Capabilities

ENGINEERING SERVICES

With so many years of experience in the solar industry RRACKS™ is always committed to providing its clients with the very best solutions and designs to get the job done.

Not every solar project is the same and RRACKS™ understands this better than anyone. No challenge is too great or too small and our engineers will always work with your team to get the job done. Our team of engineers are committed to working closely with the ASNZ/1170 Australian standards code to always prepare and design the strongest and most durable solar mounting structure for small households, commercial rooftops or large multi-megawatt utility scale solar projects.

Understanding that the most important part of PV solar installations is ‘time’, all our products are carefully designed with fast installation always in mind. Time is money and with years of experience in dealing with solar installers RRACKS™ understands just how important it is to have a safe and reliable system that can be installed quickly and efficiently.


MANUFACTURING

Our group has more than 30 years’ experience in manufacturing aluminium and steel components and works strictly under ISO 9001 manufacturing standards with Quality always at the forefront of RRACKS™ ‘s manufacturing program.

Our manufacturing facilities are strategically placed in both the southern and northern provinces of China, with our aluminium factory in Guangdong province where the world’s largest Aluminium producers have been situated for many years; while our steel plant is situated in Hubei province, China’s heart and soul of steel production and manufacturing.

RRACKS™ will always work with our customers and our team to get the best quality products installed on time every time.


ARRAY DESIGN

RRACKS™ has a team of engineers ready to assist our customers and their own customers with any solar mounting solution design whether it be a small roof or large scale utility solar farm.

Our experience allows us to come up with the most efficient design as well as making the whole installation as easy as possible.

Over the years, our team has worked on a wide variety of rooftop designs, wind conditions and soil composition. We make sure that your installation will last for as long as possible to ensure that you have a smooth running and reliable installation.

Our team of experts will always be available to answer any of your questions on existing or upcoming projects.


EARLY WORK STUDIES

Commonly, engineers representing Banks and Financiers will most likely want to see the following studies to finalise funding.

Our team has been involved in every aspect of engineering services for many large scale projects. We offer stamped and certified documents for funding institutions, insurance or EPC companies.

Topographic and boundary studies

Topographic Surveys are used to identify and map the contours of the ground and existing features on the surface of the earth or slightly above or below the earth's surface (i.e. trees, buildings, streets, walkways, manholes, utility poles, retaining walls, etc.). If the purpose of the survey is to serve as a base map for the design of a residence or building of some type, or design a road or driveway, it may be necessary to show perimeter boundary lines and the lines of easements on or crossing the property being surveyed, for a designer to accurately show zoning and other agency required setbacks.

Topographic Surveys require "bench marks" to which ground contours are related, information regarding surface and underground utilities, determination of required setbacks, etc.

Flood study and flood protection design

The main objective of the investigation is to determine if there is any requirement for flood protection from long term (area) flood and short term flood from storm by: Evaluation of previous flood records from nearby water resource e.g. river, canal, highway/road drainage etc.

  • Investigation of site condition to evaluate for run off coefficient of ground.
  • Obtain nearby rainfall data or rainfall intensity curve from the nearest station.
  • Check site elevation, surrounded road elevation, bridge and public drain elevation compared to the nearest National bench mark (BM) or permanent structure for datum.
  • Estimation of the peak discharges for various return period floods using modelling approach with the help of HECHMS software of US Army Corps of Engineers (USACE);
  • Analysis and estimation of the High Flood Levels (HFLs) for the site location using modelling approach with the help of HECRAS.

Subsurface investigation

Our recommendation is to do as many bore hole tests as possible. The more bore hole tests that you do can determine the different layers of soil around the whole site. On some projects we have been able to establish that we can use different size screw piles for different areas saving a lot of money for the total project, whereas if you only have few holes you need to estimate for the whole site. This means you may waste steel in the ground trying to cater for one-size-fits-all approach. For example, for some areas you may be able to use a 1600mm screw and others 1800 or 2000. If you use 2000mm for the whole project you may spend a lot more money trying to cover all areas with one size.

GEOTECHNICAL WORKS

In PV module installations, the types of foundation are spread footing or short pile with their length between 1.0 m. to 3.0 m. with an increment of pile length of 0.20 m. (1.0,1.2,1.4 m. etc). Therefore, the conventional soil investigation by SPT with an accuracy of every 1.0 m. may not be economic for the design of the short pile length. In another area (substation and other building area with heavier structure), longer pile is needed and a deep borehole is required for prediction of settlement and liquefaction study. Penetration Test (KPT) DIN 4094 (Swedish Geotechnical Institute, 1989) with a sampling interval of 0.20 m and up to 5.0 m deep. Or when hard ground has been encountered to determine initial pile length which has to be confirmed by pile load test.Soil sampling for laboratory testing by hand auger (ASTM D1452 09, Standard Practice for Soil Exploration and Sampling by Auger Borings) in order to classify soil type and their index properties. In each borehole, KPT will be conducted at every 1.0 m. depth interval to collect number of blow counts and convert to SPT for further analysis. The scope of work for the geotechnical consultancy services of the project are summarized as follows:

LABORATORY WORK

Laboratory testing of obtained samples to determine the properties of the subsoil which will include:

  • Unconfined compression test (ASTM D2166) in soft to medium clay samples.
  • Atterberg limits (ASTM D 4318) and soil classification
  • Particle size analysis (ASTM D 422).
  • Unit weight and Water content (ASTM D 2216)

Foundation design and pile testing

This is a technical study that presents the results of pile load tests to estimate the vertical (pullout only) capacities of screw or rammed piles in the proposed Solar Plant. The total piles tested will depend on the size and location of the project. It will also depend on the variance of the data gathered from the KPT soil testing.

Water storage (reservoir) design

Depending on site location and flood study there may be the need for design and building reservoir, also referred as Pond or Dam. Our team has the experience to design and sign off such civil works.

Liquefaction potential study

A study for liquefaction potential is required to ensure safety from the loss of strength in saturated, cohesionless soils due to the buildup of pore water pressures during dynamic loading from large earthquakes.

Liquefaction refers to the loss of strength in saturated, cohesionless soils due to the buildup of pore water pressures during dynamic loading from large earthquake (Sladen et al. 1985).

Generally, clay with fines = 100% does not liquefy. However, soils with high clay content do liquefy in certain conditions. According to the Chinese experience, potentially liquefiable clay soils need to meet all of the following characteristics (Seed et al., 1983)

PV module layout and electrical system design

PV module layout will be designed to optimize land usage and maximum output whilst considering shading and other factors. Electrical system design will be designed to meet international or local country standard.

Bespoke structure design prototyping services

Given the fact that not all projects are the same size, wind region, soil condition, budget, module type, and/or many other variations, it’s important to be able to have a solution no matter what the project may be.

RRACKS™ have the team to design and prototype and test for larger projects, with years of experience in this field. This can be valuable to potential developers or owners wanting to save costs on their future investments.

Soil chemical testing

Sulfate and salinity should also be tested to make sure that we use the correct coating of galvanization on the steel screws. If there is too much salt in the soil it can cause corrosion of the ground screw or rammed pile in the ground. The following tests should cover the following for all steel and concrete footing (underground structure)

  • Sulfate
  • Chloride
  • pH

This test should be done in one location central to the project site.

Works Supplied

  • Chemical analysis of soil sample to check requirement of concrete and steel corrosion. (pH, CL and SO4) Reports to be Supplied
  • Determination of geotechnical parameters required for foundation analyses.
  • Carrying out engineering analyses for foundation design.

Road and drainage design

Service road for maintenance of solar farm will be a small road 3.0 m. to 6.0 m.A drainage system is required to prevent short term flood from storm water. This will be designed at the early stages of development and can be arranged by our team.

Structural design and engineering sign-off

RRACKS™ has what we refer to as “blanket” certifications using AS/NZ 1170 Australian code. The term “Blanket” refers to certificates that we have in place for ground mount and rooftop projects.

This means that installers follow predefined instructions set out by the certification.

For large scale projects such as solar farms and large scale commercial rooftop projects it is much more common to provide bespoke certification and engineering sign off as the banks, investor or financial institutions will require this as part of the lending requirements.

Structural design and engineering sign-off

This is the report to present the performance of Soil Resistivity Measurement and the findings for solar farm projects.

The scope of work is to perform Soil Resistivity measurement at selected location. The measurement shall be performed at multiple points around the selected area of the solar farm.

Method of soil resistivity measurement will use the Wenner four-pin method.


ENGINEERING CONSTRUCTION WORKS

RRACKS™ can take care of the following services for your solar farm project. With years of experience in rooftop, ground mount, and utility scale projects, our team can design and manufacture solar mounting structures, as well as assist in the construction process.

Our competencies include:

Earth work and drainage

Common civil works for solar farm including backfill, flood protection, dikes, roads site grading and levelling are all needed in the consideration of building the solar farm.

Our team have more than 20 years’ experience in project management and construction of various Earthworks and civil works.

Land survey and pilepoint marking

For land survey and boundary, Real Time Kinematic (RTK) satellite navigation is a technique used to enhance the precision of position data derived from satellite-based positioning systems (global navigation satellite systems, GNSS) such as GPS, GLONASS, Galileo, and BeiDou. It uses measurements of the phase of the signal's carrier wave, rather than the information content of the signal, and relies on a single reference station or interpolated virtual station to provide realtime corrections, providing up to centimetre-level accuracy. With reference to GPS in particular, the system is commonly referred to as CarrierPhase Enhancement, or CPGPS. It has application in land survey and in hydrographic survey. After boundary works are finished we switch to conventional survey method for Pile marking and row spacing. This method is the fastest way of pile making and can give us tolerance of 12mm per marked point.

Pile installation

This information describes the procedure, equipment and quality control for the installation of PV module pile for solar plant project.

PV module piles are subjected to compression load (from dead load and wind), tension load (from wind load) and lateral load (from wind and seismic).

Mounting installation and assembly

We specialize in mobilization of manpower and provide teams of experienced workers to come in after piling has been completed to start delivering structures into position. Laser guided levelling systems are used to align structures perfectly.

Once structures are in place another team will come in to start installing the solar PV modules.

Cable trench and DC connection

Our teams can also handle all your DC works, including cable management, module connection, Cable trenching and tunnelling, DC runbacks and Combiner box installation.

Grounding installation

Not only does RRACKS™ have its own specialized earthing solutions that are designed and manufactured by our factory team for both ground mount and rooftop but we also offer installation services for all grounding needs.


PROJECT MANAGEMENT

The RRACKS™ team of engineers has been in the solar farm business for more than 20 years, both leading and consulting on more than 200 MW of solar farm projects globally.

This allows us to have a firmly implanted management system as well being able to help you set up your installation in the best possible conditions.

  • Site management
  • Staff installation training
  • Safety training
  • Planning and design
  • Logistics and planning
  • Schedule and budget planning

LOGISTICS & SHIPPING

Getting your products on time is so important in today’s fast paced solar world. Our company is committed to always keeping stock in our warehouse together with our dedicated team to handle shipping, paperwork and clearance documents, making sure your delivery makes it to your door on time every time.

With offices and team experts located in Australia, China, Thailand and Singapore our network reaches far and wide, helping to get your products delivered to wherever your project is located.

ALWAYS CHECK YOUR OWN COUNTRY’S IMPORT RULES
RRACKS™ has many years of experience with shipping solar mounting products to various countries around the world, recognising that not all countries’ laws are the same. They all have different governments with different rules, FORME, FTA or even no tariffs in some cases.

For example: Thailand may be zero percent duty for aluminium, but could be 20% duty for steel, and Australia might be different again. RRACKS™ understands this issue and will always work to tailor the best solution for your project whilst optimising the materials used to cater for the relevant tariff rulings in each country. link to our social medias and contact page https