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Civil engineering, the second-oldest engineering discipline, is essential for the success of any solar project. Civil engineers are instrumental in the planning, analysis and design of ground-mount solar installations. They must ensure that each project is executed in a cost-effective and quality manner that is safe for the environment, surrounding areas and all workers.

A recently completed project provides a good case study for examining the role of civil engineering. Designed by Whitman Engineering with planning and construction by Pro-Tech Energy Solutions for NJR Clean Energy Ventures, the Howell Township installation is a 45-acre, 9.9 MW project consisting of four ground-mount arrays. Civil engineering enabled its successful installation, despite a complex series of challenges. From finding the site to preparation, installation and beautification, those involved in the civil engineering efforts put time and careful thought into planning for the challenges that accompanied this project.

Making use of modern technologies for this project, civil engineers found solutions to important problems, such as the mitigation of water pollution, protection of wetlands, management of land grading and soil redistribution. Also, civil engineers ensured the safety of associated facilities, such as nearby train tracks and connection to the utility company’s power grid. Any of these types of challenges can occur at both commercial and residential sites, especially because most ground-mounted installations are constructed at remote locations with little development in the surrounding area.

The Howell Township project was no exception.

 

Start with the plan

Planning is the first step to successful completion of any solar installation. A civil engineering team should identify the best location on-site, address any challenges, take care of necessary permits and paperwork, and continually check on concerns as construction proceeds. Identifying the best location can be done in a number of ways but is most popularly accomplished by remote sensing and aerial photography. These strategies are helpful for finding locations large enough to accommodate a project and for identifying wetlands, drainage systems and other geographical concerns that need to be observed before construction and monitored throughout.

Once located, the site then requires a walk-through inspection with soil and surface surveys, shovel tests, core samples that must be taken, and on occasion, trenching. During this evaluation process, samples should be taken from various areas of the site to fully determine if it is the best place for construction. Civil engineers are trained to use non-destructive techniques to gather all of the necessary information for proper assessment of potential project areas. Some of these techniques include utilizing electrical resistivity meters and magnetometers to avoid digging up large areas. In the case of the Howell Township project, engineers deployed many of these various ground-saving techniques.

A good construction and civil engineering plan serves as the basis for developing a project’s budget and work schedule. Creating a detailed plan from initial start-up to timing and execution was critical for the management of the Howell Township installation. Civil construction involves a complex timeline of interdependent activities that is, at best, organized chaos.

With proper planning and civil engineering etiquette, the Howell Township challenges were handled appropriately and in a timely manner. In this case, the challenges were environmental, geographical and clerical. The team was keenly aware of the risks and implications of these challenges, and the site conditions were proactively managed to ensure project completion and successful installation. With careful oversight, any problems encountered were managed by construction crews.

 

Conservation and interconnection

Local wetland preservation was a concern because half of the Howell Township site bordered protected lands. The installation included significant site grading and removal of 77,000 square feet of asphalt, which, without a proper construction plan, could have potentially endangered these wetland areas.

Additionally, each array, equipped with an Advanced Energy 2 MW power station, could not be built on a poured-concrete foundation. The units were, instead, mounted on eight helical screws, which allowed for less disruption of the land while still ensuring a solid and secure foundation.

Power generated by the project would feed Jersey Central Power & Light’s (JCP&L) recently upgraded transmission line. This line, located on the opposite side of New Jersey Transit’s tracks adjacent to the property, had to be interconnected by boring under the tracks, leaving them undamaged. Although these challenges took additional planning time, they were effectively mitigated and overcome with extensive civil engineering efforts.

The installation team managed the conservation easements for local wetlands from day one of construction. With more than half of the site bordering a conservation area, having the least environmental impact was of the utmost importance. This was accomplished by working with wetland officials to follow all rules and regulations. Preservation efforts involved minimizing the environmental impact and destruction of natural land surrounding the wetlands, as well as keeping all waste and construction materials out of, and away from, protected areas.

These preparations included building a silt fence prior to construction, which was inspected daily for potential repairs. Additionally, soil could not be added to or removed from the site - all of the dirt on-site had to be graded. Moreover, when grading the site, the control of water runoff was anticipated. Any water encountered was put into two large retention ponds and kept from flooding local wetlands. The civil construction team protecting the wetland sites worked closely with area officials to ensure compliance.

Another unique challenge for the Howell Township installation was negotiating the physical connection to JCP&L’s grid on the other side of the New Jersey Transit tracks. This required boring under the tracks adjacent to the property. This process took partnership and communication with New Jersey Transit early in the process to ensure that the transportation system was not delayed or damaged in the construction and connection process. Additionally, the team needed to make sure all appropriate permits and paperwork were submitted. New Jersey Transit was presented with a detailed engineering plan with supporting documentation, including a list of workers and proposed equipment, so transit officials were comfortable with the crew’s ability to complete the task.

 

Finishing touches

At the conclusion of the project, the civil engineering and construction teams were able to replenish and beautify the construction area, including installing a mix of vinyl, split rail and chain link fencing, as well as building 1,200 feet of new planting berms. The berms included a mixture of evergreens, trees and plants. A once-neglected plot of land now produces energy and has improved the overall image of the location.

The Howell Township project was successful due to strategic planning, scheduling and preparation conducted by civil engineering teams. This installation offers financial benefits to accompany the achievement of a green energy initiative for the township. The solar power generation now helps to bring down energy costs for a number of homes and businesses.

During construction, no harm was done to wetlands or New Jersey Transit tracks, thanks to the communication and partnership with wetland and transit officials. This previously unused site was cleaned up and is now a huge asset to the township as a whole.

The civil engineering team played a critical role in the success of the Howell Township installation, incorporating site preparation and scheduling to ensure a safe and timely construction effort. With a significant civil engineering effort in place, the team was able to anticipate and mitigate any environmental, geographical and clerical challenges and to bring the project to a successful, well-planned end.

 

Jeff Hill is a project executive for Pro-Tech Energy Solutions, overseeing all aspects of project operations. Hill has industry certifications from the North American Board of Certified Energy Professionals in photovoltaic installation, as well as a professional energy manager designation.