Large Solar Array Installations

Steps to Prepare Industrial Sites for Large Solar Array Installations

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Switching to solar is a smart investment. Whether it’s a factory, warehouse, or corporate distribution hub, the shift to solar energy brings down utility costs and meets growing sustainability targets. Industrial properties already have the space, the infrastructure, and the energy demand to make solar pay off.

Installing a large solar array takes more than stacking panels on a rooftop or in an open field. It’s a detailed process with eight key steps. From site selection to system maintenance, every stage plays a role in shaping long-term success.

Let’s walk through how it’s done.

Key Steps and What to Consider

Wide solar array field set against a mountainous backdrop
Massive solar array spanning a desert plain with mountain views|Artlist.io
Step Activities Considerations
Site Selection Analyze sunlight, access, topography, soil, and grid access Avoid environmental conflicts; use PVWatts or similar tools
Feasibility Study Review costs, energy savings, and environmental impact Evaluate infrastructure upgrades and regulatory risks
Market Research Examine incentives, local rules, and energy resale options Consider PPAs and local energy demand
Site Preparation Clear land, test soil, remove rooftop obstacles Plan for shading and stormwater drainage
System Design Layout panels, choose mounts and inverters, plan electrical connections Add energy storage if needed for continuous operations
Permitting Secure all building, electrical, and zoning approvals Address industrial site-specific safety codes
Construction Build foundations, install panels, connect wiring, test system Schedule around operational downtime
Maintenance Monitor performance, clean panels, perform repairs Align checks with facility maintenance schedules

Site Selection

Spacious solar array farm strategically placed on rural land
Strategic site layout for a solar array farm, maximizing space and solar capture on open land|Artlist.io

It starts with finding the right location. Industrial sites usually have a leg up here, thanks to flat rooftops and open land next to facilities. But a few key factors still need checking:

  • Sunlight Exposure: The area should get strong sunlight throughout the day. A tool like the PVWatts Calculator from NREL can help estimate how much solar energy a site might produce.
  • Ease of Access: Trucks, cranes, and workers need clear paths. Loading docks and service roads already in place are a big help.
  • Flat Surfaces: Flat rooftops or level ground cuts down installation costs and speeds up work.
  • Stable Soil: For ground-mounted systems, soil needs to support the structure. Engineers typically run a geotechnical study to confirm stability.
  • Close to the Grid: Sites already connected to the grid can simplify integration.
  • No Red Tape Hotspots: Avoid areas with environmental restrictions or historical protections.

Example: A logistics company might use both rooftop space and a five-acre lot beside its warehouse to install a dual solar array system—one on the roof and one on the ground.

Feasibility Study

Before committing resources, it’s time to assess what’s possible. A feasibility study looks at technical, financial, and environmental factors:

What the Study Covers

  • Cost vs. Savings: Can solar offset half or more of the facility’s energy usage? What’s the return period?
  • Infrastructure Review: Does the site’s power system need upgrades to support solar input?
  • Environmental Impact: Will construction affect wildlife or water systems? Are there remediation steps for brownfield land?

The Environmental Protection Agency notes there are over 450,000 brownfields in the U.S., and many of them are great candidates for solar. Cleaning up a contaminated site while adding clean energy is a double win.

Example: A metal fabrication plant might discover that a solar array can meet 60% of its daily power needs and shave hundreds of thousands off its electric bill every year.

Market Research

Solar doesn’t exist in a vacuum. Regulations, utility rates, and local incentives shape the financial outlook. This is where market research steps in.

Key Areas to Review

  • State and Local Incentives: Are grants or rebates available? Programs like NY-Sun offer generous support to commercial solar installs.
  • Power Purchase Agreements (PPAs): If a site produces more power than it uses, it can sell that energy under a PPA.
  • Utility Connection Rules: Some areas limit how much solar you can feed back into the grid.
  • Competitor Projects: Understanding other solar activity in the region helps gauge demand and utility capacity.

Example: A facility in California may find that selling excess energy through a PPA is more profitable than using battery storage.

Site Preparation

Once a site is confirmed, it needs to be prepped for construction.

Ground-Mounted Systems

  • Clear the area of debris or vegetation
  • Perform a soil stability analysis
  • Grade the land to manage water runoff
  • Plan access paths for trucks and equipment

Using tools like a rotating grapple attachment makes it easier to manage large, uneven materials during early-stage prep, especially when grading land or removing industrial waste.

Rooftop Systems

  • Inspect the structure’s load-bearing capacity
  • Remove old HVAC equipment or clutter
  • Reinforce the roof if necessary

Shading also plays a big role. Even partial shade from nearby trees or tall equipment can cause significant losses. A shading analysis maps potential obstacles throughout the year.

Example: Before installing panels on a distribution center, contractors might remove outdated vents and upgrade the roof with steel reinforcements.

System Design

Designing a solar system isn’t just about cramming as many panels as possible. It needs to fit the site’s needs and physical layout.

Major Design Elements

  • Panel Placement: Rooftops with HVAC units or skylights may need creative layouts.
  • Mounting Systems: Fixed-tilt is cheaper but less efficient. Single-axis trackers boost energy capture by around 25%.
  • Inverter Choice: Match the inverter size and type to the array and facility load.
  • Electrical Integration: Plan how the system will connect to the facility’s internal grid. In some cases, transformers and protective gear must be added.
  • Battery Storage: Energy storage systems can keep operations going during power outages or low-sun periods.

Example: A 2-megawatt ground-mounted system at a packaging facility might include battery banks to store solar power for night-shift use.

Permitting and Compliance

Solar array installation on a large industrial rooftop for compliance and permitting
Large-scale solar array installed on a commercial rooftop as part of regulatory compliance efforts|Artlist.io

Solar construction requires a stack of approvals. Permits vary by location and installation type, but most projects will need:

  • Building Permits: Especially for rooftop structural changes.
  • Electrical Permits: For any work tied into the power grid.
  • Environmental Clearances: More common for larger or brownfield projects.
  • Zoning Approval: Some areas restrict panel visibility or use of certain land types.

For industrial sites, additional considerations include fire code compliance and workplace safety regulations. Facilities dealing with chemicals or heavy machinery may require extra safety buffer zones around electrical equipment.

Example: A site near wetlands may require wetland mitigation plans before starting construction on a ground-mounted array.

Construction and Installation

Technicians securing solar panels during installation process
Solar array installation in progress, with technicians ensuring proper panel alignment and safety|Artlist.io

With design approved and permits secured, the build begins.

What the Process Involves

  1. Install Foundations: Ground arrays need anchors—usually steel piles or concrete footings.
  2. Mount the Panels: Position and secure panels with the right tilt and orientation.
  3. Connect the Electrical System: Run wiring, connect inverters, install monitoring hardware.
  4. Commission the System: Once installed, the system gets tested for efficiency, code compliance, and safety.

Construction timelines vary by project size. A 500-kilowatt rooftop array might take a month. A 5-megawatt ground system could take several months, depending on weather and soil.

Tip: Coordinate construction with low-production windows, like holidays or planned shutdowns, to avoid interrupting operations.

Maintenance and Monitoring

Worker cleaning solar panels during maintenance check
Routine maintenance of solar array panels to ensure efficiency and long-term energy performance|Artlist.io

 

Once live, the system needs regular care to stay efficient and safe.

Maintenance Tasks

  • Visual Inspections: Look for cracks, wiring issues, or loose mounts.
  • Cleaning: Dust, pollen, and bird droppings can reduce output. Cleaning schedules depend on the local environment.
  • Performance Monitoring: Digital tools track real-time energy output and alert teams to issues.
  • Repairs: Faulty inverters or connectors should be replaced promptly to avoid long-term losses.

Most industrial facilities already have teams handling electrical systems. Solar maintenance can often be added to existing workflows or contracted to a third party.

Example: A warehouse might schedule inspections every six months, with extra checks during storm season.

Other Factors to Keep in Mind

Brownfield Redevelopment

Installing solar on a cleaned-up industrial site not only makes economic sense, it also attracts funding and public goodwill. Programs like the EPA’s RE-Powering America’s Land encourage solar use on former brownfields.

Dual-Use Systems (Agrivoltaics)

If an industrial site borders farmland, consider pairing solar panels with crops or grazing. Some farms have seen crop yields increase under partial shade from solar arrays.

Stormwater Management

Large ground-mounted systems need to manage runoff. Grading the land properly or planting low-maintenance vegetation under the panels can help prevent erosion and comply with local codes.

Case in Point – Amazon’s Solar Buildout

Amazon has committed to powering its operations with 100% renewable energy by 2025. That means solar panels on rooftops, parking structures, and open land near fulfillment centers.

Each installation follows the same methodical process – site analysis, feasibility study, regulatory prep, and long-term maintenance. The result is a scalable model any industrial site can follow.

Final Thoughts

Preparing an industrial site for a large solar array takes work, but the payoff is long-term energy savings and a step toward cleaner operations.

The U.S. has enormous solar potential, and industrial properties are in a perfect position to lead the charge. With proper planning and execution, a well-installed system can deliver reliable power for decades, without disrupting daily operations.

Start with a good site, follow a clear process, and lean on trusted resources like the Department of Energy and NREL. That’s how solar goes from blueprint to bottom-line benefit.

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