total project cost reduction...precast concrete ballast block i. precast lead time – 3-6 weeks...

Total Project Cost ReductionThrough both Short and Long Term Effective/Efficient Design

Developing Solar on Brownfields & Landfills ConferenceChicago – June 2017

John England Eric Oetjen

www.rbisolar.com

Rough Brothers

Founded 1932 – 80+ Years in Business

2

RBI Solar History

RBI Solar Inc.

3

RBI Solar History

Manufacturing Best Business Practices Raw Material Bulk

Purchases National Suppliers Timely Deliveries Procurement of WEEBS National & International

Manufacturing Facilities - Cincinnati, OH - Temecula, CA- Washington, NC - Shanghai, China

Material Certifications- ARRA Compliance- “Made in the USA”

Certification Available

Installation On-Site Representative Experienced Installers

- Foundations - Racking - Modules

OSHA Compliant Crew Leaders Components Pre-Assembly Installation Manuals Pre-Designed Field

Adjustments QA\QC Warranty As-Built Drawings Detailed Schedule

Engineering

In-House Engineering Licensed/Registered In All

50 States Project Specific

Engineering- Wind- Snow- Seismic

Wind Tunnel Tested Foundation Design

- Geotech- Pull Tests

Stamped Drawings (Including Foundations) Combiner Box Mounting Inverter Pad Supports

Design

In-House Designers Site Layouts Options For Sloping Sites UL 2703 Classification

Available Multiple Cost Saving

Bonding/Grounding Options Wire Management Installation Manuals

Advancing the Entire Solar Value Chain 4

Single Source Provider

Part I – Rack & Foundation Design / Engineering Considerations

Part II – Rack and Foundation Production

Part III – Installation

Part IV – Case Study

Agenda

Part I

Rack & Foundation Design / Engineering Considerations

Site Specific RequirementsI. Verify current state building code along with local AHJ requirements

II. Determine load factors and combinations from building code and local AHJ

• Snow (PSF), Wind (MPH), Seismic Loads• Exposure Category (ASCE 7-10)• Importance Factor (ASCE 7-05)

• IBC 2015 (ASCE 7-10)• IBC 2012 (ASCE 7-10)

• IBC 2009 (ASCE 7-05) • IBC 2006 (ASCE 7-05)

• State Specific Building Code• Unified Facilities Criteria (UFC)

• Surface Roughness and Exposure Categories• Kzt, Kd, Kz Factors • Load Resistance Factor Design (LRFD) vs.

Allowable Stress Design (ASD)

ASCE 7-05 ASCE 7-10

Lower Wind Velocities Higher Wind Velocities

Higher Wind Load Combination Lower Wind Load Combination

Uses Importance Factor Uses Exposure Category

One Wind Speed Map Three Wind Speed Maps

Larger Hurricane Prone Areas Reduced Hurricane Prone Area

Table 1 – Differences between ASCE 7-05 and ASCE 7-10


Site Specific Requirements (cont.)

Assumptions and Factors per Code LRFD Method ASD Method

ASCE 7-10 D = Dead LoadW, Wind Load = qz, velocity pressure Kz, exposure coefficient = 0.85 (29.3-1)Kzt, topographic factor = 1.0 (26.8-1)Kd, wind directionality factor = 0.85 (26.6-1)V= 105 MPHExposure Category C, up to 15 feet above ground

D = 5 PSFW = qz = 0.00256*Kz*Kzt*Kd*V2 (29.3-1)W = 0.00256*(0.85)*(1)*(0.85)*(105)2

W = 20.4 PSF

Load Combination(0.9D + W) / 0.9(0.9*(5) + 20.4) / 0.927.7 PSF

D = 5 PSFW = qz = 0.00256*Kz*Kzt*Kd*V2 (29.3-1)W = 0.00256*(0.85)*(1)*(0.85)*(105)2

W = 20.4 PSF

Load Combination(0.6D + 0.6W)*1.67{0.6*(5) + 0.6*(20.4)}*1.6725.4 PSF

ASCE 7-05D = Dead LoadW, Wind Load = qz, velocity pressure Kz, exposure coefficient = 0.85 (6.5.6.6)Kzt, topographic factor = 1.0 (6.5.7.2)Kd, wind directionality factor = 0.85 (6.5.4.4)V= 90 MPHI, Importance Factor = 0.87 (6.5.5)Structure Risk Category I

D = 5 PSF W = qz = 0.00256*Kz*Kzt*Kd*V2*I (29.3-1)W =0.00256*(0.85)*(1)*(0.85)*(90)2*(0.87)W = 13.0 PSF

Load Combination(0.9D + 1.6W) / 0.9{0.9*(5) + 1.6*(13.0)} / 0.928.1 PSF

D = 5 PSF W = qz = 0.00256*Kz*Kzt*Kd*V2*I W =0.00256*(0.85)*(1)*(0.85)*(90)2*(0.87)W = 13.0 PSF

Load Combination{0.6D + W}*1.67{0.6*(5) + 13.0}*1.6726.7 PSF

Table 2 –Example of Wind Load Calculation with Different Load Combinations


Site Specific RequirementsIII. Determine soil and cap characteristics with Geotechnical Engineer, Environmental Engineer, or AHJ

Interface Materials, Concrete Cast on…… Friction Coefficient

….Clean sound rock 0.70

….Clean gravel, gravel/sand mix, coarse sand 0.55 – 0.60

….Clean fine to medium sand, silty medium to coarsesand, silty/sandy gravel

0.45 – 0.55

….Clean fine sand, silty or clayey fine to medium sand

0.35 – 0.45

….Find sandy silt, nonplastic silt 0.30 – 0.35

….Very stiff and hard residual or preconsolidated clay 0.40 – 0.50

….Medium still and stiff clay and silty clay 0.30 – 0.35

Source: Armstrong, Richard C. Engineering And Design: Revision Of Thrust Block Criteria In TM 5-813-5/AFM 88-10, Vol 5 Appendix C. Ft. Belvoir: Defense Technical Information Center, 1992. Print.

• Vent pipe set-backs• Soil erosion• Stormwater runoff

Table 3 – Friction Coefficient for Concrete Cast on Soil

• Allowable bearing stress on access roads

• Allowable bearing stress on landfill• Friction coefficient (Table 3)


Topography and Layout ConsiderationsI. Maximize areas with flatter gradeII. Verify built-in adjustment in rack (additional adjustment with gravel)III. Continuous row or tablesIV. Verify as not all racking systems are non penetrating. V. Windy Tunnel Analysis to maximize interior zones

Figure 1: Example of Using Gravel for Additional Adjustment

Location: Windsor County, VT; COD: 2015; Capacity: 750 kWdc Location: Burlington County, NJ; COD: 2014; Capacity: 10,000 kWdc

Figure 2: Example of Built-in Rack Adjustment


Foundation Selection ConsiderationsI. ScheduleII. Site access / staging areasIII. Open-shop, DBA, Union IV. Weather / temperatureV. Cost of concrete (ready-mix vs precast)

Figure 4: Stockpiling Ballast Foundations

Project Location: Riverside County, CA COD: 2015; Capacity: 9,396 kWdcLocation: Middlesex County, MA; COD: 2016; Capacity: 1,134 kWdc

Figure 3: Example of Limited Space and Access Roads


Part II

Rack and Foundation Production

Racking- Lead Time – typically 3-4 weeks from release- Corrosion Protection

I. Pre-galv - G90 minimum per ASTM A653II. Hot-dip Galvanization – per ASTM A123III. Verify Soil Corrosion Potential

Figure 5: Pre-assembled Brackets

Location: RBI Solar Manufacturing and Pre-assembly Facility in Cincinnati, OH


Racking- Pre-assembly Advantages

I. Reduces total number of connections and man-hoursII. Less potential for improper installationIII. Reduces on-site staging areaIV. Quicker unloading and stagingV. Weather

Location: Berkshire County, MA; COD: 2015; Capacity: 3,300 kWdc

Figure 6a: Pre-assembled Top Chord


Figure 6b: Unloading Pre-assembled Top Chords

Concrete Block ProductionPrecast Concrete Ballast Block

I. Precast Lead Time – 3-6 weeks from release to first block deliveryII. Production and Delivery Rates

i. For a 1 MW, typical production is 60 blocks/day and delivery up to 200 blocks/day.

Figure 7: Precast Block Production - SCC

Project Location: Chittenden County, VT COD: 2017; Capacity: 2,132 kWdc


Concrete Block ProductionPrecast Concrete Ballast Block a. Fabrication Drawings and Concrete Mix Design Submittal

i. Verify reinforcing – rebar, WWR, or the preferred fibers.ii. Verify concrete mix design… most common type of mix is a high early strength self consolidating

concrete (SCC)b. Advantages

i. Produced in controlled environment to minimize risks and unforeseen costs compared to cast-in-placeii. Minimizes total on-site man hours

Figure 8: Precast Block Production - Curing

Project Location: Hampden County, MA; COD: 2016; Capacity: 950 kWdc


Cast-in-Place I. Cast-in-Place Lead Time – 2-3 weeks from releaseII. Concrete mix design varies by ready-mix plant, location, weather, temperature, installation methods, etc.

i. Admixtures – adds cost– retarders, accelerators, water-reducers, non-chlorides, super plasticizers, evap. reducers

Figure 9: Cast-in-place from Ready-mix Truck

Location: Test pour at RBI Solar Manufacturing Facility - Cincinnati, OH


Cast-in-Place I. Means and methods of placement:

i. Ready-mix mixing 8-10 yd3 truckii. Skid steer 0.5 yd3 bucketiii. Concrete pumps or concrete pump truck

II. Construction plan for Cast-in-PlaceI. Form assembly and form layoutII. Rack and post assembly

III. AdvantagesI. Shorter lead time than precastII. Can virtually be done anywhere


Figure 10: Cast-in-place from Skid Steer

Source: www.danuser.com

http://www.danuser.com/

Part III

Installation Considerations

Equipment SelectionI. Equipment Ground Pressures

i. Standard Telescopic Boom Lift (Lull or telehandler) – 40-80 psi unloadedii. Skid Steer Loader

i. Wheeled – 20-60 psi unloadedii. Tracked – 4-6 psi unloaded

iii. Medium Sized Excavator (30 Ton) - 3-8 psi unloadediv. Tracked Carrier – 2-6 psi unloadedv. Ready-mix Concrete Mixing Truck – 80-120 psi loadedvi. Rear Mount Crane Boom Truck – 75-120 psi unloaded

Figure 12: Rear Mount Crane Boom TruckFigure 11: Excavator Setting Blocks on Landfill

Location: Burlington County, NJ; COD: 2017; Capacity: 16,500 kWdc Location: Erie County, NY; COD: 2016; Capacity: 4,100 kWdc

Part III – Installation Considerations

Responsibility Matrix

TaskDeveloper

/ EPCRack

ProviderConcrete Provider

Installer

Foundation / Rack Design I R I I

Provide Anchor Rods I R I I

Provide and Install Reinforcing Materials A C C R

Purchase Concrete A I I I

Pre-assembled Posts C C A A

Provide and Review Concrete Submittal A C R I

Manage Concrete QAQC per ACI Industry Standards R C A A

Manage Ballast Deliveries A I A R

Equipment Plan and Verifying Exerted Ground Pressures A C I R

Unload and Set Blocks A I I R

Install Racking / Modules A I I R

Manage Racking QA/QC per Manufacturer's Installation Manual A C I R

Table 4 – Example for Responsibility Matrix for Ballasted Projects

R = Responsible A = Accountable C = Consultant I = Informed

Part III – Installation Considerations

Part IV

Case Study

Part IV – Case StudyBurlington County, NJ


Site Specific RequirementsA. Code – IBC 2009, ASCE 7-05B. Wind – 100 mphC. Snow – 25 PSFD. Importance Factor – IE. Minimum set-backs required at gas vents – 20 feetF. Friction coefficient – 0.5

Figure 13: Minimum 20’ Setbacks at Vent Pipes



Topography and Needed AdjustmentA. 5-20% slopes

A. Gravel pads utilized at areas greater than 10% on as needed basis.B. Continuous RowsC. Wind Tunnel – Interior / Perimeter (SEE FIGURE 16)

A. Interior Blocks (smaller blocks and larger spans) – 7,348 ct. B. Perimeter Blocks (larger blocks and small spans) – 2,586 ct.

Figure 14: Gravel Pad Utilization at Undulating Slopes



Figure 15: Gravel Pad Utilization at Undulating Slopes


Figure 16: Interior and Perimeter Blocks

Foundation SelectionSite access / staging areas

- Areas available on-site for staging of concrete blocksOn-site Wage Rates

- Prevailing wage ratesWeather / temperature – install started in Winter 2016

- Precaster started fabricating blocks in winter during their slow period thus lower precast pricingSchedule – producing more than 100 blocks per day and installing more than 200 blocks per day

Figure 18: Installation during Winter Months


Figure 17: Installation during Winter Months

Part II – Racking and Ballast Production:


Figure 19: Pre-assembled Top Chords Delivered to Site

Part II – Racking and Ballast Production:


Figure 20: Pre-assembled Posts on Precast Ballasts in Staging Area

Part III – Installation


Figure 21: Thirty Ton Tracked Excavators Setting Blocks

Size 16.564 MWModule Quantity 53,432Angle of Tilt 20°

Part V – Case StudyBrowns Mills, NJ

Landfill Project Map

11.47MW

States we have completed Landfill projects

0.04MW

2.3MW

0.09MW

7MW

0.11MW

27.32MW

3.81MW

43.22MW

41.5MW

Brazil – 3MW

TaskDeveloper

/ EPCRack

ProviderConcrete Provider

Installer

Foundation / Rack Design I R I I

Provide Anchor Rods I R I I

Provide and Install Reinforcing Materials A C R I

Purchase Concrete A I n/a I

Pre-assembled Posts A C R I

Provide and Review Concrete Submittal R C R I

Manage Concrete QAQC per ACI Industry Standards A I R R

Manage Ballast Deliveries A I R R

Equipment Plan and Verifying Exerted Ground Pressures A C I R

Unload and Set Blocks A I I R

Install Racking / Modules A I n/a R

Manage Racking QA/QC per Manufacturer's Installation Manual A C n/a R

R = Responsible A = Accountable C = Consultant I = Informed

Table 5 – Burlington County, NJ Responsibility Matrix


total project cost reduction...precast concrete ballast block i. precast lead time – 3-6 weeks...

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