Project Overview
We successfully engineered and commissioned a 125 kWp rooftop solar power plant for BARC, one of India’s most prestigious and technically demanding institutions.
The project required a customized modified ballast type mounting structure, carefully designed to meet stringent technical, structural, and site specific requirements.
This installation stands as a testament to our engineering precision, structural integrity planning, and safety first execution methodology.
Engineering & Structural Design
Heavy Duty Mounting StructureTo meet the demanding site conditions and ensure extended service life, the project was executed using:
- Heavy duty mounting structure
- HDGI coating of 120 microns for superior corrosion resistance
- Designed for enhanced durability under varied environmental conditions
The Hot Dip Galvanized Iron (HDGI) coating ensures:
- Long term protection against corrosion
- Structural reliability
- Reduced maintenance over the system lifecycle
Modified Ballast Tray Design
The mounting system incorporated a carefully engineered ballast configuration:
- 30 trays installed
- Each tray designed with 7 ballast blocks
- Engineered for stability without compromising rooftop integrity
This ballast based system eliminated the need for invasive roof penetration, making it ideal for sensitive and high security infrastructure environments.
Execution Challenges & Precision Planning
Structural Weight Considerations
The project involved significant structural weight management:
- Base tray weight: 70 kg
- Each counterweight block: 60 kg
- 7 ballast blocks per tray
- 130 trays installed
Given the substantial weight of the mounting system and ballast blocks, meticulous planning was required for:
- Safe material handling
- Load distribution assessment
- Controlled lifting and placement
Crane & Boom Deployment
To ensure safe and precise installation:
- Crane/boom lifting arrangements were strategically deployed
- Materials were lifted and positioned with controlled precision
- Strict adherence to safety protocols was maintained throughout execution
This approach ensured:
- Zero compromise on safety
- Structural alignment accuracy
- Efficient installation within project timelines
Performance Driven Design
Scientifically Optimized Orientation
The solar modules were:
- South facing
- Scientifically positioned to maximize solar irradiance capture
- Engineered to deliver optimal generation throughout the year
This orientation ensures:
- Maximum energy yield
- Improved performance consistency
- Higher return on energy output over system life
Key Project Highlights
- 125 kWp rooftop solar installation
- Modified ballast type heavy duty mounting system
- 120 micron HDGI coated structure
- 130 engineered ballast trays
- Precision crane-assisted execution
- Optimized south-facing module alignment
Delivering Reliable Solar Power for a Critical Institution
Executing a project for an institution like BARC demands:
- Engineering excellence
- Rigorous quality standards
- Structured execution methodology
- Safety first planning
This 125 kWp installation reflects our capability to deliver technically complex, structurally demanding, and performance oriented solar EPC projects with uncompromising quality and precision.
A project built not just to generate power but to deliver long term reliability, structural stability, and optimized performance.
