Installation tips: Terafab lends major helping hand to utility-scale solar contractors

For insight into the “installation aid” segment,SPWtalked with Matt Campbell, CEO ofTerabase Energy,to learn more about the company’s Terafab automated construction platform that takes most of the manual installation out of utility-scale solar.

What is the latest status of the Terafab system?

The Terafab system is being tested with partners on a pilot scale (10-50 MW) on large utility-sized solar projects. The current version of the system is called Terafab 1.0; the next generation, called Terafab 2.0, is currently under development and planned to be launched mid-2025.

What were the key takeaways from the successful White Wing Ranch installation? 

The Terafab construction automation platform installed 17 MW of the 225-MW White Wing Ranch project in Arizona during Fall 2023. Some key benefits of the Terafab system were demonstrated during that project:

Provided workers with shaded and cooled working conditions to allow for system operation in a very hot desert environment (up to 120°F during some days).
Completely eliminated the manual lifting of heavy steel tubes and solar panels, a first in the industry.
Demonstrated labor productivity improvements of 25% compared with manual installation.
Enabled 100% return of PV module packaging for reuse by the manufacturer.
Demonstrated the compelling synergy of automation, internet of things, a digital twin and data analytics to improve solar construction management on a remote site with difficult environmental conditions.

What type of project is the best fit for using the Terafab system?

Terafab is deployable on any project, but the best fit would be projects greater than 50 MW in order to better amortize fixed costs (system shipping, mobilization, etc.) over a greater amount of megawatts. Also, sites with difficult access to labor, high ambient temperatures, heavier or more complex racking system and PV modules to install are particularly good matches for Terafab.

Instead of lifting panels and connecting steel tubes, what kind of work does the solar worker complete alongside the Terafab system?

With Terafab, the solar worker operates machinery and equipment to assemble, transport and install solar structures. The significant reduction in strenuous and repetitive tasks allows the solar worker to increase his/her focus on safety, quality and production.

What other requirements are needed on site to get Terafab set up?

Terafab is a self-contained unit that includes all the necessary power and communication provisions. It can be deployed with limited site preparation, similar to the setup of a materials laydown yard (light compaction/stabilization of soils) commonly found on traditional solar projects.