Pile and Soil Stiffness in Solar Plant Foundations: Why Load Tests Matter

 

engWhen designing foundations for solar farms, it is vital to consider both pile stiffness and soil stiffness; neither should be ignored. While pile stiffness is usually estimable with reasonable accuracy, soil stiffness is far more challenging to measure precisely. These uncertainties can impact both safety and reliability. That is why pile load tests (POT) are essential: they verify design assumptions, enhance safety,                                          and help keep project costs in check.

Why Pile and Soil Stiffness Are Critical in Solar Plant Foundation Design

Insufficiently embedded piles (too short piles) may fail to withstand lateral loads, such as those generated by wind, leading to structural failure and increased project costs. Simply increasing pile length is not always effective. If the pile lacks stiffness, loads won’t be appropriately transferred to the deeper, more stable soil layers.

In many cases, selecting a stiffer pile cross-section is a more efficient strategy. Greater stiffness allows for reduced embedment depth while still providing the required load-bearing capacity.

Three different pile cross sections (example)

   Three Example Pile Cross-Sections

 

Stiff vs. Flexible Piles

Consider two rods representing piles of different stiffness levels. These could be either driven or screw pile foundations:

Pfahlsteifigkeit, Länge und Steifigkeit des Untergrundes: Anschauliches Modell zur Erklärung der Wechselwirkung zwischen diesen drei Parametern

Pile Stiffness, Length, and Subgrade Modulus: Illustrating the Interaction Between Key Design Parameters

  • Left rod: This represents a new foundation with enough stiffness. It handles horizontal loads well.
  • Right rod: This one is thinner or maybe corroded, so it’s less rigid. It bends a lot more under the same load.

This variation becomes especially problematic in solar table foundations when piles with unequal stiffness are installed in sequence. The result is a “zipper effect,” where stiffer piles are overloaded due to uneven load transfer.

Risks of Incorrect Pile Foundation Design
  • Structural failure due to inadequate lateral resistance.
  • Material wastage when pile tips extend into soil layers that do not contribute to load capacity.
  • Increased costs from over-dimensioning without addressing stiffness.
  • Dynamic effects during load reversal scenarios, particularly for screw foundations, where corrosion at joints increases slack and decreases stiffness.

These issues highlight the importance of precise pile-soil interaction analysis for reliable solar plant foundations.

AquaSoli’s Approach: Reliable Data for Safer Designs

At AquaSoli, we carry out pile load tests to accurately assess the bending stiffness of the pile-soil system. To ensure long-term durability, we also perform:

  • On-site soil sampling
  • Laboratory analyses of soil corrosiveness
  • Risk assessments for pile corrosion

This comprehensive approach provides reliable data that results in safer designs, optimised material use, and long-term performance.

Building Stronger Solar Plant Foundations

By optimising pile selection based on pile stiffness and pile-soil interaction, engineers can balance safety, efficiency, and cost-effectiveness. This ensures reliable performance while minimising material use; meeting the needs of engineers, project managers, and stakeholders alike.

Contact AquaSoli today to learn how we can optimise your foundation design and ensure the long-term reliability of your solar project.AquaSoli

 

Meet our AquaSoli Team in San Diego – at the InterSolar North America!

Meet AquaSoli at InterSolar North America

AquaSoli’s Engineering Team runs for you at InterSolar Trade Show …

Meet us at Intersolar in SAN DIEGO

25th – 27Th of FEBRUARY 2025

Sd_CS_inclined

Aengre you ready to meet AquaSoli at InterSolar (25th to 27th of February) in San Diego? If you decide quickly, please contact our secretariat: Mrs. Rumi Shirahama will be happy to schedule an appointment with you and  our sales team: rumi.shirahama@aquasoli.com.

deutschMöchten Sie AquaSoli auf der InterSolar (25.10.-27.02.2025) in San Diego zu treffen? Bitte kontaktieren Sie unser Sekretariat: Frau Rumi Shirahama vereinbart gerne mit Ihnen und unserem Sales Team einen Termin: rumi.shirahama@aquasoli.com.

AquaSoli Consulting Services – Our expertise explained in brief (Part 3 of 3)

eng

Site Survey

AquaSoli provides site surveys in any phase of your project.

We can visit potential land and carry out a feasibility study before planning and construction starts. During construction we can supervise the construction process.

For commissioning we can support you with the final inspection and we also offer regular inspections throughout the lifespan of your PV-plant.

 

Review of existing Design

It is often helpful to get a second expert opinion about the quality of design documents. With our know-how and experience we can analyze and assess existing design documents.

We can indentify opportunites for improvement and optimize the design.

AquaSoli Geotechnical Services – Our expertise explained in brief (Part 2 of 3)

eng

Load Tests

According to all technical rules and standards for pile foundations the most efficient investigation for the foundation design is load tests on site with the projected piles.

 

The piles are installed on site whereas the duration of installation can be measured. Installation difficulties or obstructions are identified.

After installation, load tests are performed in axial compression, axial tension and horizontal direction. The resistances of the piles are measured directly and the foundation design can be done.

Geological & Geotechnical Survey

With the evaluation of direct outcrops (drillings or excavated pits), indirect methods (dynamic probing or SWS Test) on site with the corresponding laboratory work the building ground parameters can be determined.

Soilmechanical Laboratory

Soilmechanical Laboratory

Corrosion Analysis

The evaluation of the Corrosion potential of soil has become a very important part of foundation design. The corrosivity depends on the chemical and physical parameters of the soil. AquaSoli performs the necessary analyses and determines the aggressiveness of the soil towards steel and concrete.

AquaSoli Planning Services – Our expertise explained in brief (Part 1 of 3)

eng

Preliminary Layout: Fast and economic

In the first step, it is often necessary to get an impression of a potential new project. A decision has to be made on whether it is worth pursuing the project further or not.

In this step it is required to keep the efforts and costs as small as possible. Therefore we provide preliminary module layouts based on (public) available terrain data.

This preliminary layout can be done for a low budget, but is already detailed enough for estimating the quality of a potential PV-plant and executing a cost-benefit analysis.

 

Detailed 3D Layout Plan

Planning PV-parks, including all necessary parameters is a very complex process. The optimal design is affected by:

 

  • Table Configuration
    • Module type
    • Arrangement of modules
    • Inclination of modules
    • Single post or double post system
    • Fixed tilt system or tracker
    • Azimuth
  • Sun Angle which depends on
    • Geographic position
    • Date
    • Time
  • Tolerable grade of row-to-row shading
  • Presence of shading objects
  • Topography
  • Electrical parameters like
    • String length
    • Inverter size and location
    • Transformer size and location
    • Cable trenches
  • Clearance parameters, necessary for construction and maintenance
    • Minimum row-to-row distance
    • Construction and Maintenance roads

 

All these parameters are considered in our layouts. AquaSoli’s planning team comprises electrical, civil and environmental engineers.

Equipped with a wide range of tools and applications and a great knowhow our team performs complete shading simulations to adjust the layout and find the optimal solution and to reach the target defined together with the client.

 

 

Digital Terrain Model

The digital terrain model (DTM), together with the geographic location is the basis for our layout planning.

For final layout planning, an exact digital terrain model is required in order to display the terrain conditions as detailed as possible. The surface of the terrain is scanned on site by a geodetic survey.

Common approaches for geodetic site surveys include:

  • GPS measurement
  • Photogrammetric drone survey

Both services are provided by AquaSoli. Based on data collected by a geodetic survey, a digital terrain model is created and analyzed with regard to slopes and directions. The DTM is used for detailed layout planning in 3D CAD software.

Digital_Terrain_Model

Digital Terrain Model

 

If the shape of the terrain does not fulfill the requirements for a beneficial PV-plant, we also offer grading plans for adjusting the terrain by cut-and fill works.

 

Grading Plan

A flat or smoothly south sloped terrain is the most suitable for construction and efficiency of a PV-plant.

The available land for solar often cannot meet these requirements. In order to prevent a complicated construction phase and an ineffective PV plant caused by big distances between the rows or big losses by shading, it is often the best solution to adjust the land according to the requirements.

The execution of the grading plans is carried out by AquaSoli according to the requirements of clients and authorities. Aquasoli uses 3D CAD Software to plan the optimal Cut-and Fill Design based on a digital terrain model. Cut- and fill volumes are determined with high accuracy.

 

Cut & Fill Plan

Cut & Fill Plan

Drainage Design

A working drainage system is recommended for all PV plants – especially for graded terrain. AquaSoli performs the design of this drainage system, consisting of drainage channels and ponds. The layout and dimensioning of drainage channels and ponds are based on the digital terrain model. Requirements of clients and authorities and rain fall data are considered.

 

Construction- and Maintenance-Roads

In order to ensure a smooth construction phase, a working infrastructure with roads and storage areas is required. Also after finishing construction maintenance-roads are necessary.

Depending on the soil conditions and the intensity of traffic, AquaSoli designs the structure of the maintenance- and construction-roads and storage areas.

Erosion Protection

Heavy rainfall can cause erosion of the surface. To prevent expensive improvements of erosion and resulting damages of structures, AquaSoli performs the design of erosion protection considering the slope of terrain, soil conditions and rainfall intensity.

 

Electrical layout and String Plan

Positioning of electrical components like combiner boxes, inverter, and transformer, as well as planning the string configuration is carried out by AquaSoli.

We consider in our electrical planning economical and technical aspects and have the target to save cable length and reduce cable losses.

Cable Trench Design

Based on the electrical layout and string plan we can arrange the cable trench layout as well as the arrangement of cables within the trenches and the resulting size of the trenches.

We provide the cable trench layout and cross-sections of cable trenches.

Single Line Diagram

Single-line diagrams, which represent the electrical hierarchy of DC- and AC-rated power systems in PV plants, are a key output in the electrical planning phase. AquaSoli prepares a single-line diagram showing the proper power distribution path from the incoming power source to each sub-component, and includes the rate and size of all electrical equipment, their circuit conductors and protective devices.

 

Stake Out Plan

After layout planning has been completed and before construction can start, it is necessary to mark the positions of arrays, stations, fences, roads and other construction elements on site.

Therefore, we provide stake out plans for marking the locations of specific points like pile’s locations or corners of stations.

Stake Out Plan

Stake Out Plan

Staking Out

Staking out of specific positions on site is supplied by AquaSoli.

With GPS surveying device, we can mark all necessary locations on-site according to the layout and stake-out plan with an accuracy of a few cm.

Staking our via terrestrial GPS

Staking out via terrestrial GPS

20 years AquaSoli – The anniversary seminar during InterSolar 2023 was well attended / Das Jubiläumsseminar zur InterSolar 2023 war gut besucht

JUBEL

eng

The AquaSoli Solarengineering Team is happy together with our customers about the successful anniversary seminar on 15th of June 2023. Enjoy together with us the photo gallery:

deutschDas AquaSoli Solarengineering Team freut sich gemeinsam mit unseren Kunden über das gelungene Jubiläumsseminar vom 15.6.2023. Genießen Sie gemeinsam mit uns die Fotostrecke:

Catering_Team

CEO Jürgen Schmid & Catering Team: Carl, Sarah, Natalia

 

The special non-alcoholic drink of the day in AquaSoli logo colors red and blue …

Der besondere alkoholfreie Drink des Tages in den AquaSoli-Logofarben rot und blau…

AquaSoli - Drinks

… mixed by our bartender Simon

…gemixt von unserem Bartender Simon …

BartenderAuditorium_Aondio2_

Aondio3

Dr.-Ing. Aondio talks about the structural analysis of mounting systems and the latest achievements in the structural analysis of PV mounting systems.

Dr.-Ing. Aondio spricht über die statische Berechnung von Montagesystemen und die neuesten Errungenschaften bei der statischen Berechnung von PV-Montagesystemen

Prof_RuscheweyhProf_Ruscheweyh2

Prof. Dr.-Ing. Ruscheweyh talks about the further development of wind load approaches in photovoltaics

Prof. Dr.-Ing. Ruscheweyh referiert über die Weiterentwicklung der Windlastansätze in der Photovoltaik

Auditorium_Aondio

Our distinguished guests – customers and partners – engage in lively discussions with our speakers.

Unsere verehrten Gäste – Kunden und Partner – diskutieren angeregt mit unseren Referenten.

Red_and_Blue

Together with our customers & partners we look forward to the next two decades of commitment to renewable energy!

Gemeinsam mit unseren Kunden und Partnern freuen wir uns auf die nächsten zwei Jahrzehnte Einsatz für Erneuerbare Energie!

Join AquaSolis Anniversary Seminar at InterSolar 2023 in Munich

JUBEL

eng

The AquaSoli Solarengineering Team is pleased to celebrate together with you 20 years of project experience in a Bavarian way
and invites you for Thursday, 15.6.2023, to a
Technical Seminar & Bavarian lunch

Start: 10 am
End:    1 pm

Program:

09:30 am – Pick-up of guests at the Intersolar trade fair with shared taxis
& Welcome by Jürgen Schmid, Managing Director of AquaSoli

10:00 am  –  Dipl.-Ing. Jürgen Schmid:
„Damage prevention in geotechnical engineering of ground-mounted PV systems“

10:30 am – Prof. Dr.-Ing. Aondio:
„Economic efficiency through proximity to reality –
Latest achievements in the structural analysis of PV mounting systems“

11:00 am – M.Eng, Dipl.-Ing. (FH) J. King:
„Atmospheric and terrestrial corrosion of PV ground-mounted steel structures“

11:30 am – Prof. Dr.-Ing. Ruscheweyh:
„Further development of wind load approaches in photovoltaics“

 12:00 am – Bavarian lunch

0:45 pm – Shuttle bus back to the InterSolar exhibition

1:00 pm – Arrival at the InterSolar exhibition

GUAD

Registration requested by June 9 by email to charlotte.bachmann@aquasoli.com

Thermal Power Plant with Salt Energy Storage at Sicily – High Precision Foundation design for the mirror construction

Thermal Power Plant with Salt Energy Storage at Sicily – Delicate foundation design for a mirror structure with high-precision requirements

AquaSoli has supplied the foundation design for a new mirror power plant in Sicily. The foundations under the collector mirrors have to support dead weight, thermal expansion, wind and earthquake loads with tiny allowable deformations of a few millimeters (Fig. 1).

FokussierSpiegel_MirrorFocus

Figure 1 – Comparable Mirror Construction at preceding thermal Power Plant in Spain with AquaSoli as well in charge of the foundation engineering

This is a state-of-the-art mirror power plant with a salt storage system developed by AquaSoli’s customer FRENELL (Fig. 2), which operates on the basis of “FRENELLS Direct Molten Salt Technology”. In this technology, the molten salt serves as both heat transfer medium and storage medium.

The molten nitrate salts are heated directly in the collector field to up to 550 °C and stored in insulated tank systems. Due to the low specific costs of the tanks, their volume and salt content can be designed for up to 20 hours of full-load power generation. Due to the precise controllability and high system dynamics of the FRENELL CSP power plant design, the power plant output can be adapted to load changes in the grid within a very short time and continuous and demand-based solar power generation can be ensured around the clock.

 

Vergleichbare Anlage mit Salzspeicher - Comparable Plant with Salt Storage

Figure 2 – Comparable Plant including Salt Storage

The special requirement for AquaSoli is the extremely low permissible deformations of the foundations (Fig. 3) during operation of the mirrors. This is the only way to sustainably direct the sun’s rays from the high-precision adjusted collector-mirror construction precisely onto the salt solution in the collector tube.

AquaSoli and Frenell have been working together on the geotechnical tasks of these ThermoSolar power plants for about a decade. This was preceded by joint power plant projects and planning in Spain (Fig. 1), Chile and India (Fig. 2), among others.

 

PanoramaAufnahme der ThermoSolarBaustelle während der Tests

Bild 3 – Panoramic View of the construction site “Bilancia 1” during the execution of geotechnical Tests by AquaSoli [Photo: AquaSoli]

At the end of 2021, the financing of the FRENELL-developed CSP power plant project Bilancia 1 (Fig. 4) in Sicily could be concluded with the Swiss utility EBL (Genossenschaft Elektra Baselland) (www.ebl.ch) and Swiss Life Management (www.swisslife-am.com) as investors. The CSP power plant is based on FRENELL’s liquid salt-based Fresnel collector technology and has an electrical capacity of 4 MW. The integrated thermal energy storage system has a capacity of 15 full load hours. With Bilancia 1, FRENELL thus consolidates its market success of storage-based CSP power plants and has opened another chapter in the long-standing and trusting cooperation with AquaSoli (Fig. 5).

Fundamentbau für das Kraftwerk Bilancia 1 auf Sizilien [Foto: Frenell]

Bild 4 – Foundation construction for Power Plant Bilancia 1 in Sicily [Photo: Frenell]

Von AquaSoli beim Fundamentbau für das Kraftwerk Bilancia 1 auf Sizilien durchgeführte Eignungsprüfung und Qualitätssicherung [Foto: Frenell]

Bild 5 – Suitability testing and quality control carried out by AquaSoli during foundation construction for the Bilancia 1 power plant in Sicily [Foto: Frenell]