Utility-Scale Solar Farm – Arizona

Client Background

A leading EPC firm specializing in renewable energy infrastructure secured a contract to develop a 100MW utility-scale solar farm in the Arizona desert. The project represented a critical component of the state’s renewable energy portfolio, requiring the installation of over 300,000 solar panels across challenging terrain. With strict interconnection deadlines tied to federal tax incentives and power purchase agreements, the EPC firm faced immense pressure to complete the project on an accelerated timeline while maintaining quality and safety standards in extreme desert conditions.

The Challenge

The Arizona solar farm project presented unique staffing and technical challenges:

• Specialized Solar Expertise: Sourcing dozens of technicians experienced in utility-scale solar installations with NEC-compliant wiring knowledge
• Scale and Speed: Installing racking systems and panels across 1,000+ acres within aggressive timeline constraints
• Desert Environment: Managing workforce productivity in extreme heat conditions with temperatures exceeding 110°F
• Technical Complexity: Coordinating DC and AC electrical systems, including string wiring, combiner boxes, and central inverter connections
• Incentive Deadlines: Meeting critical substantial completion dates to qualify for Investment Tax Credit (ITC) and production incentives
• Quality Standards: Ensuring proper torque specifications, grounding systems, and electrical terminations to pass rigorous commissioning tests

The Solution

Advastar delivered a comprehensive workforce solution tailored to utility-scale solar requirements:

• Rapid Technician Mobilization: Deployed 25 experienced solar technicians within two weeks, all pre-qualified for desert construction work
• Racking Installation Expertise: Provided crews specialized in pile driving, tracker assembly, and module mounting across varied terrain
• Electrical Systems Integration: Staffed certified electricians for DC string wiring, AC collection systems, and inverter pad connections
• Grounding and Trenching Operations: Supplied teams experienced in equipment grounding, trenching for underground conduits, and cable pulling
• Safety and Productivity Management: Implemented heat illness prevention programs and adjusted shift schedules for optimal desert working conditions
• Quality Assurance Support: Embedded QC inspectors to verify torque specs, electrical terminations, and system grounding throughout installation

The Outcome

Advastar’s solar staffing solution delivered exceptional results for the EPC client:

• Ahead-of-Schedule Completion: Achieved mechanical completion three weeks early, ensuring interconnection before deadline
• Incentive Qualification Success: Met all milestone dates required for federal ITC and state renewable energy incentives
• Zero Safety Incidents: Maintained perfect safety record despite challenging desert conditions and accelerated schedule
• Quality Performance: Passed all commissioning tests and inspections on first attempt with minimal punch list items
• Expanded Partnership: EPC firm immediately contracted Advastar for three additional solar farms totaling 350MW
• Cost Savings: Early completion allowed EPC to capture schedule incentive bonuses and avoid liquidated damages