When you’re building a data center that spans more than a 3/4 a mile and employs over 150 electricians, efficiency isn’t just important—it’s critical. Every minute counts, and every misplaced material or delayed assembly can ripple across the schedule. Early in the project, our team faced a big question: How do we streamline electrical assemblies, reduce waste, and keep the site organized without slowing progress?
The answer: an offsite prefabrication shop located just five minutes from the job site. That’s where I came in. For the past year, I’ve led the charge in developing, organizing, and overseeing this shop.
Here's how we've added value on this project:
1. Streamlining Electrical Assemblies
Moving assembly work offsite into a controlled, predictable environment has been a game-changer. Prefabbing components improves quality, precision, and efficiency and ensures assemblies arrive just-in-time for smooth installation, saving both time and money.
On any given day, 10–12 team members work across multiple stations to prepare assemblies tailored to the project’s needs. Examples of prefabbed assemblies include:
- Conduit Bends: Over 62,000 feet of pipe bent—that’s more than 11.75 miles of conduit.
- Cable and Strut Racks: Pre-cut and fitted with connectors.
- Custom Light and Receptacle Boxes: Built, wired, and tested before delivery.
2. Material Management and Supply
With our project site spanning over 3/4 a mile, without a clear system electricians could waste hours searching for materials or waiting on restocks. Our prefab shop solves that problem by maintaining a full inventory of labeled electrical consumables (ex: drill bits, bolts, nuts, and more).
If a team runs out of something, they call me. Instead of waiting for vendor orders, we pull from our stock and deliver the materials the same day. This keeps the project moving without delays.
3. Just-in-Time Delivery
Communication is key. I work closely with project leads and foremen daily to schedule prefab production and deliveries. Our team ensures assemblies and materials arrive exactly when needed, no wasted space, no lost components. We make one to two trips every day to keep the site stocked and on schedule.
4. Training Ground for Apprentices
Walking onto a data center project can be intimidating…even for seasoned electricians. For apprentices, it can be overwhelming. That’s why we use the prefab shop as a training hub. Here, green apprentices learn the basics of tolling and electrical components in a low-stress environment before heading on-site. It’s hands-on, confidence-building, and sets them up for success.
5. Driving Innovation
Every week, I walk the project site to identify opportunities for improvement. I talk with foremen, gather feedback, and look for ways the prefab shop can add value. For example, during slower periods, we prep light fixtures for upcoming phases so they’re ready the moment crews need them. By planning ahead, we help ensure future success.
The prefab shop isn’t just a convenience; it’s a strategic advantage. By streamlining assemblies, managing materials, delivering just-in-time, training apprentices, and driving innovation, we’ve helped keep this large project efficient, organized, and on schedule.
By Chris Fuller
Prefab Shop Manager
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