Custom Solar substation installation and LV panel integration for large solar scheme

One of our clients, engaged in a large-scale solar energy construction project, sought our expertise for a key part of the project – delivering a cost-effective solution for substation installation and integration of low-voltage (LV) panel.

Our client, Custom Solar, a Mitie Company, is an award-winning solar energy specialist that designs, installs and maintains high quality solar installations across the public and private sectors. Having worked with Custom Solar before, there was a high level of trust in the Ashley Groundworks team to deliver what was needed.

Located at Lakeside North Harbour, Portsmouth, the installation included 3000m of ducting and multiple chambers (supplied by Rouden Pipetek), concrete cast LV, HV, BESS compound, plus SSE intake base and solar canopy bases (supplied by Bluetop Solar Parking).

The portion of the project we were responsible for involved installing critical infrastructure (the substation and LV panel) that would manage and distribute the electricity generated by the solar panels.

The substation is essential for adjusting voltage levels and controlling power flow, while the LV panel is responsible for regulating and safeguarding electrical distribution, both forming the backbone of the overall project’s energy management system.

In addition to the substation installation, we had to ensure seamless integration and co-operation with other trades operating on a live site with limited space.

Our team was tasked with:

• Design of the shoring in conjunction with Pro Mech Ground Support Systems
• Providing the required plant, materials, and skilled labour to execute the project
• Managing the project under tight deadlines on a live site with multiple trades operating simultaneously

To successfully complete the substation installation and LV panel integration, we followed a structured approach, ensuring each phase was executed with precision and attention to detail.

• Preparation: We co-ordinated the delivery of plant, materials, and labour, ensuring all resources were in place when we needed them. This included bringing in specialised trades for tasks, such as steel fixing and shuttering, essential for the integrity of the base structure. The site for the substation base and LV panel installation was carefully marked out, ensuring the layout adhered to the project’s technical specifications and safety standards.

• Base construction: The ground level was reduced to a safe and stable level to create a solid foundation for the substation and LV panel. This step was critical in ensuring the longevity and structural integrity of the installation. We installed sheet piles around the frame to create a protective boundary and excavated the area within. The excavation was followed by pouring the concrete base slab and removing the lower frame once it had set.

• Wall construction: The walls were poured according to the engineer’s precise specifications, ensuring strength and durability. Once the walls were set, the remaining sheet piles and frames were removed and off-hired, clearing the site for the final stages of construction.

• Finalisation: The surrounding area was levelled in preparation for the top section of the substation. We then tied, shuttered, and poured the top section, completing the structural framework. The LV panel, transformer, and cabinets were installed, followed by compacting and finishing the area with 20mm limestone stone to ensure a clean, functional, and safe environment.

The substation installation and LV panel integration were completed on schedule, meeting all project requirements and adhering to the engineer’s specifications. Our efficient execution allowed other trades to seamlessly install the LV panel, transformer, and cabling, ensuring minimal disruption on-site.

The successful completion of this phase of the project set the groundwork for completing the rest of the solar scheme construction, ensuring smooth operation and supporting the generation of renewable energy.

For expert groundworks solutions that ensure the success of your projects, explore our Groundwork Services Page.