When the owner of the BE Pines project, Four Twelve Renewables, chose its developer GPPT, LLC (a partnership between Propsect14 and Pro-Tech Renewables), it focused on collaborators with deep solar experience and a reputation for solving problems.

Pro-Tech Energy Solutions was selected as the EPC for its responsible sustainability, integrity, and commitment to collaboration. Pro-Tech turned to Terrasmart for its legacy of leadership, integrated PV portfolio, expertise in tough terrains, and decade-long track record of successful partnerships.

Terrasmart designed and manufactured the site’s fixed-tilt system using its ground-screw foundations and GLIDE racks. Drawing on its integrated experiences across the PV life cycle, the racking partner installed the foundation and secured the legs to contend with the site’s rugged topography and sub-surface risks.

The biggest factor for projects of this size is schedule risk. Contracts for unionized electrical labor, for example, are scheduled a full year in advance. If the project slips even a single month, the EPC risks losing the entire contract. That’s why unforeseen below-ground issues pose a critical hazard.

“If we are delayed with our racking install, it’s a disaster for the project. It doesn’t matter how many test pits you do, there’s always the unknown. We’ve done countless geotechnical tests on a job when—all of a sudden—we hit a ledge and now we’re stopping. Using ground screws wipes out refusals and locks in our schedule.” – Jeff Hill, Vice President of Operations for Pro-Tech

Using ground-screw foundations to eliminate pile refusals allowed Terrasmart to stay on schedule despite the site’s rough terrain. Subterranean risks like boulders or ledge are common throughout the Northeast. For such sites, ground screws mitigate 100% of refusal risks. Because they can be driven into the ground using advanced machinery no matter what lies underground, ground screws keep costs and schedules on track.

“It’s all about schedule and timing. We know that when we get a date from Terrasmart it doesn’t move,” said Matthew Braccio, Senior Project Manager with Pro-Tech. “If we’re driving piles and we hit refusals, we have to deal with mitigation, which becomes a nightmare that can totally derail a project. The ground screw foundation is a little more costly up front, which typically saves us money in the end.”

Working with manufacturers that also install their own products makes for a seamless project experience. Over time, this experience helps troubleshoot difficult construction conditions. Unaffectionately coined the “Seattle of the Midwest,” the BE Pines region is known for its heavy rain. This year’s weather was particularly bad. But driving screws in frozen ground is easy compared to installing them in thick mud. Terrasmart’s on-site crew had to use all of their hard-won tricks to keep each phase of the project on schedule. “We had times where everybody else had demobilized due to weather, but the Terrasmart team just kind of kept rocking right along to keep everything on schedule. You guys were rock stars—really the best I’ve worked with.” – Matthew Braccio, Senior Project Manager with Pro-Tech.