Constructability Part 2

In the last Camelot Energy Group constructability article, we discussed the importance of gathering detailed topography data as it is critical to reduce costly redesigns, permitting delays, and unexpected construction obstacles and issues. 

In this second constructability article, we are going to go through some considerations that owners and developers need to be taking when putting together project layouts and designs to set the project up for permitting, construction, and long-term success. 

As we discussed in the last article, in the early stages of development, a preliminary design is typically put together using the sometimes minimal public information on hand. The goal of this initial design is to verify project feasibility, usually in the form of DC and AC system size. Where a lot of project designers go astray is that they primarily focus on module layout and creating as large of a project as possible without considering the other layout considerations that are critical for the project’s success. Doing the due diligence and putting together an accurate and realistic project should always be the goal! 

Even during the early stages of a project, there are specific layout considerations that should be discussed and ironed out, including site and construction access, medium voltage configurations, module layout, equipment pad locations, wetland locations and mitigations, and overall site hydrology. 

Site Access: The Forgotten Risk Multiplier 

Once a potential parcel is identified and a preliminary module layout has been put together, the project team then needs to verify how the site will be accessed for construction and long-term asset management. Project sites will also need access ahead of construction mobilization to do onsite testing for racking as well as for potential tree clearing and site work.  

Site access may sound simple, but without de-risking how the project will receive racking, modules, transformers, and other equipment, the project is at risk of facing multiple critical constructability issues. The first thing that needs to be considered is the location of the site’s main entrance. Even projects that are adjacent to a paved road can present challenges, including: 

• Steep topography requiring grading or retaining walls 

• Stream crossings and culverts needing hydraulic analysis 

• Public utility crossings that may require additional design complexities and coordination 

• Local DOT requirements for driveway permits, signage, or acceleration/deceleration lanes 

  
  

It’s important to remember that large semi-trucks, some carrying oversized loads, will need to safely turn into the project site so if the approach angle or turning radius isn’t addressed early, retrofits or access delays can quickly erode construction schedules and budget.

Designing the Site Access Road 

Once the site entrance is located, the project’s access road needs to be laid out with construction, operations, and safety in mind. A well-designed access road doesn’t just connect points A and B it facilitates: 

• Efficient traffic flow for potentially hundreds of daily deliveries 

• Safe two-way traffic for large trucks 

• Designated turnarounds for dead-ends or tight sites 

• Clear routing to temporary laydown and permanent O&M areas 

Where possible, the road should follow natural contours to reduce earthwork. Additionally, early geotechnical investigations can prevent surprises during grading, particularly in regions with expansive clays, bedrock, or high groundwater tables. The design should also consider future maintenance equipment and weather impacts. 

Medium Voltage Routing: Hidden Cost Driver 

The next consideration that needs to be well thought out is how medium or high voltage will be routed and interconnected. This affects not just cost, but also the construction timeline and long-term reliability. 

Generally, there are two ways of routing MV cables: overhead or underground. There are pros and cons to both: 

• Overhead lines are typically less expensive per foot and faster to install in soft or forested terrain but may require FAA filings (if near airports), additional tree clearing, and more extensive permitting. 

• Underground lines reduce visual impact and are more protected but come with higher costs, greater trenching needs, and longer lead times on materials like duct banks or vaults. Additional onsite testing may also be required to verify sub surface conditions will be acceptable for trenching.  

Where feasible, routing the MV lines along the site access road reduces the number of disturbed areas, consolidates construction zones, and limits environmental impacts. This “co-location” strategy also minimizes total site clearing and road crossings, saving time, money, and permitting effort. 

Siting Equipment Pads with Precision 

Once the site access and MV routing are aligned, the focus shifts to the strategic siting of equipment pads, usually housing inverters, transformers, switchgear, and potentially Battery Energy Storage Equipment. 

Pads must be located with multiple variables in mind: 

• DC home run distances: Minimize string length to reduce voltage drop and avoid oversized cabling. 

• Voltage drop: Particularly on larger sites, both DC and AC voltage drop must be calculated during the 30% design stage to optimize cable size and verify the site configuration is cost effective. 

• Drainage: Pads should not be sited in low areas where water naturally collects, leading to pooling, flooding, and potentially failed equipment.  Like we discussed in our first constructability article, the site’s topography should be considered to avoid storm water run-off issues. Water and electricity don’t go well together! 

• Access: These pads must remain accessible post-construction for maintenance vehicles and emergency responders. This includes making room for service clearances, crane access (for transformer/BESS replacement), and pull-off areas. 

  
  

Wetland and Hydrology Impacts: Early Action Avoids Late Pain 

Finally, no layout is complete without overlaying wetland, floodplain, and surface water data. Many projects mistakenly treat this as a permitting detail rather than a constructability issue. 

Ignoring hydrology can lead to: 

• Equipment and roads placed in flood-prone areas 

• Unforeseen permitting delays (jurisdictional waters, buffer zones, etc.) 

• Costly re-routing of cable trenches or roads 

• Long-term operational headaches related to erosion or access loss 

• Construction delays and potentially expensive construction tactics 

Projects should engage qualified wetland consultants early and plan for buffers that not only comply with regulations but allow for construction maneuvering and long-term asset protection. Having a Civil Engineering firm put together a Storm Water Prevention Plan in parallel with the preliminary layout should be a standard task of any project’s development.  

Closing Thoughts and a look ahead 

While it's common for early-stage project designs to focus on maximizing DC and AC capacity, this singular focus often overlooks critical infrastructure and constructability elements. Without simultaneously considering site access, medium voltage routing, and strategic equipment pad siting, even the most efficient module layout can become unbuildable or result in major cost overruns. These oversights can lead to unexpected grading requirements, excessive cable runs, inefficient traffic flow during construction, and even the need for complete redesigns. Integrating these considerations ensures the design is not only optimized for energy production but also practical, buildable, and financially viable over the project's lifecycle.  

At Camelot Energy Group, we work with owners and developers to make sure these decisions are integrated into the layout process early, reducing project risk and setting the stage for a streamlined construction phase and long-term performance. 

In upcoming “Constructability” articles, we will dive deeper into other critical factors, including geotechnical challenges and how to de risk the issues that may be lurking under the surface of your next project! Stay tuned for more constructability insights from the Camelot Energy Group!