generally will come in for L4, L5, and we assist them all the way. These milestones almost become targets for us and we want to hit them. Because they’re going to ask you back. The more times you hit their milestones, they’re going to ask you back. And so whatever we can, the answer is always yes. We find a way to say yes.

Wes 


Right. So we have a lot of listeners who are in the energy space, oil and gas. Can you describe just a little bit better about maybe what is L2, L3, L4 in data center commission?

Dale


Just construction phases, generally broken down into five phases. First one, L1, would be your factory acceptance and witnessing of an asset. And then it gets on a truck or a train or a barge and then it arrives on site and you do your receipt inspections and your construction related activities. That’s all L2. That’s where the meat of the quality inspection would occur.

L3 would be pre-functional asset style testing, make sure it run it through its paces, make sure that it as an asset works. L4 then would be testing the asset within its system so that it works as intended as a system and not just an asset. And then L5 is really generally just loss of all-site power scenarios, either temporary losses of individual divisions of power or extended loss of both divisions where all of the diesels have to fire back to fire up and repower all of the existing load.

Wes 


Yeah, that all makes sense and thanks for going through that explanation there. I guess curious in my mind, so you’re really focusing obviously like you were saying all in the quality and commissioning space and that there there’s almost two competing interests that are going on right now in the data center market and they should be going hand in hand but it doesn’t always kind of work like that in everybody’s mind because we have different folks with different vested interests. 

And what I’m saying is there’s the demand to get these things built right now. And there’s the demand to get them built right. So how is it that, know, whenever you’re going into these facilities, how are you keeping, I guess, this balance between the eye on getting work done now and getting work done in the best way possible? How do you balance that demand for speed and precision?

Dale


Yeah, it’s not difficult in many respects and in others it’s impossible. So we can only control the things that we have control of. And one of the things is like the specs, the specs between the site specifications and say the integrator project specifications, they don’t line up. So we can expect the gear to be a problem when it arrives, in that, just joint pack installations on busway. If they use, if the integrator uses all the margin, there’s no margin left when it gets to the site. And then you’re just breaking the connection they made at the integrator facility. So there’s that communication thing there. 

And then there’s other things that we can control. We can control the knowledge of our own inspectors. We provide training and then we can, and that is really kind of cool because our clients have seen the effectiveness of our training, both on a weekly basis, a monthly basis. Bringing them all here. I’m sitting in one of our training facilities in Omaha now. 

And so now they’ve asked us to provide torque training, BIM training to the entire workforce on the site. And I think it’s imperative if we want to get that velocity, we’ve to take these young folks and train them and they’re yearning for it. And we have that skill set, obviously. So I think that really, you can have a modular design, but you want a modular workforce too, and you have to train it. And it doesn’t need to be beyond the tasks that you’re going to perform. So it’s a very targeted training.

Wes


So that makes sense. And I guess just to dig down a little bit deeper into that in the spirit of, why would we then provide the training? Because something that I’ve heard from contractors in the past, even if it’s working across different industries, is, well, I’m hiring a journeyman. I expect them to be a journeyman. I shouldn’t have to tell them how to do X, or Z. 

It’s all well and good, but it’s the reality where we’re living, I suppose, right? Is it really looking at emphasizing something like the on tool training to prevent issues later? Is that really what it’s largely around is just kind of issue mitigation, issue prevention to prevent the rework? I guess, is that where your logic is?

Dale


Well, a journeyman has minimum proficiencies possibly. A journeyman with 15 years of experience should have beyond minimum proficiencies. But we’re getting a lot of new journeymen. So to say they should know, I think that’s kind of a stretch. You don’t know everything once you get certified. A pilot doesn’t have experience once he gets a pilot license. He has a pilot license. And that experience is just as valuable as the license itself.

So right now I would say there’s a large majority of our workforce that doesn’t have a lot of experience, doesn’t know how to respond probably in less damaging ways. And I don’t mean equipment damaging, maybe damaging to the process. Then they would if they had experience. They’ll take action. That’s what most people want to do. When the best thing we could do is stop, because we’re going to end up doing rework. They don’t have the experience. We practice human performance tools with our folks.

STAR is directly stolen from the nuclear industry. We STAR, that means Stop, Think, Act, Review during your human interactions every time. Just take a moment and perform these four things please. And then don’t proceed in the face of uncertainty. Just come see somebody who has experience. That’s helped us stay out of trouble because it is, that’s ubiquitous throughout our entire organization. We try not to go backwards.

Wes 


That makes sense. And you know, you said it in there also that like people really are well intended whenever they’re bias toward action, right? Hey, they messed something up. The immediate thought or desire is, well, I’m going to go fix it. That’s a good thing. Like that, to have that motivation and that drive, we shouldn’t, I guess, punish that, but we should understand maybe that’s not always the right solution. We should take a step back first, assess maybe ask a question or two, and then move forward in a more methodical approach. So love that you touched on that and then you also said that you do similar trainings for your quality and commissioning personnel as well. Is that right?

Dale


We do. Torque is a big one for us because these modular designs, I think the ultimate goal is really just to, they show up on site and you connect them together. So the connection itself ends up being the most important thing on site. Whatever kind of fastening action that is to connect two things together. They could be welded, they could be bolted, whatever.

That’s where we really provide a lot of emphasis to our inspectors. Torque and torque review of the paperwork. Because at the end of the day, our work product as quality inspectors, is paperwork. You don’t get to go home and say, boy, look what I built today. You really just look at what I laid my eyes on today. It’s in my daily logs, my narrative report, and my quality checklist. And it really can be disheartening if you think that you really, where’s my work product? What did I get done today? So that’s something they have to get over.

Wes 


Yeah, it’s just kind of part of the job a lot of the times. You know, I ask the question because I’m thinking about what I’ve seen out of some inspectors that again I think are well intended oftentimes. That maybe they don’t know what they don’t know and then they’ll start writing up punch list items against what they think, not necessarily what they know.

And just because you’re certified as an inspector in some regard doesn’t mean that you actually do know everything. And I don’t think we should expect people to. So we should really train them to the standards that we have to avoid unnecessary rework. Because that’s, I guess, another angle where it could happen. 

So it’s great that you guys are taking that proactive approach there as well to just ensure that everybody’s competent to the standards, right? That’s ultimately the goal is each project is a little bit different. And we should take the time to train people to do the things that are specific for this project.

Dale


Well, each campus, each building on a campus is different because they’re having lessons learned. They’re modifying the second building and the process within that building. By the time we get to the sixth building on a campus, it may not look anything like what we were doing on the first building because there’s been an evolution. And we see that all the time. So I think the folks showing up, or I could agree, they want to do a good job. And they’re not trying, no one’s trying to make a mistake. I don’t think they’re sabotaging the builds or anything like that. 

I think we just, we go too fast without knowing and we don’t provide enough oversight. And if you want to shift left and speed the thing up, I think the workforce has to be modular and the expectations themselves then become standardized. And because we don’t create a standard, we only enforce it. 

So we’re going to read the project’s specifications and that spec becomes our minimum acceptable standard. We don’t if you go above it, we could care less. It just has to meet this thing and if it says bolt one of every you know, ensure one of every six bolts on a flange is torqued. Well, all right, give us one bolt. That’s all the client wants. We’ll do it. We will suggest and recommend otherwise, but in the end of the day, we work for the client.

Wes

 

Yeah, that’s funny. You had brought up earlier kind of the deliverable item for a lot of these QC and commissioning agents is really just the documentation that work was inspected or done appropriately. I guess I wonder, here’s like how much documentation through relating it back to what we talking about earlier, like kind of L1 through L5. 

What’s the typical like load that we have for documentation just out of my own curiosity for each of those phases?

Dale

Well, I think that every commissioned asset at a minimum is going to have a receipt seat inspection. And a lot of times that is verified boat wrap in place because we’re not going to get up on a truck.

And a lot of times the clients don’t reject anything regardless of what it looks like. They just accept it because assets are valuable and they’re not sending them back so someone else can get them regardless of whether or not all the breakers and relays are missing in it. And just got pelted, you know, by gravel from Texas to Omaha for the last 800 miles. They still take it. 

And then so the receipt inspection, you start your paperwork then. And if you’re doing it inside an environment, online type deal using application, that’s not that bad, right? It’s when the paper starts coming out. Torque was a perfect example. It creates a very large burden on our quality assurance team to gather all these torque logs, verify they’re accurate, that the torque that’s recorded is within the allowable that’s on the torque sheet itself, on the checklist as well. 

That ends up being a huge burden for quality assurance team. And then, it’s really crazy, it starts out electronic, they’ll print it in paper. They’ll fill it out. Then we have to review so then guess what we’re gonna scan it and put it up and upload I mean, it’s so 1990 all over again drives me insane. So looking for those things that can provide velocity now, they’re not hard. They’re out there.

Wes

Yeah, right. I guess, know, obviously, to disclose to the audience, we have a relationship. Fulcrum is utilizing the Cumulus platform in certain areas. But I guess with that, without having it just being necessarily a shameless plug, you know, what all solutions are you seeing out there to help aid in this space? Because it is an annoying space, right? Like it’s senseless. Like you said, it’s doing things like it’s 1990 to just print things out, fill it out on paper, then scan it back in. It’s a lot of administrative burden.

It’s a lot of just changing hands for no apparent reason. So I guess just, you know, what all out there are there for options that y’all are saying again, in the spirit of how are we balancing the application of the standards as a floor, not a ceiling, and then delivering the highest quality product faster. If that’s, if that’s ultimately what we’re trying to do.

Dale

I think that the big products out there, starting with how you’re going to manage the project, how you’re going to identify issues, how you’re going to put your submittals, right? The big three, I guess, that we see are Autodesk’s BIM, CX Alloy, and Procore.

And but downstream from there is where we can get a lot of project velocity as well. And, you know, I didn’t mean to plug y’all, but we are excited.

Wes


I definitely appreciate it. I do.

Dale

We’re excited that we’re saving so much time. I’m not lying. But obviously, Cumulus provides torque. They do have a Bluetooth wrench and stuff. But for us, just the electronic torque sheets themselves are a time savings. Then autoLOTO, we’ve been reviewing autoLOTO and we think there’s some savings there as well to get some project velocity. Beyond that…

Those so far are kind of the major ones we’re seeing. Can you think of any Wes beyond those that we use?

Procore, CX, Alloy, BIM, you know, Cumulus product right now and autoLOTO. And I think it’s a space where a lot of folks, there’s opportunity for nerds to create a solution.

Wes 
Absolutely. Yeah, absolutely. And trust me, we’re working more and more in that space. We have the nerds. We’re definitely driving there.

Dale
Yeah, I wish we had a nerd.

Wes

Hahaha, no kidding! It’s actually encouraging for me to hear over and over how much it is that torque is a big problem that you’ll have to be honest, because it is an area, as you know, that we have a solution that’s out there. 

So it’s great to hear that we’re helping you all to solve a problem that is providing value back to the projects. Honestly, I say that as somebody who’s deployed this on projects and also as somebody who’s had a product for everybody who knows and listens. So that’s great. It’s really great to hear that we’re helping to solve a big problem for y’all.

I guess drilling back into the issues here, I’d be curious if you have any real world examples of instances where maybe rework a topic that we’ve talked about quite a bit already, where that has caused delays in the project or could have obviously just been avoided out of taking just a little bit more time, maybe taking the STAR approach as you were talking about earlier.

Dale


I can think of several, but offhand, I would share this with you. Our very, very first building and our very, very first asset, I won’t tell you the vendor, but it’s a very, very large piece of switchgear supporting 30 megawatts, right? And there were two divisions of power, so there’s two of these supporting the power coming into the buildings at 30 megawatts a pop.

And we had a small team of three people performing a point to point on the very first piece of switch gear. And at the end, as we’re doing the control sections, the entire DC section had reverse polarity. And there was a placard in it that said, reverse polarity will cause MOSFET damage to relays.

And the entire thing was wired wrong. It was huge. And we couldn’t believe what we were seeing, but there was two of them. So we’d go to the other one and go, well, one of these has to be wrong. So we just started documenting. We documented 81 issues the first day on miswires. And this is why we were called, because the person that asked us to come up, he was afraid that these things were probably going to be wired for it. They were wired very poorly.

And the vendor themselves didn’t believe us. And this causes delays. And then we just solved it very simply. Let’s go look at the other one. And then you’d select which one you want to be right and make the drawings match that. And then we’ll write the issues on the other one. Yeah. So, lots of things like that. Not, to that extent, cause that was probably that made a name for us. That was a very, very expensive piece of gear with swipes or relays all over it.

And they’re not necessarily inexpensive. And the lead time alone, I don’t think it’s the cost of the components of the assets any longer that matter. It really is the time to get them.

Wes

Yeah, to go back and remediate the issue, right? You there were 81 of them with reverse polarity. That’s probably not 100 % of them. There was some that I’m sure you had to go back, put hands on again and…

Dale

Well, that would represent about 5%.

Right, so exactly. So to go back and to do the inspection of all of these, open up the aperture to inspect more and more and more, because you get what you inspect, not what you expect, right?

Wes

And then to remediate the issues. What did it take? How much time did that delay the project overall if you had to estimate?

Dale


If I had to estimate, the vendor’s tech probably took a week to fix those. And we didn’t know at the time that we could offer our assistance in find and fix type assistance, which makes it go a lot faster. So we do offer that now. It wasn’t in our contract. We were just supposed to identify the issues, turn them over to the vendor.

And obviously our first asset at our first building, they’re pretty immature in the process actually. But now we know when in suggesting early on during pre-con activities, hey, if we find these conditions, do you want us just to document and fix them to keep the thing going? So I don’t have to come back after a vendor comes and fixes it. And then I have to do a re-inspect so that I can close out the identified issue, take a photograph possibly and upload all that. If we just take care of it all at once while we’re there.

So we make that offering now, but we didn’t used to. Cause we didn’t know we had the option. We thought we had to be a third-party vendor that didn’t touch anything. So now they’re realizing we have a skill. mean, most of us have either been electronics technicians in the Navy or electricians, commercial or nuclear. So yeah, it’s worked out I reckon we’re starting to learn more and more every day and our capabilities are broad. So we just constantly doing a needs analysis, see where we can help.

Wes

That’s interesting. That’s something that I usually like. I think just like you probably had seen before, I’ve never really seen the inspection group, whether it’s internal within the organization or a third party or what have you, never seen them also be the ones to go forward and fix. 

It’s good that you are, like you’re saying, it’s just wasted cycles. We could be so much further ahead if we say, hey, all right, we know this is wrong. It’s not conformed to the spec.

How do I know? You we’ve gone through the trainings, we’ve reviewed the specifications and standards, we know, let’s just fix this right now, rather than having a big debate about it and who’s gonna do it and trying to schedule it all in. That’s excellent, glad to hear it.

Dale


Yeah, if it’s agreed upon early on, a good example is cutbacks. 

Integrator cutbacks can sometimes get fairly sloppy. And so if we disagree upon wire cutbacks, they can’t exceed a quarter inch. Makes it very simple and if it does exceed a quarter inch, we’ll go ahead, recut, retrim, re-land, perform a quality inspection, a third party quality inspection, meaning a second inspector has to watch that and sign off on it, even if we do it. So that there’s always, there are always four eyeballs looking at things.

Wes 
Yeah, excellent.

Dale
Trust but verify.

Wes


Yeah, absolutely. Absolutely. And so a lot of the work that Fulcrum is doing focuses on, again, quality commissioning for hyperscale down centers. 

So can you share just a bit more about how it is that your team is ensuring that the contractors are installing the original kit properly the first time? What tools are you using? What have you found to be most useful in ensuring that we’re getting that work done right the first time?

Dale


I think the one thing is training. For instance, we just worked with 3M, such that we now have five 3M termination trainers in Omaha. So we can train people on the proper methodology of terminating a medium voltage cable using 3M kits. 

And we’re always looking for those opportunities because I really think most of the frustrations the client sees rework, it really is just lack of training. And that training, you can take a 15 year journeyman electrician. Each site expectations are different. And if they default towards what they know, it could be the exact opposite of what this client’s requested. Not in the NEC code, but maybe in terms of practicing how torque verification is going to occur or how the torque marks are going to be striped onto the actual bolt or nut or whatever they’re doing. 

So a lot of variance in each building, each campus. And just because you have 15 years of experience, are they being trained to go into project specifications and have it, hey, here’s what we expect each site. And usually it doesn’t happen to the level that we would like to see, but we’re not in control. Once again, we’re just the quality inspectors working for the same client they are.

And we love to get them involved in our training too. We like to invite them as well because we will go over construction expectations from the client. They’re not ours. They’re what we know the client wants. And they don’t get to hear that. You don’t bring your 80 electricians or your mechanics in a room and go, all right, everyone, this is exactly what we need to do. And then give them a test on it. And if they don’t pass the test, we get to do it. Well, that’s how we do it. You have to pass the test.

But you can see why. I mean, everyone’s struggling for folks. You fail the test, they’re not getting rid of you if you know how to terminate. But…

Wes 


No, that totally makes sense. Cause it’s one of those things you hear all the time on project. It’s, well, this is how we did it on the last job. Well, we’re not on the last job anymore. And I don’t blame you for saying it because you probably you’re exposing that you don’t know how we’re supposed to do it on this job. 

So like you’re saying really just reinforcing, at least putting it in their hands, the right information for how it is that this project needs to be executed on. think that totally makes sense. 

I’m curious what sort of.. you know, what does the labor force look like right now? The folks that you’re getting in training. Do we have the level of 15 year journeymen on these projects or are we seeing a younger workforce entering it?

Dale

If there’s a 15 year journeyman, he’s at least a superintendent. He’s not turning wrenches because it is a very young and inexperienced workforce. But that doesn’t, I’m not saying that they’re dumb. They’re young and inexperienced. Now let’s train them up. There’s a lot of good folks out there. We just want, I want to get my hands on them and show them, you know, certain things that I think they’re not seeing. They just run them through some basic industrial behaviors. Communications being the biggest one, you know.

That can be frustrating because folks don’t know the importance of possibly just great communications when they’re writing things up so that everyone at that afternoon meeting in the commissioning trailer can understand exactly what the issue is. They’ve already gone home for the day, their phone is up and not picking it up and they wrote a non-conforming condition on an asset or something, not our guys, someone else. Because our guys know, you know, we review our issues every day and if there’s any, you know…

Any question as to what the problem is that well, first of all, they should have provided a photograph of the problem, but then a write up and we encourage our folks to use AI because if they’re not, you know, not everyone’s the greatest writer in the world. So we’re like, Hey, put your ideas into Chat GPT tell them what the problem is and then spit it out. It’s our reports are wonderful when they do that.

Wes

So at Fulcrum, you really have obviously a heavy, heavy emphasis on training. And in that, you you’re effectively giving all of your personnel the tools that they need in order to succeed, right? You’re really empowering the team and providing that kind of continuous improvement effort there. 

So I guess I’m curious, like, how do you train? How do you motivate the contractors, pardon me, to prioritize quality in their installations and what role does this play in building data centers as fast as possible? Without sacrificing those standards, maintaining that floor of the base set of standards and requirements.

Dale

I think that’s the problem. I don’t think the workforce understands or knows the standards. So that’s why training is so important to these folks and they’re yearning for it. Like I said, we have a procedure on how to use procedures.

Wes


Right.

Dale


Because it’s, and then we have 21 core procedures which starts with project overview, set up and execution and ends on organizational effectiveness. And then there’s 20 admin procedures. Then we have everything mechanical and electrical. 

Which, you know, I don’t want to downgrade anything or seem like we’re cool, but I mean, there’s in reality, electricity meets cold fluid at a computer in a data hall. So essentially I see three systems, the computer system, the electrical system, and the cooling system.

Hey, a nuclear plant is 90 systems highly integrated with the most extreme logic and interlocks you can imagine. So this isn’t hard for us. It really isn’t. We can get our arms around pretty quick. What we can’t get our arms around is the unknown, you know, there’s a lot of that. So we’re figuring out what we don’t know as we go to because it wasn’t presented to us. We didn’t see it anywhere. No one’s mentioned it. And all of a sudden, poof, here’s something we don’t know.

Wes

Right, like you’re saying, know, lot of the folks, just don’t necessarily know that there is a spec or if there is a spec, what it is for this individual project. You know, a lot of these folks, haven’t really worked a whole lot of projects in the past. 

So what I’ve seen has helped is where you can put as much information kind of in their hands through training or just kind of by breaking the bits down and putting that in their hand as they go kind of step by step through the process of completing whatever the procedure says.

Do you see that as well, just making sure that they do have access to the right information? Does everybody have that access? What sort of issue are you seeing there?

Dale


As good as you can get on a very fast moving site, seems like there’s lags. Certain vendor drawings sometimes lag behind the asset themselves. RFIs can take a minute, things like that. But kind of if…

Here’s what I see with most of the folks out there. They don’t have training departments within their companies in the manner that I would expect. And it’s because they don’t know like basic structure of a training organization. And it doesn’t have to be complicated. 

Really, we follow what’s known as a SAT-ADDIE model. It’s a militaristic model that adopted by airlines and nuclear plants. But, and it does get kind of cumbersome. So we just stripped all of what we call SLR, Silly Little Rules. We stripped all of that out and took the good. 

So, you know, it’s the SAT-ADDIE model stands for systematic approach to training using five steps, essentially. The A in ADDIE is analyze. So and that’s what we’re doing constantly. We’re doing the first part of analysis is doing needs analysis on the site. Walk around and what do we need?

And then after you see the need, now we have to solve that need through training. So we’ll do a job and task analysis on that need. Right. And the output of a job analysis is a list of tasks to perform the actual get the outcome you want.

And then we’ll go through those each individual tasks and we’ll get elements of the tasks so that we can create training on it. 

Then the D is we’ll design the training and develop it. The D isn’t necessarily what folks think. It’s a lot of times we create mockups for joint pack and busway training. It ends up being way better than a two hour training session in a classroom. This way we have 30 minutes in the classroom talking about a joint pack just being nothing more than a kind of a fancy splicing device to connect conductors together. 

And then we go into a lab and we have all the different joint packs there. We can insert them and they can see the difficulty, how they position their body in a scissor lift, how it’s heavy, right? Some of them are heavy. you know how you’re going to have to position your body to get leverage and get the joint pack inserted, establishing critical dimensions. 

So you follow this process of analyze, design and develop. Then you get to how you implement it. And then the last one is evaluate. You’re constantly trying to make it better, constantly providing feedback. They don’t know it’s that easy and they’re not supposed to. I did it for 30 years. It seems easy to me. But I mean, that’s why we end up doing most of the training on the site for the general contractors.

Wes 


I think it makes sense. Like you’re saying, they’re just not set up for it oftentimes. So it’s great having that.

Dale

They’re not. They construct big buildings. They’re not trainers.

Wes 


Right, yeah, exactly. It’s great that there’s a resource out there like Fulcrum in order to kind of help streamline that process and take those lessons that have already been learned and just apply them in these different areas.

The last question that’s in my mind, Dale, is exactly on that topic. In your mind, what more can be done? there’s one solution that you would try to, I guess, push through across the entirety of the industry, what more do you think can be done industry-wide to improve the outcomes of these projects in the space of both quality and velocity?

Dale


Gosh, that’s a catch-all question. I think pre-con activities are the key. And that’s where everyone can get on board. Because so often, we’re three months into a build, we haven’t even energized the first piece of gear. But no one’s really on the same page yet three months in. 

Pre-construction activities are where we can all get alignment. And we can all work towards the same common goals. And we see that our pre-construction activities are stolen virtually every time with many of our clients. The contracts don’t get signed to the last minute. We’re deploying and we’re having to figure it out. And we’re drinking from the fire hose like everyone else. 

If we could get those pre-construction activities to create our work packages, to figure out our assets, to scope it out and figure out, okay, we’re gonna have to create scoping groups because this cable is gonna go underground. No one’s going to be able to do anything so we’ll have to analyze that to see how we’re going to energize and test the gear. We’re fortunate that we’re using standard design that doesn’t change that much. 

But now when we go to a new client and it’s all brand new, we’re on our way to Atlanta here first week in July for some 60 megawatt builds that are never seen before. But we’re getting good pre-con activity. So there’s all the drawings. We’re going to take a look at things. We’re involved. But that doesn’t always happen.

So we don’t have the fear factor that we might have. We just had to the ground running and the walls are tilting up and the gear is coming tomorrow. And by the way, are you guys available? And we have seen that before.

Wes

 

So you’re saying basically out of the need to move quickly, we’re not always giving ourselves the time necessary or that would really be optimal for ensuring that we’re really ready to go to site, right? That we’re ready to build whenever we go to build and just a little bit more collaboration in that pre-con phase would yield to the other end of the package.

Dale

 

Preparation, you know the old saying, if we could just, if we would make it sacrosanct, no one can touch these three weeks while we all get on the same page. But we don’t get that. And that’s probably pie in the sky.

Wes 

 

Yes.

Dale

 

But if we can all get on the same page, let’s do all electrical for this week. Let’s do all mechanical for this week. We’re all on the same page, the superintendent’s mechanical, superintendent’s electrical, general superintendent’s onboard. They understand how we’re do this and then how we’re gonna do the data. And three weeks is all it would take. But that is asking for a lot with these construction schedules.

Wes 


Three weeks on one of these data centers and operations is a lot of time, it’s a lot of money. So I don’t know if we can always get that, but definitely having a more established and grounded plan with all of the stakeholders, the subs, the contractor, everybody, is definitely the way to go, right? You don’t plan to fail, you fail to plan. So, it’s great.

Dale


Right. I go to an outage at any North American nuclear plant. Generally, it’s every two years. They went from 18-month cycles to 24-month cycles. So every two years, you’re going to refuel the unit. You get two years to plan that.

Two years to plan a 30 day refueling outage where thousands of people are crawling all over this place like ants. And I don’t think we need two years to perform 30 days worth of work, but 30 days should be really nice to do two years worth of work. Just flip it over, it will be valuable.

Wes 


The ratios are a little skewed there between the different activities, right?

Dale


Yeah, just sanctify those three, four weeks on the front end that there’s, if they knew how valuable they were to getting everyone on board, at least for us, we’re fortunate that we know what’s important. At least we think we know what’s important. 

Generally, a lot of folks don’t know yet. And we see it. We see it when they bring in a new commissioning agent. Maybe we only get quality and there’s a new commissioning agent. And a lot of times their jaws will just drop. ‘The client wants what?’ Yeah, no kidding. You know, we do. But here’s how you do it. So there’s some eye opening stuff that happens that you’re just not used to.

Wes 


Yeah, definitely. Well, it’s definitely a fast paced and kind of emergent field that’s growing more and more and changing every single day right now. 

So Dale, this has been a great conversation. Thank you, sir, for coming on the show and really for the work that y’all are doing at Fulcrum. And for me with getting the next generation of the labor force ready with all the training that you’re doing, I appreciate it. That’s definitely a soft spot that I have in my heart. So thank you, sir. I do appreciate the conversation.

Dale


Wes, I had a great time.

Wes 


Thank you sir. I appreciate it.

Dale


Alright, have a good day.

The post Building It Right: Training, Torque, and Quality in Hyperscale Data Center Delivery | Work Done Right with Dale Jennings appeared first on Cumulus Quality.]]>
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Safety, Speed, and the Future of Modular Construction | Work Done Right With Jim Ellis https://cumulusquality.com/safety-speed-and-the-future-of-modular-construction-work-done-right-with-jim-ellis/?utm_source=rss&utm_medium=rss&utm_campaign=safety-speed-and-the-future-of-modular-construction-work-done-right-with-jim-ellis Wed, 02 Jul 2025 16:15:29 +0000 https://cumulusquality.com/?p=13758 In this episode, Jim Ellis, CEO of Ellysian and former VP of Global Construction at Microsoft, shares insights from his...

The post Safety, Speed, and the Future of Modular Construction | Work Done Right With Jim Ellis appeared first on Cumulus Quality.]]>

In this episode, Jim Ellis, CEO of Ellysian and former VP of Global Construction at Microsoft, shares insights from his 40+ year career spanning nuclear, oil & gas, and hyperscale data center construction. He emphasizes the need for a systems-based approach to capital project delivery—balancing speed to market with safety, quality, cost efficiency, and sustainability.

As data centers grow in scale and complexity, Ellis warns against sacrificing quality under schedule pressure, noting significantly higher rework rates in the data center sector (7–8%) compared to oil and gas (~1–2%). He highlights the role of proactive QA/QC, early supply chain integration, and modular construction as critical levers for success.

About Jim

Jim Ellis is a globally respected corporate executive with 45+ year’s international and visionary strategic leadership with DuPont, SABIC and Microsoft. Jim has served in executive roles including Corporate Operations, Manufacturing, Engineering, Technology Commercialization Business Development, Merger and Acquisitions and Capital Project Portfolio/Development/Execution Management. Jim has an excellent track record of delivering and sustaining business, project and operating results at-scale.

As CEO of Ellisian and BOD Chairmen of the Construction Users Roundtable, Jim is leading transformational industry changes that are enabling safer, more sustainable, efficient, predictable and profitable capital projects and portfolios across the globe.

Top 3 episode takeaways

1. A Systems Approach Is Essential to Balancing Speed, Quality, Safety, and Cost in Data Center Construction

Jim emphasized that speed to market is critical in data center construction, particularly due to surging global demand driven by AI and digital infrastructure. However, speed cannot come at the cost of safety, quality, or sustainability. Drawing on decades of experience, including his leadership at Microsoft and in oil and gas, Jim advocated for a holistic, systems-based project delivery model—one that begins with careful planning and site selection, continues through disciplined execution, and finishes with a reliable handover to operations.

This approach requires:

  • Early alignment of project objectives and KPIs
  • Rigorous planning and integrated execution strategies
  • Discipline in following a structured project delivery framework

He stressed that balancing competing KPIs (cost, schedule, quality, safety, sustainability) is possible but requires intentional trade-offs and leadership commitment across all project stages.

2. Quality Assurance Must Be Treated as a Core Value, Not a Trade-Off

A major theme was the critical role of quality assurance (QA/QC) in ensuring the success and safety of capital projects—especially in high-stakes environments like data centers and oil and gas. Jim shared that compromising quality, even unintentionally, often leads to safety risks, schedule delays, and increased costs.

Key insights:

  • QA/QC should be proactive, not reactive (avoid just “throwing bodies” at the problem).
  • Quality must be designed into every project phase—from feasibility and procurement to construction and commissioning.
  • Tools and platforms (like Cumulus) that provide real-time quality tracking and documentation are essential for lifecycle traceability and operational readiness.
  • In the data center sector, he observed rework rates as high as 7–8%, much higher than the 1–2% in oil and gas—highlighting a critical opportunity for improvement.
3. Modularization is a Key Enabler of Efficiency, Quality, and Flexibility

Jim made a strong case for modularization and offsite construction as a strategic solution to many of today’s data center construction challenges. He shared his experience building modular facilities since the 1990s and emphasized that:

  • Modularization supports higher safety, better quality, and shorter schedules due to controlled factory environments.
  • It helps mitigate global constraints like permitting delays, skilled labor shortages, and limited on-site power.
  • With the rise of AI and high-density racks, modularization is becoming not just a preference but a necessity for managing complexity and delivering reliable infrastructure.

He also pointed out that early supply chain engagement and repeatable, scalable module designs are key to maximizing modularization’s value

Episode Transcript

Wes

Today’s guest is Jim Ellis, a globally respected senior executive with over 40 years of transformational leadership across engineering, manufacturing, project management, and operations. 

Jim has led diverse high impact teams across 60 countries and held senior roles at industry giants like DuPont, Sabic, and Microsoft, where he most recently served as corporate vice president of global construction. 

Now as CEO of Ellisian, he’s helping organizations deliver safe, sustainable, and innovative capital projects all around the world. Jim, welcome to the show.

Jim

 

Great, thanks Wes. Great to be here and I appreciate you having me and looking forward to our discussion today.

Wes

 

Yeah, absolutely. So with that, I did my best to summarize your expansive experience. 

But you know, I’m curious, one, if you could dive in a little bit more on maybe some of the specifics as far as what you’ve done across your career, how you started in the industry, really to how did you make that pivot from working in heavy industrial oil and gas, which is really where my experience lies and a lot of the frame of reference that I’ll use for this conversation, but into the data center environment, which is in a lot of ways, it’s a separate world. 

A very much emerging market right now that everybody’s talking about, but how did that change happen? So if you don’t mind just providing that context there.

Jim 

 

Absolutely. It’s a great question, Wes. So I started out very early in my career as an engineer working in the nuclear part of the business for DuPont and making nuclear fuel rods as a supervisor that was on shift and leading people. 

And really got a lot out of that part of my career very early on because I recognized at that point in time how important the folks that work for you are in your development. And that convinced me that, I was really into the operational side of things, right? Although I was trained as a mechanical engineer and undergrad and electrical engineer on my grad studies or masters, you know, I felt like operations was the right place for me to be. 

And that’s kind of defined my career. I’ve spent a good part of that, and when I speak about operations, I’m speaking broadly. So it includes business operations, it includes manufacturing.

It includes technology and it includes, you know, actually engineering and capital projects because that’s the way many companies, you know, sustain their operations in terms of run and maintain. 

And it also is a way that they grow. So that really excited me and I’ve been blessed to have just an outstanding career that kind of went, as you mentioned, through 35 years with DuPont and then another 10 years with Sabic. 

And then, you know, the Microsoft piece was really exciting. So most of my career, as you stated, has been in the kind of that industrial kind of environment. Petrochemicals and oil and gas and so forth and so on. But it was always focused on, you know, how do I help companies really think about strategy for growing in the latter part of my career? 

And then when I had the opportunity to come, you know, before me with Microsoft, that’s what it was all about. I started doing the research on data centers and looked how exciting that was and the growth that was just totally aspirational for a lot of these companies like Microsoft and Google and Amazon and Meta and now Oracle. 

Clearly, that got me really excited. So when I got the opportunity to go in there and really lead Microsoft’s hyperscaling strategy across the globe again, that really was something that I was really intrigued on looking at and spent a good part of my time developing those strategies with Microsoft. 

And today that market is just continuing to grow in such a significant way based on the needs of people that want to stay connected and want to be able to improvement in productivity and improvement in their lives, right?

Think about how AI is going to transform that over time, right? It’s already started to transform that in our lifetime. I’m really looking forward to my grandchildren really enjoying the benefits of all of this AI work that’s going on and making their lives in terms of work-family balance and a whole lot better.

So that’s how I got here and I just had a great experience, met a lot of people, have a lot of relationships around the world that I still have today and I’ve been blessed, frankly speaking, to really have those experiences.

Wes


Definitely. That’s, that’s the thing that I always say is really for me. The experience of it is great, but the people that you meet along the way is really, was really what makes it. 

That’s the thing that I look back and I remember. I don’t just remember the mega projects. It’s really the folks that I worked on these projects with, that really is just phenomenal to kind of recollect on. 

So with that, that’s sounds like there’s an organic sort of pivot to go from the heavy industrial oil and gas into the data center space. And one of the things that I’m hearing a lot more these days is that it’s not just that there are a lot of projects that are happening very quickly in the data center market, but there are very large projects that are initiating in the data center market, which in our experience in heavy industrial oil and gas, seems to be very, I mean, that’s much more commonplace, right? 

We’re very accustomed to these industrial mega projects, multi billion and multi tens of billions of dollars. But maybe not so often in the data center market, but it’s seeming to me like it’s happening more and more and more. 

So what sort of, guess, key drivers do you look at, or did you see within Microsoft that maybe you had to bring in from industrial construction, oil and gas into the data center market? 

And how did you, how did you help them to evolve their processes, looking at these larger projects?

Jim 


Now, that’s a great question. And the simple answer is, in order to scale, you have to have a systems approach.

And the systems approach becomes extremely important when not only you’re scaling, you know, from just say, you know, data centers were nominally 40 megawatts to 100 megawatts today where they’re sitting somewhere and into the future, you know, upwards of a half a gig to a gig. 

You know, that might be one of the biggest challenges in terms of how you drive a systems approach to getting these data centers to the point where they can deliver to both the company’s expectations as well as the client customer expectations. 

And today, one of the bigger challenges is because the scale is such a huge scale and time to market is the key priority for all of these data centers. And I was told when I got into Microsoft, ‘Time to market drives MPV, Jim’. And I said, get it. So we got to go fast. 

But if we’re going fast, we also have to go safe. We have to go sustainable. 

We can’t ignore cost because cost still has to be efficient. And we’ve got to be able to drive that schedule. And we’ve got to be able to drive quality and assurance of quality across that end-to-end cycle in a systems way. 

So that at the end of the day, when you turn over that asset to operations, they got something that’s safe. They have something that’s reliable. They have something that’s efficient. They can provide reliable, you know, megawatt capacity to their clients and customers. 

And that’s just, you know, something that is going to be essential moving forward that hasn’t changed and I don’t expect it will change with AI. 

Are we hitting the pause button a bit on that with AI in terms of, you know, model development and large language model training and things of that nature? For sure. But once you get into agentic AI and you start to get into inference AI, those expectations are going to be exactly the same, if not more so, in terms of the need for quality and reliability to the client. 

And it starts at the very beginning when you select a site, you develop the project, you execute the project, you fit it out to customer need, and then you basically turn it over to operations in a way that they can operate to expectations of both internal stakeholders as well as external stakeholders.

Wes 


And that all make sense. I hear oftentimes that right now, speed is everything. It’s all about getting these things up and running as quickly as possible. But you’re saying effectively in order to get value through the whole life cycle of this, it’s not just about speed. 

It’s also balancing the other kind of key performance indicators that we have throughout the project that we hear all over the place, right? It’s, it’s safety, it’s quality, it’s productivity cost, know, schedule in there.

So how is it that you see the balance between, honestly, I think that safety is always at the forefront of everybody’s mind on a project. Nobody will say, hey, we’re ever gonna sacrifice safety. 

But I feel like we’ll say maybe focus on quality is something that will go by the wayside or even focus on cost as opposed to schedule some side, sometimes we’ll go by the wayside.

How is it that you see the trade-offs there, the balance, how do you manage that process as a system like you’re saying, so that we’re delivering long-term value out of these data centers, returning value back to shareholders, et cetera?

Jim


Yeah. So I really like what you said around safety because safety is a core value. So that’s not something that anybody’s going to compromise. And I really feel good about our industry, both in the industrial side as well as the commercial side that, you know, across the supply chain, that clearly is not just a priority, but it is really a value because at the end of the day, it’s about people like we discussed earlier. 

But, you know, when I was coming through in my early part of my career and I was working on my very first couple of projects, you know, I was told, you know, the story of the three-legged stool. 

You could have cost, you could have schedule, or you could have quality, but you can only pick two out of the three. 

And so we made trade-offs based on that, right? Very early on in my career. And when you do that, you do it very early in a project cycle. You make these decisions in terms of what are the business objectives? 

How does that flow down to the project objectives that helps to guide decisioning across the end-to-end project itself? And at the end of the day, that tended to work because you made some decisions and you had some criteria that you went by in order to do that. 

What I find today, again, in the data center world and some other high-tech types of projects that I’ve been also involved in through my company, Ellisian, where I’m the CEO, I find that those trade-offs and that discussion just doesn’t happen as it used to happen because the stakeholders say, we have to have it all. 

We have to have time to market in a schedule. We can’t sacrifice safety. We can’t sacrifice quality. We got to have cost efficiency. And by the way, sustainability has got to be built in this. So when you’re making material selections, as an example, or you’re making energy choices, that’s got to be very clear in the decision making process. And that can’t, you know, drive things like schedule out. 

Now we do see that today with power being kind of the, I think the biggest constraint that we’re facing as a data center industry, but it’s broader than that. It’s just as a set of industries in the aggregate, right? 

Because if we can’t get power and we’re going to put all this gigawatt into, and some of the forecasts I’ve seen recently are upwards of 250 to 275 gigawatts by 2070, by, excuse me, 2030, not 2070, it’s 2030. You know, that’s an amazing task to move from where we are, which is nominally around 85 to 90 gigawatts across the globe. 

And to deliver all of those KPIs to your point, you know, key performance indicators, and get that turned over to operations and get that capacity in the hands of the clients that are, you know paying the bills at the end of the day for these hyperscalers and co-locators and enterprise players. That’s a huge challenge that we’re facing. 

But for a capital project and capital project teams and their leaders, it makes it a bit of a challenge when you have to kind of manage all of that, right? And it gets started very early in and decisions you’re making around site selection, decisions you’re making around how you’re going to develop the project and not only how you’re going to develop, who you’re going to develop it with and what are your degrees of freedom that you do have in order to deliver across a spectrum of KPIs that have to be all delivered on.

And you use the word balance. I would say that, you know, we do have still in order of priority in that market, right? Again, the market has not changed anything. It’s all kind of on the minds and hearts and souls of individuals that are facing that day in and day out. But it doesn’t forego those things we talked about: safety, quality.

Efficiency is starting, especially on the cost side, starting to surface a lot more in terms of a dollar, capital dollar per megawatt. And I see a lot of benchmarking out there from company to company and how we can do that. 

But that’s interesting, but not relevant because what these companies have to do, and this is where the systems approach comes in, you’ve got to really have a disciplined process approach to figuring out where those opportunities reside in terms of cost efficiency.

And what strategies can you deploy in order to get schedule and cost and quality, safety, so forth and so on, to the point where, you you go and that becomes part of your execution strategy for that project? And once you have that execution strategy, the success factor is based on how disciplined are you to really go by that execution strategy in a way that, you know, it was planned and thus how it should be delivered.

So that’s kind of where I see this balance kind of question you’re asking. So it’s not easy, it’s difficult. But is it doable? I’ve seen some really great projects that have met on all of the various KPI measurements that are again, required internally and externally. 

And then I’ve seen a lot of projects, and this is kind of fits where we are today, that are exceeding things like schedule and cost and not having the right level of quality. And sometimes when you’re not providing the right quality, there’s a huge connect with safety too. 

And I’ll use one example that I was faced with very early on and it wasn’t just the company I was working for, was across the industry. And that was the quality assurance around the electrical side of the job on a data center which that’s probably the biggest scope, is so important. 

And when you do that, you have to make sure that you assure the quality and the actual building of the equipment itself, the inspection of the equipment itself, the install of the equipment itself, the storage of the equipment itself, it doesn’t go in as soon as it’s delivered. 

And what we found is we were having a lot of arc flashes across the industry. And that you know, an arc flash is something that clearly is something that you want to avoid. Even if you’re protected from a standpoint of personal protective equipment, it still creates a risk for the humans that are at the interface of that installation, you know, day in and day out. 

And, you know, that was a key learning for me saying, hey, you know what, these do all connect. You’ve got to have the right assurance. You have to understand, okay, number one, you’re having these types of incidents take place. You know, what are the root causes associated with that?

And once you understand the root causes, what are the things you’re going to put in place to prevent recurrence? And that can’t just be an owner. It’s got to be across the entire supply chain, because a lot of different parts of that end-to-end supply chain touch this. 

So to me, that was a big lesson. But again, illustrates the importance of this balance between the various KPIs, because if you push quality out, other things kind of happen, like I just described.

Wes


Yeah. And that that totally makes sense to me. I used to one of the things I used to say whenever I was running crews back, geez, 10-15 years ago even, was that the quality of the work that we’re doing is directly going to impact the safety of the people who are operating the facility. 

Like that is, they’re so directly intertwined. But I feel like whenever we say that we have safety as a value, whenever it comes to all things construction, it’s really with all things construction, it’s no, do you have the guard on your grinder? Are you using tools and equipment properly? Do we have the safety measures in place for the way that we’re executing work, but not for the way that we’re, we’re effectively delivering the work or the manner, the form factor that it’s in whenever we deliver it. 

We don’t think about the safety of the life cycle of the facility. We really just think about the safety of the individual worker on the construction project. I, I feel like there’s a flaw in that somewhere that that we’re maybe a little bit short-sighted with some of the decisions that we’re making. 

So we do maybe inadvertently sacrifice quality because we’re chasing the efficiencies, we’re chasing schedule. But I think that also goes back to the way that we incentivize our contractors on projects in order to to maybe deliver faster. 

Do you see that as well? Is that something that that you saw either in your time in oil and gas or even whenever you switched over to working in data centers where those drivers that we’re incentivizing on are really still schedule based more than anything, rather than focusing kind of on the whole of the delivery?

Jim


Yeah, no, absolutely. Again, good question, Wes. And it’s not related just to data centers. Obviously, it’s across the industry where you see that, right? And, you know, the folks that are at the interface of the work, the project teams, the contractors that are supporting it, right? The operational teams that are overseeing it, they all feel the pressure of you know, if I don’t meet the costs and I don’t meet the schedule, you know, I’m not going to basically be meeting my boss’s expectation or their boss’s expectation or the company’s expectations. 

So we make these decisions. And what I put that in the category is folks will say it’s prudent risk. I say it’s risk that’s not always prudent. 

And so, you know, that whole balance of making sure that QA/QC happens across that life cycle and it doesn’t get pushed out, like safety, I think of it more like a core value. 

And when you do that early QA/QC, know, the buzzwords as well, of course it’s going to reduce your rework. Of course it will, right? If you don’t have to do the work twice, but you know, it’s also going to create a lot of other opportunities around risk reduction, you know, mitigating things like schedule delays.

Mitigating cost overruns, mitigating warranty issues, which can be very costly. And faster time to market. If you want faster time to market, proactive quality controls, streamline things like the install process, the commissioning process. 

Reduce the retesting that has to get done, whether that be during a fact test at the OEM shop or when it’s received at the field where you’re actually doing field inspection testing. And one thing I’ve seen the real value is when or the impact when you don’t do it is it actually extends the schedule and impacts the handover to that operating group that essentially has to take final care custody and control of that asset. 

And you said something here that resonated with me. We think a lot about the human element of safety that gets a lot of attention, but you when I was in oil and gas, process safety was, you know, is equally important as it is in the electrical side and somewhat the cooling side of the data center world, right? 

So if you don’t make sure things are tight, for example, and you haven’t assured the actual, you know, quality assurance of the install itself at a component level, you know, by default, you’re taking on risk and that risk has consequences if left unmitigated. 

So to me, I think you’re spot on. There are tools that I can say right now that can help, like the Cumulus tools that are available today in the market, which I’ve seen had tremendous value both in the oil and gas industry as it relates to high dense piping jobs and as well as the electrical side on the install and data centers, which is probably the key area in terms of magnitude and building that data center and doing it safely. 

So yeah, the end-to-end quality assurance QC, if pushed out, will have consequences. And so we’ve talked about some of those. 

The other pieces that we haven’t talked about is compliance and certainty, right? So a lot of these builds have to be compliant to certain tier certifications, right, at a permitting level.

You know, clients have SLAs, for example, with various agencies like FedRAMP. And, you know, regulatory on hyperscale specific standards are important. And what you don’t want to do is find a surprise when either you have an audit by one of these agencies or you’re at the end of the day and you’re looking to get that final sign off that you need to actually start up and turn it over to operations. 

So compliance and certainty is also an important element where if you have this end-to-end robust QAQC system that cuts across the end-to-end project delivery and then gets transferred to the operating team over that lifecycle of the operations, I think you’re going to be way ahead. 

So way ahead, what does that mean to me? You’ve done the project efficient, both cost and schedule. You’ve done the project safe.

You’ve assured the quality, you’ve turned over a reliable asset to the operating team. They can run that with confidence in terms of their ability to deliver their expectation to stakeholders, both internal and…

So why wouldn’t you do that? Why wouldn’t you put a robust QA, QC, end-to-end process in place? So I’ll look back to the systems approach on getting things done. This has to be a mission critical element of the systems approach to building and operating data centers.

Wes


Yeah, that to me, I think it all seems like it’s all obvious, but they’re the common objections that people will say, right?

And the first of which is, yeah, that checks out, but I don’t have these quality problems, right? My, my projects are, are always robustly built. We hire the best craft. We ensure we have these processes already in place.

So quality is just kind of a given, right? It’s what we expect. Well, I’ve also been told you get what you inspect, not what you expect, right? 

Jim 


Exactly.

Wes

 

So, I mean, what do you see though? What has been your experience with this? Pardon me. With like, what’s the rework rate that you’ve seen in data centers versus oil and gas experience, maybe?

 

Jim

 

Yeah, no, great question. So the rigor in an oil and gas, because of the process safety management concerns there, I see to be a lot more robust and not more focused. And when I think about that over the life cycle of the asset, right, let’s start with the build itself. I find that the rework that goes on in a construction environment is probably in the order of one to no more than 2%, which is fairly low, right?

And that’s not just having a good QAQC program. It’s also associated with good planning, making sure you’re understanding the scope. The scope is frozen. You can deliver on that with certainty because you know exactly what you’re doing. The priorities are very clear, and you can execute that project with the kind of expectations around safety quality, cost and schedule efficiency, productivity in the field, so forth and so on. 

When I came into the data center world, it was a little bit different. And a lot of that was driven by speed to market, right? I mean, getting out very quickly with, you know, 100% issue for construction drawings that we can go out to tender because we wanted to move so fast in a very finite period of time, right? There were certain decisions that get made. 

It doesn’t mean that people were sacrificing safety or quality in the design. That’s not what I’m saying here. But speed kind of trumped everything else in that process. And you’d probably push that out to other parts of the supply chain to make sure it got addressed along the way before you actually turn that asset over to the operating team. 

But I didn’t see the same level of rework in oil and gas that I saw in the data center world. That was upwards of a range depending on the job, right? But I would give you a range on average, maybe it was about seven or 8% of the rework that was done there. 

And some of those required stoppages too, because there were safety incidents that would take place.

And I’m not referring to Microsoft now, I’m talking about the broader industry across data centers. And so there’s an opportunity there, as I see it. 

You know, and I don’t think that opportunity is in any way misaligned with expectation, right? There is an expectation that quality is part of the job, and that’s no matter where you are, oil and gas, petrochemicals, data centers. But, you know, when you feel the stress of the moment, what gets pushed? And I think that becomes the problem, yeah.

Wes 

Definitely Yeah, you know, you know, you never explicitly hear somebody say, Hey, we’re just gonna wad up quality and throw it in the bin. But really, what you do here is where people putting their emphasis, right? 

Like what what, like, if everything’s equal, or, know, what, what does it say in Animal Farm? We’re all equal, some are just more equal than others, right? Like, we are like, whatever comes whenever push comes to shove, what are we really, really putting as our core value above the other and how..to me, it plays a balance, right? 

You should be able to weigh these things together and really think about it whole, as you say, as a system, right? How are we looking at not just the incident that we’re focused on or this one instance, but really how is this going to play to the life cycle of the build, of the asset, of what have you. 

So it’s interesting to hear that maybe at least initially on what we’ve been seeing, not just again, not within Microsoft or naming anybody specifically, but across all these data center projects. There was a significantly higher rate of rework than maybe what you had seen across your decades in oil and gas. 

And I got to say, like we know in oil and gas that we do still have rework on these projects. 

Jim

 

Absolutely.

Wes


We have a lot of people working through these things and there’s still a lot of opportunity to be made there with reducing a lot of that to help with schedule and with costs on these projects. 

So to say that was an order of magnitude higher within the data center market, just again, highlights the opportunity that we have in my mind. It’s not how do we condemn folks for not doing better. It’s how do we do better, right?

Jim 


Yeah, and we all want to do better at the end of the day, you know, whether it was DuPont when I was working there or Sabic or Microsoft, these are great companies, right? And they have great values and great approaches to how they get their capital project work done. 

But it’s not about that. It’s about can we do it better? Can we do it more efficient? Can we do it more safe? Can we do it more sustainable? Right. And what are the what are the key levers that enable that to happen? 

And I think our discussion today, when we focused a little bit on quality assurance end to end, that I see as a very key lever on this. And you’ve got to build it into the system in order to get entitled to the performance that we all know we want and should be entitled to, right?

Wes 


Yeah. I learned early on in my life that if you don’t put something as a priority, you’re just not going to do it. So if you don’t expose it, it’s never going to be fixed, effectively. So I think, you know, what I’m hearing is, let’s make sure that we are in fact, just looking for the opportunities and identifying the opportunities so that we can go forward and execute on that. 

You know, I’d be curious to hear what you’ve seen or, or what you’re seeing presently for how it is that across all of these KPIs, these, these five men KPIs that we’ve really been talking about today. What role do you see modularization playing in this? Because from what, from what I’m seeing from the statistics are showing online, about half of data center projects right now are using modularization in their, in their, project strategy. 

And when asked on a, I think it was a Vertiv study, something like 93% of data center owners and customers, owners and contractors, are saying that they plan here in the very near future to be using modularization in their build strategy. 

So what do you see? How do you see that aiding and delivering across these key drivers?

Jim


Yeah, so to me, yeah, modularization is something that I have been championing since the early 1990s when I built my first modular facility in Corpus Christi, Texas, right, with great success.

A build that was basically constructed in Japan and shipped over and plug and played into a facility in South Texas, and I became a believer very early on.

And do believe that modularization, which I have championed along with others in the industry as offsite construction, has the ability in a safe kind of environment and a controlled manufacturing approach to really deliver the expectations, I think, more with more certainty than, you know, a stick build construction job. 

And what I mean about that is, you know, when you’re in an environment that’s like a, you know, a closed environment for manufacturing driven prefab or modularization or integration, you’re going to buy a better safety. You’re going to be able to improve your quality assurance. You’re going to be able to get efficiencies on both cost and schedule delivery. 

And the technology and approach to this manufacturing has improved so much over the course of the last 30 years to the point where, yeah, a lot of the data center providers today are exploring that. And you might say, well, why are they doing it? Is it just cost and schedule efficiency? No, it is the safety. It’s the quality. 

The other piece I’ll say is also about eliminating the constraints. So when you think about schedule and you think about the fact that these modules eventually still have to end up at the site. Imagine a point where it is going to be plug and play. 

The constraints that you see today are very significant in the data center world. One: power, power, power availability. Number one, we’re short across the whole globe on power. We talked about that earlier. 

Second, permitting. Getting permits to the point where you can secure something that can be started into the field. And it’s taking longer and longer. And of course, everybody talks about expediting them and we have all the right approaches and government relationships and community relationships. But at the end of the day, the agencies are driving this and it just frankly takes longer. 

And then you talk about the labor shortages that are going on across the globe, right? You might say, well, we got a huge challenge in the U.S., here Statistics will basically show that we’re three to four million quality skilled crafts short in the U.S. to actually meet the infrastructure demand needs today. 

We have not done a very good job to really renew that and attract our early career folks that are coming out of the high schools and choosing to go to college versus going into trade schools or not having the the program sitting in the high school level anymore that kind of encourage and train and create opportunities for these students to go and make different career choices. And so we remain short.

Modularization helps that in a way that you’re doing it in this environment where you’re going to encourage folks to potentially want to be in an environment like that versus being out in the weather and being out in mud on boots and all that kind of stuff that goes with construction.

You you think about the constraints I just mentioned and think about how modularization plays into that.

Power right now, with what’s going on. If grid power can’t be there, you still have that power. So modularizing the power availability to the site of construction and maybe even early on into delivery to operations through these bridge power strategies on modular strategies that can be deployed.

Permitting. You could be building the module sitting in the prefab yard while you’re still waiting on permits. As long as you’ve kind of cleared the kind of basics from a technology standpoint with the AHJs and so forth and so on, that can progress. 

The building itself can be built in a modular fashion on the site and save time. I’m hearing all kinds of stories from different providers can come in here and cut the time of a building install in half just by putting in modular buildings that could be very applicable in a commercial construct environment. 

And then finally, think about just the shortage of labor that we talked about. So is it pivoting over to be a primary strategy with many of the hyperscalers? Yes, with all? No, but I think they’re all exploring at this point in time, so I think you chose the right words. 

Will it evolve with time to be the prominent strategy to go to construct? And I would say, yes, you’re seeing that already and I think it will continue to grow with time.

Wes


It’s an interesting thought with getting it ready even before permits come through. Cause I know that that can be a long time in the making a lot of the time, you know, be the long pole in the tent is just waiting on permits to come across. 

So really just saying, hey, we have the design. It’s been, maybe it’s been proven out in another facility before. So this is something that we’ve already done. Yep. We’ve already checked with, uh, with, like you said, maybe with the AHJ or with anybody else through this and we can go forward and while we’re waiting on all of this, this bureaucracy to kind of progress along with it, we can get construction at least going, even if it’s not done yet, we can at least start it offsite before we are fully cleared. 

And if something happens where maybe it doesn’t go through, we can pivot to a new facility. Cause this is something that we know that we want to do anyway. So that’s, that’s interesting, especially thinking about how it is that we, shorten that delivery process to as early as possible effectively.

Jim


Yeah. The other point I’ll make is with the changing to Wes and the technology that’s coming up, especially on MEP, right, which is basically mechanically electrical in the plumbing side of the job. Most of that’s going in and rack level today in a data center. 

And, you know, the rack densities because of AI are going to significant levels versus where they are today some stories of up to 500 to 600 kilowatts. It’s very difficult to construct that in the field. You have to do that in a much more controlled environment when you have bus bars and cooling piping and so forth and so on sitting all at a rack level, all your cable trays, potentially your batteries, maybe the servers and from an IT standpoint, you got to be able to cool it a lot more efficiently, right? You got to be able to provide power to it. 

So this whole shift in the technology is also a key driver for modularization moving forward with the data centers, as again, rack densities increase and complexity within the rack increases.

Wes


That makes sense. That fully makes sense. And it sounds like, again, there’s just a real opportunity there in order to improve this full delivery process at the system level, rather than just focusing on the one individual component. Wr can pivot a lot faster as needed just by utilizing this new approach or this modularization. 

It’s not really new, right? It’s just new to some folks. Like you said, modularization has been around for quite some time.

Jim


Yeah. And just think about the quality assurance pieces of that integrated rack right now too, that you’ve got to do it along what I’ll call the time schedule of the install rather than waiting to the end. Otherwise, it’s going to be a lot of rework taking that rack apart. So think about building that into, again, your system’s approach for modularization.

Wes


Yeah, that fully makes sense. Now I’d be curious to hear what other opportunities you see to improve, we’ll say that overall QA, QC process even, which has really largely been a lot of what the conversation has been focused around today.

Because what I usually see it, or at least what my experience has been a lot of the time and in my past experiences, we’ll just throw more bodies at it, right? 

That that’s typically how our approach toward quality is like, well, we’ll just throw more people to check it out of the backend, rather than maybe looking at something that we can do on the front end of the process or through the process maybe in order to assure it. 

So rather than, or is that the only option, right? Is that what you see? What do you see as the options, the opportunities that we have in front of us in order to streamline this process, improve this process, whatever it is?

Jim


Yeah, so I’m glad you mentioned about throwing more bodies at it because I have found that when we throw more bodies at it, becomes less efficient. 

Wes 


Hahaha, right? 100%.

Jim


You never get enough of that. And when projects go behind schedule, the first kind of gap closing strategy is let’s throw more bodies at it. And it doesn’t work. 

Wes

 

Every time, every time.

Jim

My experience is that it does not work. Can it work partially? Sure. But the root cause is, as you stated, is right up front in the planning process. It’s in feasibility and design. It starts there, design reviews. 

You want to catch code violations, constructability issues, spec conflicts before they cascade. Then it moves into the procurement, right? And vendor QA checks, ensure material and equipment meet the specs, right? And that it mitigates any counterfeit substandard inputs.

You know, I’ve seen some of that with bolting, for example, coming from China as an example in my days in oil and gas. Then in construction, you know, the whole in-process inspections that have to go on, right? 

Verify installation standards. You got the sequencing, avoid costly rework, you know, make sure the quality is built in. Then commissioning and fit out, right? Validate the whole system performance before you get to IST, which is basically integrated systems testing. 

You got to make sure that you’ve got that all of the quality built in and more importantly you’ve got to have what I’ll call a record of that quality over the life cycle and it can’t be sitting in a handwritten set of notes or even in an Excel spreadsheet I find that stuff is just so inefficient and goes back to my comment on system is there a system or a set of tools like Cumulus does provide, that can essentially provide that end-to-end documentation and so you’re not searching for it when you’re turning it over to operations or to the final quality guys that are going to do, or the guys that are doing the IST on the integrated testing. 

And it all has to be signed off on. And you want to catch things early along the life cycle of the project. Feasibility, design, procurement, construction, into commissioning and fit out, and then finally into turnover to operations. You need to have complete O&M manuals that have to be developed.

You want to be able to make sure you understand where the red lines are and the asset tags are. You have to ensure the facility teams have visibility into what was built. And those 2D and 3D models have to be kept up to spec and refreshed when changes take place. So what I’m describing to you is what I mentioned very early. 

A systems approach to building quality in, quality assurance in, and quality control, not just quality assurance, is essential number one to the success of delivering that asset to the operating team in a way that they can perform.

Wes


Yeah, no, I mean, all of that is music to my ears because what I’m hearing is taking more of the proactive approach rather than the reactive approach, right? 

If you take the reactive or the backend approach toward any of this, you’re just going to end up with a good way of finding issues. But that means that you’re still ending up with issues, right? 

So whatever we can do in order to prevent as early as possible any issues is really the approach that we want to take.

We’re coming up close on time here, Jim. So I want to ask just one last question. 

So overall in this world of data center construction, what do you see as being the biggest issue that’s still kind of pervasive throughout the industry and what can be done about it?

Jim


Okay. So, so yeah, so, so again, you know, that whole, speed to market is a driver that kind of trumps everything and it has, and it continues to trump everything. you know, leaders have to basically step up and say, okay, I understand that I want to be accountable to it. 

By the end of the day, I want to be also entitled to it. And the way I get entitled to it is through the way I plan the way I integrate the systems approach to getting things done.

The engagement of the supply chain early and often into the process. That’s something that doesn’t happen because it’s viewed as a cost versus a value. And I see it as a value personally coming in on my oil and gas days. 

And at the end of the day, you’ve got to bring this all together in terms of the team. Get them on board. 

I see a lot of what I’ll call vertical execution strategies here that don’t do real good integration of the project itself. And I don’t want to use the term, but I will, you know, through integrated project delivery, IPD. 

Is it for every project? No, you got to be entitled to the right project strategy and where you are in the world and so forth and so on. But at the end of the day, working as a team, doing in a collaborative way, engaging the team members with a system where they can work within that they can rely upon end to end, which includes managing safety, managing quality, delivering on cost and efficiency and sustainability and productivity.

And finally delivering again that asset to operations at where they expect to have it, which is being a cost efficient, reliable supplier of megawatt capacity to the client and customer.

Wes


Excellent. Well, hey, thank you for this excellent conversation today, Jim. I do appreciate it and hope to talk again soon.

Jim


Very good, Wes. I really enjoyed it. Thank you so much.

Wes

 

Yes sir, thank you.

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