Designing and installing a Ground Mounted Solar Module Mounting Structure (MMS) is a systematic engineering process. Every stage, from the initial site survey to the final commissioning, plays a vital role in ensuring structural safety, quality, durability and long-term performance.
Many people assume that Solar MMS design begins with structural drawings. In reality, the process starts much earlier with site data collection, topographical surveys and geotechnical investigations. Proper planning during the early stages helps avoid costly design changes, construction delays and structural problems.
In this article, we will understand the complete Solar MMS workflow followed in a typical Ground Mounted Solar Power Plant.
PROJECT DETAILS
- Project Type
- Ground Mounted Solar Power Plant
- Structure Type
- Fixed Tilt Solar MMS
- Module Configuration
- 2P × 28
- Total Modules
- 56 Nos
- Module Size
- 2382 × 1134 × 35 mm
- Tilt Angle
- 11°
STAGE 1 – SITE RECONNAISSANCE
The first step is a preliminary visit to understand the project location.
The following items should be verified.
- Site accessibility.
- Existing roads.
- Nearby transmission lines.
- Water availability.
- Land condition.
- Obstructions.
- Flood-prone areas.
- Existing utilities.
A proper site visit helps identify challenges before starting the engineering design.
STAGE 2 – TOPOGRAPHICAL SURVEY
A detailed survey is carried out to determine the site profile.
The survey generally includes
- Site Boundary.
- Existing Levels.
- Contours.
- Roads.
- Trees.
- Drainage Channels.
- Utility Crossings.
The survey data is used for preparing the layout of the Solar MMS.
STAGE 3 – GEOTECHNICAL INVESTIGATION
A soil investigation is conducted to determine the engineering properties of the ground.
Typical information obtained includes
- Soil Profile.
- Safe Bearing Capacity.
- Ground Water Level.
- Soil Classification.
- Foundation Recommendation.
The foundation type should always be selected based on the geotechnical investigation.
STAGE 4 – SOLAR PLANT LAYOUT
After collecting site information, the preliminary plant layout is prepared.
The layout generally includes
- Module Tables.
- Internal Roads.
- Inverter Locations.
- Transformer Area.
- Control Room.
- Drainage.
- Cable Trenches.
- Boundary Clearance.
The objective is to maximize energy generation while maintaining adequate maintenance access.
STAGE 5 – MODULE TABLE LAYOUT
The module arrangement is finalized.
Typical design parameters include
- Module Configuration.
- Tilt Angle.
- Row Spacing.
- Ground Clearance.
- Table Width.
- Table Height.
- Module Orientation.
This stage determines the overall geometry of the Solar MMS.
STAGE 6 – STRUCTURAL MEMBER LAYOUT
The primary structural members are arranged according to the approved layout.
The Solar MMS generally consists of
- Columns.
- Rafters.
- Hat Purlins.
- Front Bracing.
- Rear Bracing.
- Wind Bracing.
- Cleats.
- Connection Plates.
STAGE 7 – STRUCTURAL DESIGN
The structural engineer develops the design based on the project requirements.
The design generally considers
- Dead Load.
- Wind Load.
- Load Combinations.
- Member Selection.
- Structural Stability.
- Foundation System.
The objective is to ensure that every structural member performs safely throughout the design life of the project.
STAGE 8 – PREPARATION OF DRAWINGS
After completing the design, fabrication and construction drawings are prepared.
Typical drawings include
- General Arrangement Drawing.
- Foundation Layout.
- Structural Assembly.
- Member Details.
- Connection Details.
- Bill of Materials.
These drawings are used during fabrication and site installation.
STAGE 9 – MATERIAL PROCUREMENT
After drawing approval, structural materials are procured.
The materials generally include
- Steel Sections.
- Connection Plates.
- Fasteners.
- Foundation Materials.
- Protective Coatings.
Every delivery should be inspected before acceptance.
STAGE 10 – FABRICATION
The structural members are fabricated according to the approved drawings.
Typical fabrication activities include
- Cutting.
- Punching.
- Drilling.
- Marking.
- Surface Preparation.
- Galvanizing.
Each fabricated member should be inspected before dispatch.
STAGE 11 – MATERIAL DELIVERY
Fabricated members are transported to the project site.
During unloading,
Verify
- Member Identification.
- Quantity.
- Damage.
- Galvanized Surface.
Proper storage is necessary to prevent corrosion and deformation.
STAGE 12 – FOUNDATION CONSTRUCTION
The selected foundation system is installed.
Typical activities include
- Survey Marking.
- Excavation (if applicable).
- Foundation Installation.
- Level Verification.
- Alignment Check.
- Final Inspection.
STAGE 13 – STRUCTURE ERECTION
The steel structure is assembled in sequence.
Typical installation sequence
1. Columns.
2. Rafters.
3. Hat Purlins.
4. Front Bracing.
5. Rear Bracing.
6. Wind Bracing.
7. Cleats.
8. Connection Plates.
9. Bolts.
Proper alignment should be verified before final tightening.
STAGE 14 – QUALITY CONTROL
Inspection should be carried out at every stage.
Typical inspections include
- Material Inspection.
- Foundation Inspection.
- Structural Alignment.
- Bolt Tightening.
- Galvanizing Inspection.
- Final Structural Inspection.
STAGE 15 – SOLAR MODULE INSTALLATION
After structural approval, the PV modules are installed.
The installation should ensure
- Correct Orientation.
- Proper Alignment.
- Uniform Spacing.
- Safe Handling.
Module installation should only begin after the structure has been approved.
STAGE 16 – ELECTRICAL INSTALLATION
Following module installation, the electrical works are carried out.
Typical activities include
- DC Cable Routing.
- String Connections.
- Earthing.
- Cable Management.
- Junction Box Installation.
- Inverter Connection.
STAGE 17 – FINAL INSPECTION
Before commissioning, inspect the complete Solar MMS.
Verify
□ Structural Alignment.
□ Foundation Condition.
□ Bolt Tightness.
□ Bracing Installation.
□ Member Condition.
□ Galvanized Surface.
□ Site Cleanliness.
STAGE 18 – COMMISSIONING
After all inspections are completed, the project is commissioned.
The final activities generally include
- Documentation Review.
- Client Inspection.
- Punch Point Clearance.
- Handover.
- Operation and Maintenance Handover.
COMPLETE PROJECT FLOW
Site Survey
↓
Topographical Survey
↓
Soil Investigation
↓
Plant Layout
↓
Module Table Layout
↓
Structural Design
↓
Fabrication Drawings
↓
Material Procurement
↓
Fabrication
↓
Material Delivery
↓
Foundation Construction
↓
Structure Erection
↓
Quality Inspection
↓
Solar Module Installation
↓
Electrical Installation
↓
Final Inspection
↓
Commissioning
COMMON PROJECT CHALLENGES
- Incorrect survey data.
- Delayed material delivery.
- Foundation alignment issues.
- Improper bolt tightening.
- Damaged galvanized coating.
- Poor drainage.
- Incomplete quality inspection.
- Documentation errors.
BEST PRACTICES
- Complete all engineering studies before fabrication.
- Verify drawings before procurement.
- Inspect every stage of construction.
- Maintain complete documentation.
- Follow approved installation procedures.
- Perform a detailed final inspection before commissioning.
BENEFITS OF A SYSTEMATIC WORKFLOW
A well-planned workflow provides
- Better Engineering Quality.
- Faster Construction.
- Reduced Rework.
- Improved Safety.
- Better Structural Performance.
- Lower Maintenance Cost.
- Longer Service Life.
CONCLUSION
The successful execution of a Ground Mounted Solar Module Mounting Structure depends on careful planning, accurate engineering, proper material selection, quality construction and systematic inspection. Following a structured workflow from site survey to final commissioning helps deliver a safe, reliable and long-lasting solar power plant.
SERIES COMPLETE
This marks the completion of the Solar MMS Fundamentals Series.
Topics Covered
Part 1 – Solar MMS Table Dimensions
Part 2 – Dead Load Calculation
Part 3 – Wind Load Calculation
Part 4 – Load Combinations
Part 5 – Hat Purlins
Part 6 – Rafters
Part 7 – Columns
Part 8 – Bracing System
Part 9 – Cleats & Connection Plates
Part 10 – Bolts, Nuts & Washers
Part 11 – Foundations
Part 12 – Quality Control & Site Inspection
Part 13 – Preventive Maintenance
Part 14 – Material Selection
Part 15 – Complete Solar MMS Design Workflow
Thank you for following this series. Future articles can explore advanced topics such as tracker structures, corrosion management, digital quality control, lifecycle assessment and project optimization.