The Southgate Solar energy project consisted of the complete engineering, procurement, and construction (EPC) delivery of a 50-megawatt, alternating current, utility-scale, ground-mount solar facility, as well as modular construction of the site’s operations and maintenance buildings. The site’s varying topography and geotechnical conditions presented some of the most difficult design and constructability challenges in North American solar projects. The project team developed a dead-man anchor foundation (a type of ground anchor) to counteract the site’s clean beach sand and glacial till, a process that expedited the economical construction of 22,000 foundations and ensured the successfully delivery of the project to meet the client’s project pro forma.
To enhance profitability for the client, PCL’s modular construction division, PCL Agile, prefabricated the operations and maintenance building at its off-site manufacturing facility and self-performed all building foundations within the solar array. The operations and maintenance building consisted of three modules that make up the office portion and a modular flat-pack wall system for the maintenance portion, both of which were erected on-site. The roof was also modularized and sent to the site in sections to ease installation.