Distributed Energy Infrastructure (DEI), an EPC firm for solar and battery storage, has completed the 3.37-MWDC Sapphire Solar project in Jefferson County, New York.
Shallow bedrock and a high water table presented site challenges that required the team to adapt its design mid-construction. During excavation, DEI encountered shale bedrock only 16 to 20 in. below grade across several areas of the site, accompanied by groundwater continuously seeping into open trenches. The conditions impacted installation and equipment pad areas, making the original underground DC conduit design impractical to implement.
DEI’s engineering, construction, procurement and contractor teams collaborated closely to quickly develop a revised design that converted a portion of the DC underground scope to an above-ground CAB system. Underground trenching was retained at row-to-row crossings and other locations where it remained appropriate. The revised design also preserved site access for the owner’s long-term operations and maintenance needs.
The full redesign, material procurement and field implementation were completed within the timeframe originally planned for the underground trenching scope.
“When we encounter unexpected challenges, our goal is to address them quickly and adapt our approach to what will work best for the site,” said Rusfid Haroon, senior project manager at DEI. “Even hitting shallow bedrock and water table across the site, we brought together the experience of each team working on the site to re-evaluate, re-design and implement a solution that kept the project moving while ensuring long-term reliability.”
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