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.