As technology cycles accelerate at an unprecedented pace, getting up and operational ahead of the next wave of change has never been more critical – or more challenging.

Across the data center ecosystem, pressure is mounting on multiple fronts. Supply chains are increasingly constrained, skilled labor is stretched thin, and lead times are volatile. And yet, despite this complex landscape, the demand for accelerated speed to market shows no sign of waning.

Amid the excitement surrounding the newest compute capabilities and the next-generation infrastructure that will support it, one essential element that often goes underappreciated is the time, planning, and critical decision-making required to construct the right foundations of the facility itself.

Securing future-ready power and cooling systems along with the latest rack architectures means little if the structure that houses these components is unfit for purpose – or worse, not ready when it’s needed.

In today’s environment, bottlenecks and unexpected hurdles along project timelines are inevitable. New Millennium is focused on ensuring that securing the right construction materials when they’re required is not the pebble on the tracks that derails or delays new facilities from meeting strict schedules.

Sean Smith, market development manager at New Millennium, explains how the company is helping owners and developers accelerate speed to market via its comprehensive delivery model and the flexibility of flush frame composite joists for modern data center construction.

It’s all in the foundations

While structural steel may not be the most visible or glamorous component of a new data center project, it’s nonetheless fundamental to meeting aggressive timelines and ensuring long-term durability. Smith emphasizes that early engagement is critical to unlocking its full value:

“One of the advantages of engaging with a national company like New Millennium is the ability to lock in pricing. We tie costs to an index from the outset to provide security and transparency. Customers can track when things move up or down but are protected from major market fluctuations.”

In a volatile materials market and a pressurized landscape, cost certainty provides much-needed peace of mind. Early engagement also allows production slots to be secured in advance, ensuring steel is delivered precisely when it’s needed.

Owners and operators can share projected tonnage and anticipated build locations for the coming years – group these requirements, and secure both pricing and scheduling in advance. This comprehensive approach strengthens planning and reduces the risk of delays and unexpected costs.

New Millennium works closely with structural engineers to streamline designs based on specific business requirements and long-term scalability needs. These relationships are essential for optimizing efficiency and aligning structural solutions with unique operational goals.

“One of the biggest challenges data centers face is permitting,” adds Smith. “Organizations often have to pivot from their original plans to build in one location in favor of another. If we’re engaged early, we can pivot with you. But if steel decisions are made later on in the process, then your project enters the queue in sequence, risking drawn out timelines. It’s a very collaborative process.”

An owner-negotiated contractor-procured (ONCP) agreement can formalize pricing and scheduling commitments well before final structural drawings are complete. Smith expands on what best practice looks like:

“Ideally, customers bring us in on project plans – however many facilities and over whatever timeline that may represent – before structural drawings are even finished. You might only have site plans and high-level information, but that’s enough for us to start scheduling and pricing discussions. We can leverage the total tonnage across all proposed projects nationwide into guaranteed pricing.”

In warehouse construction, structural steel often represents a significant percentage of total building cost, so it takes a front seat in design and planning. In data centers, steel may represent a smaller percentage compared to the volumes of IT equipment, power systems, and cooling infrastructure that characterize modern operations. As a result, it can often be left to the last minute.

“We’re a smaller line item compared to racks and CPUs,” says Smith. “But the building is what supports and protects the significant investments inside it. Getting that structure right and getting it up on time is crucial.”

Good bones

For decades, wide flange beams have been the go-to solution in data center construction. They offer strength and stability to support heavy equipment loads and enable the large spans required for expansive white space. But as project demands evolve across the data center ecosystem, traditional solutions are increasingly struggling to keep pace.

Modern facilities require structures capable of supporting heavier loads, accommodating future equipment upgrades, achieving greater heights and spans, and adapting to increasingly complex mechanical and electrical systems – all while navigating supply chain constraints and compressed schedules.

“We’re seeing an incredible amount of pressure building from hyperscalers, data center owners, and developers to get their buildings up and running as quickly as possible,” says Smith.

“There are fewer wide flange manufacturers compared to joist manufacturers, and so with the surge in data center demand, wide flange lead times are extending significantly and joists are offering more flexibility from a supply standpoint.”

This is where structural steel – specifically flush frame composite joists – emerges as the ideal solution for balancing the durability, speed, and adaptability modern construction projects demand.

“Structural steel provides a level of strength and stability that wood and concrete simply can’t match,” says Smith. “It also offers strong sustainability credentials and flexibility for future loading requirements.”

Flush frame composite joists differ from traditional wide flange beams in a few key ways. Wide flange beams are solid members, while composite joists feature an open web system. Despite weighing less, joists can provide equivalent structural performance in terms of vibration control and load capacity.

The open web design reduces material usage – enhancing sustainability while maintaining strength. One of the most significant advantages lies in coordination with mechanical, electrical, and plumbing (MEP) systems, as Smith notes:

“A critical benefit of composite joists is the ability to pass MEP systems directly through the web openings. That streamlines construction and improves efficiency when erecting and integrating the building.”

By allowing cabling, piping, and high-density services to pass through the structure rather than below it, flush frame systems help reduce overall building height requirements. This can translate into cost savings and improved spatial efficiency inside increasingly complex high-density environments where every inch matters.

As composite joists are physically lighter, they’re also easier and faster to transport and install. More material can be shipped per load, and erection timelines are streamlined. In today’s competitive, high-stakes landscape, these efficiencies compound to deliver a valuable strategic advantage.

The digital advantage

Digital transformation isn’t confined to server racks and AI workloads – it’s reshaping construction workflows and optimizing the very structure of the data center, too.

Advanced modeling platforms and building information modeling (BIM) processes enable more precise coordination between structural and MEP systems. New Millennium utilizes Tekla for BIM workflows, plus proprietary plugins tailored to joist systems.

“One of the historical coordination challenges with steel joists is that web layouts are not fully finalized until shortly before fabrication,” explains Smith. “When we’re involved early, we can lock those panels in and therefore MEP teams know exactly where systems will run.”

Unlike beams, joists are highly engineered components with no single top chord, bottom chord, or web configuration that fits every setup. As loads increase or decrease, each joist must be individually optimized. This engineering flexibility is a key strength – but it also requires close coordination.

By integrating Tekla models from structural engineers with internal design software, New Millennium can finalize joist optimization earlier in the approval process. This allows MEP teams to design around fixed structural conditions – reducing clashes, extended redesigns, and field modifications to ensure swift installation and overall project delivery.

Smith also stresses the importance of simultaneous collaboration across the chain: “Bring your MEP contractor in with us and the structural engineer at the same time. If all three groups are at the table early, we can resolve issues much more efficiently than working in isolation at different stages.”

For many construction projects, MEP systems are released later in the schedule, creating downstream coordination risks. Early cross-disciplinary engagement mitigates these risks and supports a smoother, quicker path to commissioning.

The big picture

“We understand that construction materials aren’t always at the top of the priority list,” reiterates Smith. “Components like switchgears or transformers often have the longest lead times and demand early attention. But engaging structural partners early ensures steel doesn’t become another bottleneck.”

Providing owners and developers with direct access to structural expertise is now mission-critical. Data center campuses represent increasingly significant investments, meaning the structure that protects those assets must be adaptable and proven.

Looking ahead, Smith sees both opportunity and challenge. In regions where land and power are abundant, single-story facilities that distribute loads directly to slab-on-grade foundations may become more common. While in markets, such as Virginia, where land is scarce and demand remains high, multi-story data centers will likely continue to be the norm.

Ever-increasing densities will continue to bring new structural challenges. As AI workloads grow, so does the volume and complexity of the infrastructure. Liquid cooling systems, for instance, are already introducing additional weight compared to traditional air-cooled setups.

“These cooling loads and AI-driven densities are pushing the boundaries of all construction types – whether for wood, concrete, or steel,” notes Smith. “As racks get heavier and cooling systems expand, we have to continue innovating to support those demands.”

Extending innovation beyond the physical materials, New Millennium is investing in advanced technologies, including AI-driven tools, to enhance internal workflows and improve collaboration with engineering partners. Seamless, real-time model integration will help eliminate the inefficiencies of redrawing from static PDFs and enable smarter coordination.

“The sooner we collaborate and understand our partners’ pain points,” says Smith, “the better positioned we are to develop the right solutions and deploy at pace.”

In an industry increasingly defined by speed, complexity, and relentless technological advancement, the foundational elements of data center construction cannot be an afterthought. Structural systems must be strong, adaptable, and delivered on time – capable of supporting today’s loads and adapting to future innovations.

Make the bold move and take control of predictability. Contact Sean Smith to talk about your pipeline and how New Millennium’s program fits your vision. 618-694-5610 || [email protected]