In July, DCPacket—the leading deployer of digital electricity (DE) in data centers and AI factories across the U.S. and Canada—partnered with Cameron Connect to supply cable for Fault Managed Power (FMP) distribution deployments. At this year’s BICSI Conference in Las Vegas, the two companies will share a booth to showcase the partnership from Aug. 30 to Sept. 2.

Cameron supplies the cables behind DCPacket’s product portfolio, which together can cut installation costs by up to 50% and detect faults in real time, supporting hyperscale AI with sustainable infrastructure.

A statement on DCPacket’s website reads: “This partnership strengthens DCPacket’s supply chain for the specialized, limited energy cable required in fault managed power distribution—supporting reliable, on-time delivery as DCPacket scales its AI Micro Data Center and critical infrastructure deployments across North America.”

FMP’s Potential in Data Centers

AI workloads are pushing data centers toward higher power density and faster buildout timelines than ever before. The most common power source in data centers—alternating current (AC) power—struggles to maintain peak performance because it wastes energy during voltage and frequency conversions. Its cables also take up unnecessary space.

Direct current (DC) power has historically been avoided in data centers due to safety concerns—it has not been able to maintain high voltages safely and requires bulky protective hardware. FMP changes that equation, combining real-time fault management with digitally controlled distribution to improve both safety and efficiency.

FMP takes on three core challenges in data center power distribution:

• Wasted energy: Reduces physical material and increases power density, allowing operators to distribute more power in the same footprint.
• Human safety risks: Shuts down power in less than a second after detecting a short circuit or human touch.
• Limited space: Eliminates the need to overbuild capacity upfront, letting infrastructure scale with demand rather than in anticipation of it.

“As Cameron Connect further establishes itself as a trusted supply partner in the FMP landscape, the partnership with DCPacket is critical,” says Tom Stone, National Sales Director of Critical Infrastructure at Cameron Connect. “Supporting DCPacket’s Fault Managed Power solution suite with our Class 4 cable inventory allows both organizations to deliver maximum value to the marketplace.”

FMP backs every AI Micro Data Center deployment from DCPacket.

A Closer Look at DCPacket’s AI Micro Data Centers

Hyperscale, gigawatt AI campuses are becoming harder to power, permit, and site in local communities. In response, DCPacket builds data centers that are smaller, modular, and fully automated. They can run on standard available power, create minimal community friction, and can be deployed in weeks once they’re funded.

This model avoids the common challenges that traditional, hyperscale data centers face:

• Excessive power and water demands
• Siting and permitting delays in rural and suburban areas
• Community resistance, leading to stalled or stranded projects
• Limited vendors for hyperscale-specific builds

Visit the Booth

See DCPacket’s product portfolio in action at Booth 504, where the Cameron Connect and DCPacket teams will be available to talk through deployment details and answer questions.

Power distribution has long relied on traditional electrical infrastructure and low-voltage Power over Ethernet (PoE), but Fault Managed Power (FMP) is changing that. By making high-voltage power delivery safer and more efficient, FMP is reshaping how essential spaces get power where they need it: stadiums, campuses, data centers, parking lots and airport terminals, and manufacturing facilities.

1. Stadiums

In stadium settings, FMP improves cellular wireless connections, cameras, sensors, signage and lighting. One clear example of this is Hard Rock Stadium in Miami, where an FMP system, detailed in a case study from VoltServer, was implemented to solve a major connectivity challenge: the stadium needed high-speed internet capable of supporting 10,000+ users at the same time.

FMP was the clear choice because it can deliver thousands of watts of power over long distances effectively, making it well suited to power the stadium’s radio communication infrastructure. As a result, Hard Rock Stadium was able to support high-speed connectivity, turning a bottleneck into a strength.

2. Campuses

Beyond stadiums, hospitals and campuses can also benefit greatly from FMP’s long-distance power solutions. Since PoE solutions can only reach 100 meters or less, they’re an ineffective solution for larger hospitals and smart buildings. FMP doesn’t have that limitation, so it can reach the farthest corners of a campus without extra infrastructure.

Safety is just as important here as reach. Since hospital personnel are hands-on with equipment themselves and with patients, the enhanced safety component of FMP solutions is essential. If a line is cut or touched by a staff member or a patient, it shuts off instantly, protecting everyone nearby.

3. Data Centers

Data centers face a different challenge: extremely high, concentrated power demand. Before FMP, operators relied on traditional infrastructure that wasted energy, took up too much space, and created safety risks.

FMP addresses all three of these challenges. The cables use space efficiently, distribute power more evenly, and support more precise control to cut down on operating costs. By combining real-time fault monitoring with digitally controlled distribution, FMP enables data centers to run safer and more streamlined than traditional systems.

4. Hotels

Hotels bring a different kind of demand: lighting, window treatments, and temperature control spread across many floors. According to an article from Electrical Contractor, tech-heavy hotels increasingly rely on FMP to carry power from the basement to the upper floors, using far less space than traditional bulky cabling would require.

This efficiency also makes more luxurious guest experiences possible. High-end hotel brands are using FMP to power smart mirrors in bathrooms, touch screens at the entrance of every room, and custom light configurations. One hotel in Fort Worth supports more than 8,000 light fixtures on PoE technology without any conduit—a setup made possible by FMP.

5. Transportation Networks

Transportation hubs present one of the toughest distribution challenges: airport terminals, parking garages, and railway stations. VoltServer worked with several industry partners to develop an FMP solution for a large municipal transit agency operating across a large network of tunnels, stations, and tracks in an urban environment.

Since FMP has a wider reach than traditional electrical infrastructure, the agency can successfully deliver power to the farthest areas of the rail system. The result was smoother operations and stronger communication across the entire hub.

6. Manufacturing

Manufacturing facilities benefit from FMP in a more structural way. Rather than routing every connection through one central server, FMP lets companies place small networking hubs throughout an entire facility. That decentralization eliminates the need for additional infrastructure and long cable runs. And since fewer components are required overall, installation takes less time and costs less money.

These advantages translate into daily operations: FMP helps manufacturers flag equipment problems before they escalate, power AI-driven charging stations, and manage supply chain logistics—all while delivering the safe, reliable power the industry needs.

The Universal FMP Advantage

From packed stadiums to quiet hospital wings, from data centers to parking garages, the same advantages keep showing up: FMP delivers power over far greater distances than PoE, and it does so with a safety mechanism that shuts off at the first sign of trouble. That combination makes FMP a viable alternative to traditional electrical infrastructure across every industry that needs reliable power.

The terms Fault Managed Power (FMP), Digital Electricity, and Class 4 are often used interchangeably in power delivery. They’re related, but not the same thing. For companies that source and install cable, knowing the difference between all three terms matters.

The Problem FMP Solves

For years, power distribution came down to two options: traditional electrical infrastructure or low-voltage power like Power over Ethernet (PoE). Traditional infrastructure was expensive and inflexible, and PoE was too weak for most applications. FMP closes that gap by delivering strong power without the cost and rigidity of traditional infrastructure.

FMP: The Concept

Standard, low-voltage classifications (Class 2 and Class 3) cap power output at the source. Instead, FMP continuously monitors the line for faults and cuts power off in milliseconds if something is wrong. That safety-first approach lets FMP deliver higher voltage and power than older, low-voltage standards can.

Digital Electricity: The Proof

Digital Electricity is Voltserver’s specific implementation of FMP. It sends power bursts (500 times per second), running a safety check between each one. If something goes wrong—like accidental human contact, a short circuit, or a ground fault—the system shuts down instead of sending another burst. DE was among the first proven FMP systems to prove that the concept actually works at scale.

Class 4: The Code Classification

Class 4 is the classification the 2023 National Electric Code (NEC) created for FMP systems. Rather than mandating a specific engineering approach, it limits how much energy a fault can deliver. This sets a safety outcome that every FMP system can achieve. As long as it meets the right requirements, any FMP system can qualify as Class 4, regardless of how it was built.

Comparing Class 2, Class 3, and Class 4

	Class 2	Class 3	Class 4
Power limit	Capped at the source	Capped at the source	Limited during fault events
Safety method	Limits the energy current	Limits the energy current	Active fault monitoring
Power delivered	Low (PoE range)	Medium	High (supports long-distance power runs)
Distance capability	Limited	Limited	Long distance without power loss
Installation	Simple, low-voltage rules	Simple, low-voltage rules	Once certified, it’s installed the same way as Class 2 and Class 3
Use cases	PoE devices and sensors	Low-voltage equipment	Data centers, manufacturing, stadiums

Note—Digital Electricity isn’t a separate classification, it’s a specific implementation that qualifies as Class 4.

Understanding the classification is one thing. Deploying it is another. Once a system qualifies as Class 4, the next question companies have to answer is: Who is qualified to install it?

Who Can Install FMP Systems?

A common question surrounding FMP systems is whether only certified electricians can work with them. According to the FMP Alliance, that decision is ultimately made by local jurisdictions.

“Your local building jurisdiction really determines what work a contractor is licensed to do,” Ronna E. Davis, secretary for the FMP Alliance, shared on LinkedIn. “This is based on safety and contractor qualifications.”

According to the National Fire Protection Association (NFPA), the 2023 NEC is currently in effect in 25 states, with adoption still expanding. Since the code is revised every three years, Class 4 recognition is only expected to grow. Davis encourages businesses to pay attention to these local jurisdictions, as they ultimately decide whether a licensed electrician is required or not.

From a technology standpoint, she says, FMP is a relatively safe technology to work with. Many businesses tend to wonder if their electrician needs to have the same safety training as those who work on systems that are more dangerous—Davis says no.

“The answer is technically no,” she explains. “But you do need a qualified electrical professional to install these systems. FMP systems need to be installed professionally, as it requires an advanced skill set.”

FMP is practical to deploy at scale because entry barriers are low, even though the technical rigor behind it is real. It’s worth stepping back to see how the pieces add up.

How FMP, Digital Electricity, and Class 4 Work Together

FMP is the concept, Digital Electricity is the proof, and Class 4 is the code that recognizes it. Companies are no longer forced to choose between strong and safe or between fast installation and long-distance reach. For anyone sourcing and installing cable, that’s the whole point.

By 2050, the demand for electricity will increase by 125%—and the world isn’t prepared to keep up with it.

For the next eight years, 81,000 electricians are expected to retire annually in the U.S. And with a lack of people pursuing careers in electricity, there’s no one to pass their knowledge on to. As a result, the current two-year lead times for wire cables will likely stretch even longer.

That’s where Fault Managed Power (FMP) solutions come in, designed to ease the strain on an industry that’s already stretched too thin.

Suitable for manufacturing, transportation, and data centers, FMP solutions deliver reliable, low-voltage transmission over long distances. Cameron Connect, which sources its VoltServer FMP cable through manufacturing partner Marmon IEI, brings these advantages to its partners in these three industries.

Here are a few things companies working in these areas should know about FMP solutions, from how they work to the potential benefits they have to offer in each industry.

How Does FMP Work?

Traditional electrical infrastructure is expensive, difficult to install, and can be dangerous. Powering remote locations like Wi-Fi antennas and cameras is especially challenging and costly.

Rather than relying on alternating current (AC) and direct current (DC) power alone, FMP solutions send small bursts of digital electricity 500 times per second—between each one, the system runs a safety check. If someone touches a wire or something else goes wrong, the power cuts off in milliseconds. This makes electrocution and fires much less likely.

Utilizing digital electricity is the main thing FMP solutions do differently than traditional power sources. As a result, they help reduce labor, equipment, and maintenance costs while making it easier to coordinate across multiple crews.

FMP plays a different role in each industry it serves. This piece will focus on the markets Cameron Connect works with specifically and how FMP solutions impact those clients. These markets include manufacturing, transportation hubs, and data centers.

Market 1: Manufacturing

FMP offers distinct advantages in manufacturing environments. Instead of routing everything through one central server, FMP lets companies place small networking hubs throughout the facility. This keeps industrial devices connected without long cable runs or extra infrastructure.

FMP also reduces the setup time and costs of getting a network up and running, as it has fewer components to install and requires less specialized labor.

Here are a few instances where FMP delivers safe and reliable power to streamline processes in the manufacturing industry:

• Quality assurance: Machine-learning (ML) sensors installed throughout the facility can flag maintenance problems before they happen.
• Manufacturing process: FMP powers AI robots and the charging stations that keep them running.
• Supply chain: AI-powered inventory, demand forecasting, and transportation logistics.

FMP brings these same advantages to transportation networks, where power needs to reach sprawling and hard-to-access infrastructure.

Market 2: Transportation Networks

From railway stations to terminal technologies, FMP supports smarter and more sustainable transportation hubs. These include:

• Railway stations: Signaling systems, rail yards, ticketing systems, and tunnel infrastructure.
• Airport terminals: Emergency response, parking and rental facility security, and communication between passengers.
• Roadway infrastructure: Tolling systems, roadside emergency communication, and traffic management systems.

VoltServer worked with several industry partners to develop an FMP solution for a large municipal transportation agency that had an extensive network of tunnels, stations, and rail tracks in an urban environment. The FMP technology could transmit power up to 2 kilometers, which surpassed the limitations of traditional AC distribution methods.

With this extended reach, power was reliably delivered to the farthest, most remote areas of the rail system. This helped operations run more smoothly and improved communication.

Where traditional infrastructure hit its limits, FMP kept going.

Market 3: Data Centers

With AI integration challenges and rising power demand, FMP helps operators use space and materials more efficiently, distribute power evenly, and keep up with rising demand. FMP also supports energy control and monitoring to reduce operating costs.

While they’re the most common power source in data centers, AC setups often waste energy during voltage and frequency conversions. This makes it challenging to maintain peak performance—their large cables also take up more space than an FMP solution.

DC isn’t the preferred power source for many data centers due to safety concerns, until FMP addressed those concerns directly.

Previously, DC power struggled to maintain high voltages and needed bulky hardware to protect operators from faults. But when FMP entered the picture, it combined real-time fault management with digitally controlled distribution to improve safety and efficiency in data centers.

Here are a few advantages of using FMP-DC power solutions in data centers:

• Accelerated sustainability and efficiency: Distributes power and data in the same volume, increases density, and reduces physical materials.
• Improves DC power safety: Distributes high-voltage DC power over long distances to better support server systems.
• Supports scale and maintenance: Grows with demand, eliminating the need to overbuild from the very beginning.

The industries Cameron Connect serves can’t wait on two-year lead times or shrinking labor pools. FMP shortens timelines, reduces costs, and grows with demand, so the infrastructure built today doesn’t become a liability tomorrow.

In a steel mill, a skipped maintenance check can be the difference between a productive day and a catastrophe.

“Safety should be a top priority for steel mill workers,” says Jim Vaughan, national director of steel sales for Cameron Connect. “There’s a lot of equipment, a lot of heat, and a lot of electricity.”

This makes maintaining the steel mill critical. The equipment and cables that keep the mill running aren’t going to last forever. As a cable supplier, Cameron Connect recognizes that.

“There’s no perfect cable for a steel mill,” he says. “We used to tell people that if you think you have a product that can survive anything, put it in a steel mill and see what happens.”

In steel mill environments, equipment and cables degrade faster than anywhere else. Rather than waiting for a cable to fail or equipment to break down, operators should protect themselves by performing routine maintenance.

What Happens When Operators Defer Maintenance?

If operators don’t plan routine maintenance, Vaughan says, then maintenance will schedule it for them.

“If you don’t maintain your equipment, then it will break down at the most inopportune time,” he explains. “Most of our customers have scheduled downtime to do maintenance, and that’s definitely something they should be doing.”

When operators defer maintenance, it puts them in a critical position. The equipment that broke needs to be replaced as soon as possible. This typically means they have to pay a higher cost for the cable as well as an expedite fee—but that’s not all.

“If they weren’t able to bring the plant down properly, there could be lost product, lost materials, and lots of other issues,” Vaughan says. “It’s big dollars, especially for the bigger steel mills.”

Why Do Operators Defer Maintenance?

Steel mills defer maintenance for several reasons. In recent years, Section 232 Tariffs, which reduced steel imports and shifted demand toward American steel producers, have caused many mills to push their capacity.

“The tariffs have resulted in significant investment in steel production in the U.S.,” he says. “Everybody’s sales have increased, so their outputs have increased.”

This is more of an issue for smaller steel companies, as larger companies have the ability to shift production. Bigger steel companies perform the same tasks in different areas of the mill—smaller mills do not. As a result, they can’t shut down a “redundant” part of the mill like the big mills can.

Working closely with a supplier like Cameron Connect makes deferring maintenance much less of an issue. By helping steel mills respond to the expedited schedule and ensuring they use high quality cables, the company helps keep the steel mills running.

What Happens When Routine Maintenance Fails?

Cameron Connect only sees a dozen emergency situations per year. And while that may seem like a small number, a steel mill outage is no small problem.

“When a mill goes down and the plant doesn’t have redundancies built into its systems, it could be a ‘completely down’ situation,” Vaughan says. “If something goes out, there’s usually going to be an incident that takes out equipment, conduit, cabling, and sometimes personnel. This could also cause additional problems downstream.”

While these situations are disastrous and sometimes preventable, it’s possible for steel mills to recover. Cameron Connect keeps a constant inventory of the cables and configurations that are used in all areas of the mill.

“Being partnered with the right wire supplier that knows what you need and how to address the impact of an incident is critical,” he explains. “They need to get back up and running as soon as they can because downtime is dollars.”

Knowing how to respond matters. But for most mills, emergencies are the exception.

How Can Steel Mills Shift to Preventative Maintenance?

According to Vaughan, about 80% of U.S. steel mills are on a routine preventative maintenance schedule. It’s worth noting that most of these mills are newer ones—it tends to be a different story for older steel mills.

“Many older mills start servicing or planning an outage based on where they think it will fail in the near future,” he says.

Unlike larger, updated mills that can shift production to other areas, older mills rarely have that flexibility. Auditing equipment, establishing baselines, and building inventory requires downtime—and dollars—they simply cannot afford.

Cameron Connect aims to make this transition easier. It often works closely with a steel mill’s maintenance team, encouraging them to be aware of long lead times should an emergency situation occur.

“We’ll help mills build a wire and cable inventory so they can respond to these situations fast,” he says. “We encourage them to develop critical spares continuously, ensuring they have what they need in stock.”

For steel mills operating on a reactive schedule, the message is clear: the cost of preventative maintenance is much less than the cost of recovery.

Like many professions in the skilled trades, the steel sector is sourcing from a shrinking labor pool.

This affects all players involved in steel projects, including engineers, suppliers, and electricians. But electricians face the steepest shortfall. In fact, The Bureau of Labor Statistics estimates that there will be a shortage of 81,000 electricians every year between 2024 and 2034.

“The part that really affects us is the lack of electricians,” says Jim Vaughan, national sales director for steel at Cameron Connect. “Labor-wise, it all comes back to the shortage of electricians.”

When crews are stretched thin, spec errors slip through the cracks. And getting the wrong specs can push a project well past its deadline.

“About 80% of the materials are accurate for the proportions that are designed,” Vaughan says. “That means there are constant fire drills going on because they recognize that they need a cable but it wasn’t built into the bill of materials.”

Avoiding those fire drills starts before the cable order goes through.

Working With the Right Supplier Matters

When a cable doesn’t meet the right specs, steel mills must rely on suppliers to identify the correct cable needed on-site.

“They really need to work with a supplier that specializes in these types of projects,” Vaughan says. “This enables them to continue making progress.”

But what happens when a supplier isn’t available for immediate customer support? The answer may lie in who’s left to pick up the phone.

“From a wire distribution perspective, the industry is built on the foundation of the talent that sat at the desk,” Vaughan says. “In 10 years, that talent is going to age out of the workforce.”

The expertise sitting behind the desk is extremely valuable. When someone calls in looking for a specific cable they can’t find online, these industry experts can save a project deadline and ensure the steel mill is designed with cables that have been sourced and specified correctly from the start.

That knowledge gap is widening on the procurement side, too. For suppliers, it’s clear that many present buyers don’t come from the wire cable space or aren’t familiar with it.

“When I have an electrician saying they need a six-gauge red cable, it’s up to us to dig in and find out what the application is,” Vaughan explains. “So I think the service we’re providing will grow exponentially over the next 10 years.”

The Need for Experienced Support

As veteran contractors retire and newer, inexperienced contractors take their place, working with a knowledgeable cable supplier is more important than ever.

Vaughan and his team draw on experience from both sides of the industry.

“We bring experience and expertise from both the desk standpoint and the field standpoint,” he says. “We don’t spend all our time waiting for a phone call or sitting behind the desk waiting for an email.”

When a new contractor is assigned to a project, they’re expected to get to work as soon as possible. This means they don’t have time to research what cables they need or whether the information they’re receiving from engineers is correct.

As a result, the supplier must take the information they’re given from contractors, verify it, and figure out which cables they need to complete a project.

Their job gets much more difficult if an incorrect cable has already been ordered.

The Cost of Getting the Wrong Cable Specs

If the wrong cables arrive on-site, it costs the project owner more than money.

“When they order the wrong cable, they find out when it’s delivered,” Vaughan explains. “So you’re driving the cost up, you have to wait till the other cable gets there to keep working, and that all compounds to delays.”

In the steel industry, every day is project-oriented. There are daily spot buys that suppliers complete, and it’s all done within projects—making it that much more important for deadlines to be met.

Delays are inevitable at times, and mistakes will be made. Cameron Connect makes a conscious effort to prepare for them by keeping popular cables in stock.

“We’re constantly looking ahead based on the progress of the project to make sure we have material on order,” Vaughan says. “We know what configurations will be needed next, and we put those into production to make sure we have the right cables when customers need them.”

Staying ahead of demand will be even more important if workforce gaps continue to widen.

Filling Workforce Gaps

With less experienced contractors, engineers, and electricians working on steel mill projects, cable suppliers have had to be more hands-on.

“We get requests from customers daily asking what kind of cable they need,” Vaughan explains. “We’ll give them a list of questions to ask the engineers, which makes them sound more intelligent in the long run, which helps them dial into the correct cables. And once we get the answers from them, we’ll give them the cable form they need.”

For steel mills navigating a shrinking labor pool, a supplier who can ask the right questions and source the right cable isn’t nice to have. It’s how a project gets done on time and on budget.

In the steel industry, distributors win on trust that carries from project to project and company to company. Cameron Connect’s success in the steel sector stems from treating every contractor and manufacturer as a long-term investment rather than a transaction.

“The relationships we have with our manufacturers are just as important as the ones we have with our customers,” says Jim Vaughan, national sales director of steel for Cameron Connect.

After spending more than two decades in the steel industry, Vaughan has experienced the significance of business relationships first-hand. His first clients have lasted his entire career; he continues to work on their projects even now.

Trickle-Down Relationships

When people join the steel workforce, Vaughan says, they hardly ever leave. While his first clients may not work for the same company, they’re still active in the industry and take on similar roles elsewhere.

As those individuals move companies, Cameron Connect moves with them. This expands the relationship rather than resetting it. “We started chasing projects along with them, and it continues to grow from there,” he says.

That growth only compounds. His trusted long-term partners have broadened his network by introducing him to other companies.

This partnership-driven model takes territory out of the equation entirely, as he now has business partners in several states across the country.

“We follow projects with these people as they move from plant to plant,” Vaughan says. “Regionality isn’t really a thing with us.”

What This Means for Steel Companies

Strong relationships ensure projects perform better for both contractors and manufacturers. Since each team has experience working with the other, expectations and workflows are familiar to both parties. This often prevents project delays.

Supply challenges and design changes are inevitable. Established relationships across construction, engineering, and procurement make it easier to resolve problems faster. Cameron Connect’s familiarity with steel capital projects across applications allows them to respond quickly. This includes unexpected wire needs that appear on a weekly (sometimes daily) basis.

Perhaps most importantly, trusted relationships reduce financial risk. Trust isn’t tangible, as it shows up in how business is handled.

“We trust each other to do the right thing every time,” says Vaughan. “With all the manufacturers and contractors I’ve worked with in the last 20 years, I’ve never had to write off an invoice.”

These relationships aren’t limited by geography. Since Cameron Connect moves with their partners—and often forms new partnerships in response to that—neither team has to start over when people move companies. The network of trust only expands and continues to move forward.

But this model isn’t common across the steel industry.

Cameron Connect sets itself apart as a long-term partner in the steel industry network.

Why Most Distributors Can’t Operate This Way

In most distributor environments, long-term relationships aren’t at the top of the priority list. Geography limits how relationships are built, and manufacturer relationships are treated separately from those with clients.

This structure makes it difficult to invest in relationships that don’t translate into revenue or to follow people when they switch companies. Cameron Connect operates differently.

Vaughan handles all of the mill’s cable buys, working directly with the owner and the electrical construction crews. In many ways, he is an extension of the team.

“We’re not technically an employee,” he says. “Right now they have 2,000 people out there with all the different trades, and we’re probably the only ones not billing for their time.”

You Can’t Separate the Model from the People

When people join the steel workforce, they’re typically in it for the long haul. And if they plan to have a 20-year career that’s fulfilling, Vaughan says, they must be passionate about their work.

“I love being out in the mill, I love working with contractors, and I love working with my customers,” he explains. “I’ve developed good friends throughout the years, and we do right by each other every time.”

On top of building relationships with customers and manufacturers, it’s important to have team members who share the same passion and value their professional connections.

“I’m a part of the best team in the industry with Mike Broz and Joe Garbus,” Vaughan says. “We’ve worked at three companies together, and you won’t find someone who knows more about the inside of the industry than those two.”

For Cameron Connect, relationships transcend company titles. The most important, long-lasting ones hinge on interpersonal conversations that last an entire project and beyond. For Vaughan, this means being a reliable partner when it matters most.

“When these guys get into the industry, they don’t leave,” he explains. “So we always want to be the company they call.”

In rail systems, fire safety is built into every material choice, every specification, and every installation. When it comes to cable, the stakes are especially high. 

Cable runs through vehicles, tunnels, and stations. It carries power and signals. And in the event of a fire, it can either limit the spread of danger or contribute to it.

Understanding what makes cable “fire-safe” in a rail environment means looking beyond simple flame resistance. It involves flame behavior, smoke production, toxicity, and the testing standards that verify performance.

Why Fire Performance Matters More in Transit

A fire in a railcar or tunnel presents different challenges than one in an open space. Passengers may be in confined areas. Evacuation routes may be limited. Smoke can travel quickly through enclosed environments.

In these conditions, materials must do more than function electrically. They must help protect passengers and crew. That’s why transit specifications include strict requirements for how cables behave under fire conditions.

Fire-safe cable is designed not just to avoid igniting easily, but to limit flame spread, reduce smoke, and minimize toxic emissions if exposed to fire.

In North America, the foundation of fire-safe transit cable starts with two core specifications from the Association of American Railroads: AAR S-501 and AAR RP-585.

AAR S-501: The Performance Standard

AAR S-501 defines what railcar cable must be capable of doing in real operating conditions. It covers conductor construction, insulation materials, voltage ratings, and environmental durability. But most importantly, it establishes the baseline performance expectations that make a cable suitable for use on rolling stock.

These include resistance to extreme temperatures, oils, mechanical stress, and long-term aging. A cable that meets S-501 isn’t just electrically functional. It’s built to survive the realities of transit service.

RP-585: The Test Methods That Prove It

If S-501 defines the requirements, RP-585 defines how those requirements are verified.

RP-585 outlines the testing procedures used to confirm that a cable can withstand heat, flame exposure, cold shock, mechanical crushing, and electrical overload without failing. It includes vertical flame testing, thermal aging, dielectric withstand after heat exposure, and mechanical durability tests designed specifically for rail environments.

This is where fire safety becomes measurable. A cable isn’t considered compliant because a supplier says it is. It’s compliant because it has passed these tests and can provide documentation showing the results.

The Broader Fire-Safety Framework

Most transit agencies also reference additional standards when evaluating cable performance. These may include:

• NFPA 130, which governs fire-life-safety requirements in transit tunnels and passenger environments
• APTA guidance, which often informs agency-level specifications for flame, smoke, and toxicity performance
• Recognized test methods from UL, ICEA, and ASTM used within RP-585 verification

The exact combination varies by agency, but the expectation is consistent: any cable installed on a railcar must demonstrate verified performance in flame, smoke, toxicity, and electrical reliability.

Why Documentation Matters

Because these standards are so specific, documentation becomes just as important as the product itself.

A compliant cable should be able to provide:

• Third-party test reports
• Certification to AAR S-501 performance requirements
• RP-585 test verification
• Traceability documentation

Without that documentation, even a technically capable cable can delay a project during review and approval.

That’s why procurement teams increasingly request compliance documentation with the quote rather than after award. It keeps projects moving and reduces the risk of late-stage surprises.

A Closer Look: Flame Resistance

Flame resistance refers to a cable’s ability to resist ignition and limit the spread of fire along its length. In a rail environment, this characteristic helps prevent a localized fire from traveling through cable runs and reaching other parts of a vehicle or facility.

Testing for flame resistance typically involves exposing cable samples to controlled flames and observing how they burn. Standards define acceptable burn lengths, after-flame times, and self-extinguishing behavior.

A cable that meets transit flame standards will not continue burning excessively once the ignition source is removed. This slows the spread of fire and helps contain the situation.

A Closer Look: Smoke

In many fire scenarios, smoke presents a greater immediate danger than flames. Dense smoke can reduce visibility, making evacuation difficult. It can also carry harmful gases.

Transit-grade cables are designed to produce limited smoke when exposed to fire. Testing measures both the amount and density of smoke generated under specific conditions. Lower smoke production improves visibility and gives passengers and emergency responders more time to act.

A Closer Look: Toxicity

Beyond smoke density, the composition of that smoke matters. Burning materials can release toxic gases. In confined environments, those gases can pose serious health risks.

Fire-safe cables are engineered to limit the release of toxic byproducts. Testing evaluates the types and quantities of gases produced during combustion. Standards set thresholds to ensure that emissions remain within acceptable limits.

By reducing toxicity, fire-safe cables help protect passengers, operators, and first responders during an emergency.

The Role of Testing Standards

Fire performance claims must be verified through testing. Transit specifications reference established standards that define how cables are evaluated. These standards outline test methods for flame spread, smoke generation, toxicity, and related performance factors.

Third-party laboratories conduct these tests under controlled conditions. They document results and confirm whether the cable meets required thresholds. That documentation becomes part of the compliance package reviewed by engineers and procurement teams.

Without testing, fire-safety claims remain unverified. With testing, agencies can confirm that installed materials meet the expectations defined in their specifications.

Materials and Design

Fire-safe performance starts with material selection and cable design. Insulation compounds, jacketing materials, and construction methods all influence how a cable behaves under fire conditions.

Manufacturers developing transit-grade cable choose materials that resist ignition, limit smoke, and reduce toxic emissions. They also design cable constructions that maintain electrical integrity under heat exposure for as long as possible.

These design choices are then validated through testing to ensure they perform as intended.

A System-Level Consideration

Fire-safe cable is one piece of a broader safety system. Railcars, stations, and tunnels are designed with multiple layers of protection. Materials that meet fire, smoke, and toxicity standards support those protections and help maintain safe conditions during emergencies.

For agencies, selecting and verifying fire-safe cable isn’t just about compliance. It’s about ensuring that every component in the system performs as expected under the most demanding conditions.

That’s why standards exist, and why testing matters. When fire-safety performance is confirmed upfront, transit systems gain confidence that the materials installed today will support safe operation for years to come.

On paper, a 20-week lead time looks like a scheduling problem. In practice, it’s a system problem.

Most transit projects don’t grind to a halt because of a single missing part. They stall because that missing part sits at the center of a web: labor assignments, service schedules, contractor timelines, and public expectations. When a material delay stretches into months, the ripple effects extend far beyond procurement.

Transit agencies already understand that lead times matter. What’s often less visible is the total cost those delays create once they move from the spreadsheet into the field.

When a Part Isn’t There, Nothing Moves

Consider a typical scenario. A railcar refurbishment is approved. Engineering finalizes the bill of materials. Procurement issues the RFQ. A compliant cable is sourced, but the lead time comes back at 20 weeks.

From a purchasing standpoint, the project still exists. The order is placed. The budget is intact. But in the maintenance facility, the impact is immediate. Crews scheduled to perform the work are reassigned or left waiting. Vehicles remain out of service longer than planned. Other repairs stack up behind the delayed job.

Transit operations rarely have the luxury of idle time. When a vehicle isn’t available, schedules shift. Spare ratios tighten. Service planners make adjustments to keep the system moving. What looks like a procurement delay becomes an operational strain.

Labor Doesn’t Pause With the Project

Labor is one of the largest costs in any transit operation. When materials aren’t available, labor doesn’t simply disappear.

Maintenance teams may be reassigned to other work, but that reshuffling comes with inefficiencies. Work that was planned in sequence becomes fragmented. Crews return to the same vehicle multiple times instead of completing repairs in a single window. Overtime may be required later to catch up once materials arrive.

Contractors feel the impact as well. When outside firms are brought in for specialized work, their schedules are built around material availability. A delayed component can mean rescheduling crews, renegotiating timelines, or paying additional mobilization costs.

Over time, these adjustments add up. The cost of a delayed material isn’t just the price of the part. It’s the cost of disrupted labor.

Service Reliability Takes the Hit

For riders, the effects show up as service changes. A railcar that can’t return to service on schedule reduces fleet availability. Agencies may need to run shorter trains, increase headways, or substitute bus service.

Each of those decisions carries operational and financial consequences. Running bus bridges increases fuel and labor costs. Adjusting schedules affects rider satisfaction and system reliability. Delays tied to equipment availability can erode public confidence, especially when they become frequent.

Transit systems are designed around predictability. When materials arrive late, predictability disappears.

The Compounding Effect of Multiple Delays

A single delayed component is manageable. Multiple delays across a fleet or capital program are harder to absorb.

As agencies work through backlogs, each delayed project pushes another one further down the line. Preventive maintenance may be postponed. Refurbishment programs may stretch longer than planned. Vehicles remain in service beyond their intended maintenance intervals.

The longer this cycle continues, the more expensive it becomes. Emergency repairs replace planned work. Overtime increases. Spare parts inventories fluctuate as teams search for alternatives. What began as a 20-week wait for one item becomes a cascade of adjustments across the system.

Why Availability Matters as Much as Compliance

Transit agencies cannot compromise on compliance. Materials must meet established standards and specifications. But once compliance is confirmed, availability becomes the deciding factor in keeping projects on track.

Stocked materials shorten repair cycles. They allow maintenance teams to work within planned windows. They reduce the need for rescheduling and emergency adjustments.

This is where experienced supply partners make a difference. A supplier that understands transit timelines doesn’t just provide compliant materials. They help agencies anticipate lead times, identify stocked options, and plan around real-world availability.

When availability is considered early—before an RFQ is issued or a contract is awarded—agencies gain flexibility. They can evaluate alternatives, confirm documentation, and align schedules before delays take hold.

Looking Beyond the Purchase Order

It’s easy to view material lead times through the lens of procurement alone. But transit systems operate as interconnected networks. A delay in one area affects many others.

The true cost of a 20-week lead time isn’t just the wait. It’s the labor adjustments, service impacts, and schedule changes that follow. It’s the pressure placed on maintenance teams and the strain on operational planning.

Reducing those costs starts with visibility. Knowing which materials are stocked, which are made to order, and which alternatives exist allows agencies to plan more effectively. It shifts the focus from reacting to delays to preventing them.

In transit, time is a resource. When materials arrive on schedule, projects move forward, crews stay productive, and riders experience fewer disruptions. That’s the value of aligning compliance with availability—and treating lead time as a system-wide consideration rather than a line item on a quote.