Data Center MEP: Speciality Contractor Case Study

Unistrut Installation: Accelerated by 500%

In data center construction, every mistake is costly. Each day spent on rework delays the data center's operational launch, directly impacting revenue. That’s why identifying and resolving potential clashes early is essential, preventing delays from escalating into larger setbacks.

THE PROJECT

Project:
Data Center

Location:
Nebraska, USA

Package:
Electrical

Size:
80 MW

When leading electrical contractor Interstates partnered with XYZ Reality on an 80MW data center project in Nebraska, their aim was to utilize XYZ’s platform to transform their construction methodologies and enhance project efficiency. Through this strategic collaboration, Interstates has achieved unprecedented advancements in layout procedures, marking a significant milestone in the construction industry.

In this case study, we examine how the process of laying out was accelerated by 500% (five times), cutting down the length of the task by 20 days compared to the traditional layout methods.

“The impact of this partnership is a game-changer, marking a significant advancement in construction efficiency and accuracy... This collaboration has already yielded incredible results, enhancing our precision and efficiency while significantly reducing rework and delays. We look forward to working on the next project together helping drive the data center industry towards a more efficient future.”

JOHN MOLGAARD
SENIOR PROJECT MANAGER

THE PROBLEM

Accurate laying out is the backbone of any construction site. Precisely marking out the location of foundations, structures, utilities, and other critical elements is vital to maintain momentum throughout the project. However, it is often a time-consuming and labor intensive process. Traditional methods are slow, require significant resources, and can be extremely error-prone, leading to consistent rework issues later down the line. Bringing efficiency and accuracy to laying out sets the project on solid footing to deliver on time.

The Interstates team sought a new solution to streamline the time-consuming Unistrut installation process, as the traditional method was causing delays and inaccuracies. Using paper drawings as reference, they would mark installations with a tape measure and a laser level, requiring an entirely new setup for each Unistrut markup to ensure it aligns with the reference point. This process required a minimum of three workers, who, in optimal conditions, were able to mark and install 20-30 pieces per day using this method (estimate provided by Interstates).

“When we hit delays during the layout phase, we knew we needed a solution to help us speed things up. After looking at the market, it was clear that XYZ was the only option to make that happen.”

JOHN MOLGAARD - SENIOR PROJECT MANAGER

A new method

Interstates collaborated with XYZ Reality partly due to issues that arose on a previous project, where it was discovered in the final phase that the Unistruts were installed incorrectly and numerous Unistruts were yet to be placed. This resulted in time wasted re-checking all installations and measurement, avoidable rework, and modifications to certain project components, culminating in significant delays.

By implementing XYZ’s fully managed service, the team utilized augmented reality (AR) marking. Using XYZ’s engineering grade augmented reality™ (AR) headset, the Atom™, the 3D design model was projected onto the physical element via hologram. This technology enabled the precise position of the Unistrut, with the Atom’s AR achieving game-changing accuracy of 3-5mm, well within data center tolerances.

Other solutions lack this level of accuracy and are therefore prone to the same mistakes as traditional methods. While high accuracy is crucial for all construction sites, it is especially vital for mission-critical projects like data centers due to their complexity and incredibly tight tolerance margins.

Trusting in XYZ’s partnership, this process led to exceptional results with a streamlined process. Requiring only two people – a Field Application Engineer to indicate the position of the Unistrut and a worker in a lift to physically mark them – this approach massively boosted efficiency. As a result, around 70-80 Unistruts were marked up per day, with 40-50 pieces installed daily.

Such a striking increase in efficiency and productivity is rarely seen in construction, and it has a huge positive knock-on effect. Freeing up workers allows for increased flexibility and acceleration in other areas onsite, and the speed and accuracy at which the layout process took place meant that the installation phase could begin sooner, increasing project momentum significantly.

DAYS	ZONE A	ZONE B	ZONE C.1	ZONE C.2	ZONE D.1	ZONE D.2	ZONE E.1	ZONE E.2	ZONE F	TOTAL PER DAY
1	36	-	-	_	-	-	-	-	-	36
2	29	10	-	-	-	-	-	-	-	39
3	15	24	-	-	-	-	-	-	-	39
4	41	12	-	-	-	-	-	-	-	53
5	17	59	-	-	-	-	-	-	-	76
6	-	60	-	-	-	-	-	-	-	60
7	-	10	60	-	-	-	-	-	-	70
8	-	-	5	53	-	-	-	-	-	58
9	-	-	-	58	12	-	-	-	-	70
10	-	-	-	5	84	-	4	-	-	89
11	-	-	-	-	-	79	9	-	-	83
12	-	-	-	-	-	26	74	-	-	35
TOTAL PER ZONE	138	175	65	116	69	114	107	89	56	956

A new standard for LAYING out

The collaboration between Interstates and XYZ has laid down a new benchmark for laying out, boosting productivity, efficiency and accuracy. The time spent laying out was radically reduced through the instant onsite access to the design models, allowing the project team to complete 956 Unistrut markups in 15 days, an entire 20 days faster than the traditional method.

The Interstates team were able to work more efficiently and complete Unistrut installation in almost half the estimated time. As a direct result, they freed up workers and resources to complete other tasks ahead of schedule.

The power of this game-changing approach is clear. Efficiency and speed are increased by 500% compared to traditional methods, while also eliminating costly rework. This is invaluable in fostering a positive culture on the construction site. Laying out is one of the first tasks on any project, so getting it right the first time sets the tone for the entire project. By eliminating the need for rework, teams build trust and momentum from the outset, ensuring smoother collaboration and helping deliver projects on time.

Layout Pace

Installation Pace

“By bringing together Interstates’ know-how and our cutting-edge tech, we’re not just making things run smoother; we’re showing everyone how effective construction can really be. Together, we’re pushing the envelope.”

DAVID MITCHELL - FOUNDER & CEO

Why is it important to build it right, first time?

Building it right, first time is essential for any construction project, especially when dealing with critical infrastructure like data centers. By embracing innovative solutions, like XYZ Reality's platform, teams can eliminate the risk of costly rework, improve accuracy, and accelerate workflows. This proactive approach not only saves time but also ensures that the project stays on schedule and within budget. As demonstrated in this collaboration between Interstates and XYZ, getting it right from the start fosters a positive project culture, builds trust among teams, and sets a strong foundation for the entire project, leading to successful, timely, and cost-efficient project completion.

Want to see how XYZ Reality’s innovative technology can ensure the precision and efficiency of your construction projects?

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