When Always Underground Inc. (AUI) needed fiber installation equipment for SiFi Networks’ Rockford FiberCity build in Illinois, the company evaluated options that could support a repeatable workflow across more than 6 million ft (1.8 million m) of residential fiber installation.
David Paulin, vice president of Always Underground, knew the right equipment would either support the pace or become the bottleneck. “We were looking for something that could keep up with the sequence,” Paulin said. “When you have 12 HDD crews running in one city, every minute you save on rod handling adds up across the whole operation.”
That search led AUI to the Vermeer D24 HDD and one feature that changed how the company trains operators and manages daily production: automated rod exchange (ARE).
How AUI grew fiber installation equipment operations from 1 to 62 HDD rigs
Based in Lake Village, Ind., Always Underground started in 2013 with one HDD rig and three employees. Today the company operates 62 HDD rigs and employs roughly 540 people across Illinois, Indiana, Wisconsin, Michigan, Iowa, Ohio, Kentucky and eastern Missouri.
The company self-performs most of its work and maintains Gold Shovel Standard certification with an Experience Modification Rate (EMR) of 0.74. That safety performance matters on schedule-driven fiber jobs where production and safety must both deliver.
Paulin started in underground construction in 1999 and worked his way through laborer, operator, locator and general foreman roles before launching the company. What began as subcontracting fiber-to-the-home work for larger primes shifted in 2018 when AUI secured prime contracts with AT&T and later contributed to Verizon One Fiber construction.
“We were subcontracting for different prime contractors,” Paulin said. “I just got tired of someone else controlling our schedule. We wanted to be a prime with these guys. That is what I fought for and that is where we are today.”
Across all markets, AUI installed roughly 7.2 million ft (2.2 million m) of underground construction last year. Paulin estimates that 80 to 85 percent of that work was HDD, with about 10 percent plow and the balance aerial.
Why Vermeer D24 automated rod exchange matters for fiber installation equipment
On a typical citywide fiber build, AUI crews complete 800-ft to 1,000-ft (244-m to 305-m) mainline shots, pull 2-in to 3-in (5.1-cm to 7.6-cm) conduit and move to the next bore.
Manual rod handling creates bottlenecks:
- 19 steps required per rod in traditional makeup/breakout
- Multiplied across 10-rod strings on multiple bores per day
- New operators struggle most with rod work
- Experienced hands get fatigued by end of week
- Time loss compounds across entire crew schedule
The Vermeer D24’s ARE system reduces those 19 manual steps to a single button push. “We do use the rod exchange, and it has improved our productivity tremendously as far as shooting out and pulling back,” Paulin said. “We have seen efficiencies as far as more production, more footage and overall efficiency for the company.”
How the Vermeer D24 speeds up operator training for fiber installation contractors
AUI went from operating in Illinois and Indiana to running crews across eight states. That growth required bringing new operators up to speed quickly without compromising safety or quality.
The Vermeer D24 was added to AUI’s training program because automation allows experienced operators to demonstrate the entire drilling sequence while new hires watch each step.
“You could teach an operator every step of that machine before you let them actually do it hands-on because it has the functionality to do it itself,” Paulin said. “It is great for training because you could run through the process the same way every time.”
Benefits for scaling fiber installation crews:
- Experienced operators demonstrate full drilling sequence
- New hires watch each step before taking controls
- ARE system handles rod work while trainees focus on steering and depth
- Faster deployment of new crews across multiple markets
- Consistent quality across all operators
Vermeer D24 noise levels help improve communication on fiber projects
The Vermeer D24 runs at 88 dB at the operator’s ear, making a difference on residential streets where homeowners watch, cities inspect and crews need constant communication.
“What’s nice about the D24 is the noise level,” said Adam Huber, territory manager at Vermeer Midwest. “There’s 88 decibels at the operator’s ear, so it gives him good communication with other guys on the jobsite as well as being able to work in some smaller environments around houses, businesses.”
Impact on fiber installation operations:
- Easier crew communication without shouting
- Better relations with homeowners
- Fewer noise complaints to city inspectors
- Less operator fatigue over long shifts
For Paulin, who started his career with older HDD equipment, the improvement was immediate. Operators assigned to the Vermeer D24 had the same reaction. “Crews love it,” he said. “They will not give it up.”
How AUI matches Vermeer HDD models to specific fiber installation needs
AUI runs multiple Vermeer HDD models and assigns them based on shot length, product size and ground conditions.
AUI’s Vermeer HDD fleet for fiber installation:
- Vermeer D10x15 S3: Tight residential laterals, front yards, driveways
- Vermeer D20x22 S3 and D23x30 S3: Everyday mainline neighborhood work, 800-ft to 1,000-ft (244-m to 305-m) per day with 2-in to 3-in (5.1-cm to 7.6-cm) conduit
- Vermeer D24 HDD: Mid-length production work and primary operator training platform
- Vermeer D24x40 S3, D40x55 S3 and D100x140 S3: Longer bores, bundled ducts, carrier crossings with 6 to 12 lines of 4-in (10.2-cm) conduit
“The D24 stood out to us from the automatic rod exchange system, the on-screen diagnostics and just the ease of running the machine,” Paulin said.
Vermeer D24 diagnostics and maintenance support fiber installation equipment uptime
The Vermeer D24s on-screen diagnostics help crews and service techs identify issues faster, reducing troubleshooting time and unplanned downtime on fiber optic installation projects.
AUI’s maintenance approach:
- Internal mechanics handle day-to-day service at satellite yards in each market
- New drills enrolled in Vermeer Confidence Plus® program through Vermeer Midwest
- Confidence Plus packages primary service intervals with genuine parts and dealer techs
- Larger scheduled services handled at dealer, not in field
- Fleet tracking monitors machine hours and service schedules
“It takes the burden off of Always Underground,” Paulin said. “It is just easier to maintain and keep track of.”
What contractors should consider when choosing Vermeer D24 fiber installation equipment
Key lessons from AUI’s experience with the Vermeer D24:
Crew efficiency matters more than raw power
- The Vermeer D24 isn’t AUI’s biggest rig, but operators prefer it
- On block-to-block fiber work, daily efficiency compounds over months
- Equipment that makes the crew’s day easier drives long-term productivity
Plan for training and scaling
- Automated systems like ARE speed up new operator onboarding
- Consistent training across all operators maintains quality
- Growth capacity depends on how fast you can deploy new crews
Noise levels affect more than you think
- Quieter equipment improves crew communication
- Reduces homeowner complaints on residential fiber builds
- Less operator fatigue over long shifts
Service support is critical
- Equipment is only as good as dealer backing it
- Planned maintenance beats reactive repairs
- Programs like Vermeer Confidence Plus turn service into predictable schedule
Think fleet strategy, not single rig
- Match equipment to specific fiber installation work types
- Build a mix that covers full range of needs
- Consider how each rig fits overall operation
Ready to improve your fiber installation workflow?
Contact your local Vermeer dealer to learn more about how the Vermeer D24 HDD with automated rod exchange can help your operation.
This article contains third-party observations, advice or experiences that do not necessarily reflect the opinions of Vermeer Corporation, its affiliates or its dealers. Testimonials and/or endorsements by contractors in specific circumstances may not be representative of normal circumstances experienced by all customers.
Vermeer Corporation and Vermeer MV Solutions, Inc. reserve the right to make changes in engineering, design and specifications; add improvements; or discontinue manufacturing at any time without notice or obligation. Equipment shown is for illustrative purposes only and may display optional accessories or components specific to their global region. Please contact your local Vermeer dealer for more information on machine specifications. Vermeer, the Vermeer logo and Vermeer Confidence Plus are trademarks of Vermeer Manufacturing Company in the U.S. and/or other countries.
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