Piling for Solar Farms: Methods and Modern Machinery

As we develop solar farm projects, preparing the ground through piling is a fundamental step. The right method and machinery ensure the stability and longevity of the entire installation. Here, we look at common piling techniques and the evolution of the equipment used, focusing on modern applications for solar arrays.

Common Piling Methods on Site

Several traditional methods are employed based on ground conditions and project requirements:

Driven Piling: This method uses mechanical force to drive piles directly into the soil. While ancient builders used manual labor, modern sites employ diesel hammers or hydraulic impact hammers. Sometimes, a pilot hole is drilled first to navigate hard soil layers, which makes driving easier though it may slightly reduce the pile's load-bearing capacity.

Press-in Piling: Here, hydraulic machines use static pressure to push piles into the ground. This approach generates minimal vibration and noise, making it suitable for areas near existing structures or with strict environmental controls. Its pressing force is generally lower than impact driving.

Screw Piling: These piles have a helical plate at their base. A machine twists the pile into the earth like a screw. This method disturbs the surrounding soil less and is often faster. It works well in various soils and is common for solar mounting systems, as the piles can be directly anchored to support structures.

Vibratory Piling: Attaching a vibratory hammer to the pile head transmits high-frequency vibrations into the soil, reducing friction and allowing the pile to sink under its own weight and the machine's force. It's efficient in loose or sandy soils.

The Evolution of the Piling Rig

The piling rig is the core machine on site. A standard rig consists of a lead (or mast), a power unit, and a moving base. The lead guides the pile vertically (or at an angle for sloped terrain), while the hammer—attached to the lead—provides the driving force.

Hammers have evolved significantly:

• Drop Hammers: An early, simple design where a weight is lifted and dropped.

• Diesel Hammers: Commonly used for decades, they operate like a two-stroke engine, using diesel combustion to create impact. They are powerful but noisy and produce emissions.

• Hydraulic Impact Hammers: A more modern variant, offering better control over impact energy and frequency, with reduced environmental impact compared to diesel hammers.

• Vibratory Drivers/Extractors: Used for vibratory piling, these units use rotating eccentric weights to generate vertical vibrations.

Integrating Technology: The Shift Towards Smart Piling

Today, we are integrating digital tools to bring greater precision and oversight to solar piling work. A key development is the adoption of intelligent guiding systems.

For instance, by fitting a piling rig with high-precision satellite positioning terminals, tilt sensors, and depth encoders, we can monitor key parameters in real-time. The system tracks the exact geographical coordinates of each pile, its vertical alignment, and its installed depth. This data is processed on a control terminal in the cab and can be transmitted to a cloud-based project management platform.

This allows site managers and engineers to remotely verify that each pile is placed correctly, to specification. It minimizes human error in measurement, reduces the need for rework, and creates a reliable digital record of the foundation work. For large-scale solar farms where thousands of piles are installed, this technology is transforming how we manage quality and efficiency.

For solar projects, selecting a suitable piling method—often screw or driven piles—paired with modern, sensor-equipped machinery, helps us build a more accurate and reliable foundation. This smart approach supports the rapid and robust deployment of solar energy infrastructure.