A CS Energy solar project built on a brownfield site in New Jersey.
As available land becomes scarce, solar EPCs and developers are increasingly building on less-than-ideal sites — from rocky hillsides to snowbelt flatlands. These conditions introduce new technical, environmental and scheduling challenges that can threaten budgets, timelines and even long-term system performance.
However, from my experience installing solar projects in uneven, rocky terrain and the bitter winters of the northeastern U.S., I’ve found that with the right approach, EPCs can deliver resilient, compliant and high-performing projects on even the toughest terrain. Here’s how.
Avoid future issues and overbuilding by prioritizing site intelligence
For challenging sites, sometimes the temptation is to over-engineer for worst-case scenarios. This instinct is well-meant, but time, labor and material costs add up quickly.
For instance, ground screws are guaranteed to work on almost any site — but they also have a higher up-front cost than post-driven foundations. Using them isn’t always necessary, even on rocky or uneven terrain. And when unneeded expenses start adding up, the project risks going well over budget.
On the other hand, failing to account for all site-specific conditions can create further risk and expenses down the road. For example, sites with high refusal rates make post-driving labor-intensive and unreliable. In such cases, factoring in time and labor makes ground screws the more cost-effective solution after all.
To avoid both extra expenses and unnecessary project risks, the key is to invest early in quality topographical and geotechnical data. I always begin development with accurate grading data and a detailed geotechnical investigation, including pile testing and test pitting, to evaluate how much work is needed to make a given tracker system viable. My teams work with geotechnical partners to understand subsurface consistency and identify problem zones early, allowing us to make educated decisions that limit risk and unnecessary overbuild.
Engineer for snow and frost, not just rain and wind
Snow and freezing conditions can impact energy production, system performance, structural design and long-term durability. Trackers must be rated for local snow loads and equipped with sensors or dumping mechanisms to shed snow buildup.
Frost heave, in particular, poses a major risk to structural integrity. When frozen ground expands and pushes piles upward, it can lead to misalignment or long-term damage if not accounted for. For instance, we built on a northern New York site that has a frost depth of 60 inches and soft soils. Driving piles to the necessary 20-to-30-ft embedment would have significantly increased labor, costs and installation time.
Instead, our geotechnical partner helped us design a “frost collar:” a 4-ft sand-filled borehole that absorbed frost pressure, allowing us to reduce pile depth to just 8-10 ft of embedment without impacting the project’s long-term stability.
In another project, we addressed frost heave by sleeving screw piles with PVC pipe for the top 4 ft. If the ground froze and expanded, the sleeve — not the pile — would be displaced, preserving alignment and allowing the sleeve to be easily pressed back down.
These types of innovations don’t come from off-the-shelf plans. They came from thoughtful design and collaboration with geotechnical experts and racking designers to align structural performance with the sites’ real-life conditions.
Balance construction efficiency with environmental compliance
For environmentally sensitive sites, smart planning can prevent headaches. In New York, for example, tree-clearing must avoid active seasons for endangered species like the Northern Long-eared Bats (NLEB) bat. In addition, excessive grading of uneven terrain in fall can prevent grass regrowth — triggering erosion, permit violations and delays come spring.
To avoid this, we coordinate early with developers to plan clearing schedules around season-specific windows. In addition, for two recent solar projects that impacted the Northern Harrier’s hunting territory, we helped implement habitat replacement to protect the birds and other local wildlife while staying on track. Planning this solution helped avoid potential months of regulatory delay.
Keep crews safe in winter conditions
Building for severe climates sometimes requires working in those conditions. Winter work isn’t just cold; it’s slower, more hazardous and harder on crews.
Our build schedules account for microclimate differences between towns, even within the same project zone. Once icy conditions are expected, ice cleats become mandatory across our sites. We also account for windchill and wind load during module installation — critical on open plains where gusts can shift minute-by-minute.
Carry regional lessons into other challenging markets
These best practices are often transferable as your company expands. Our experience in New York’s snowbelt and rocky landscapes has helped us tackle similar terrain and climate challenges in states like Connecticut, Massachusetts, Maine and Minnesota, where deep frost, wind and permitting requirements mirror those in the Northeast.
Finally, don’t underestimate the value of a strong EPC early in the process. By partnering early with experienced EPCs, developers can avoid unexpected costs, permitting delays and system underperformance — even on the most unforgiving terrain.
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