Engineering Tips for Preventing Permitting & Interconnection Roadblocks in C&I Solar PV Projects

Distributed solar generation continues to accelerate. According to SEIA, the US added 50 gigawatts of new solar in 2024, with commercial solar growing 8% yearly. However, the path to electrification is increasingly shaped by two critical hurdles: permitting and interconnection. With roughly 20,000 distinct jurisdictions and about 3,000 utilities, review and approval processes can make or break project timelines and profitability. The key is understanding that permitting and interconnection are not paperwork exercises but engineering challenges requiring experience, foresight, and strong relationships.

Solar Permitting Isn’t Just Checking Boxes

Permitting complexity varies drastically from one jurisdiction to another. While some authorities having jurisdiction (AHJs) offer well-defined solar permitting pathways, many still lack clarity or have evolving requirements. Documentation that passes easily in one township may trigger rounds of revisions and delays just a few miles away.

As Travis Lenberg, Senior Project Manager at Pure Power Engineering puts it, “Permitting is local, tribal knowledge,” and that reality shapes every project differently:

• New York City has unique fire code setbacks that don’t exist elsewhere in the US. They also have specific requirements for labeling rooftop conduits.
  
  
• In Los Angeles, the fire department mandates a standby inspection—a second inspection step not tracked through the regular LADBS process. EPCs must coordinate with both the fire department and LADBS.
  
  
• Some Arizona utilities and AHJs have taken the position that they won’t allow construction to begin until after interconnection approval is granted. They also apply strict formatting requirements for drawings to include specific notes.

In some jurisdictions, inspectors ask for things not listed on any official document, like a torque inspection report, because of one-off past experiences. Without local knowledge or a team with boots on the ground, such curveballs can derail timelines or require costly rework​.

What AHJs Are Worried About

At the core of a solid permit application is a well-informed understanding of the AHJ’s priorities. AHJs are often focused on safety and liability rather than on energy production. In fact, AHJs often do not have an in-depth understanding of commercial solar and its complexities. So, explaining the system may become part of the task.

Here’s what permitting officials are usually most concerned with:

• Safety: Is the system installed in a way that ensures safe access for first responders? Are there proper clearances and disconnects?
• Compliance: Are electrical systems, structural elements, and fire pathways compliant with local codes and the NEC?
• Clarity & Completeness: Can the reviewer quickly understand what’s being installed and how?
• Professional Accountability: Are the documents prepared and sealed by a licensed engineer
• Community Impact: Will the system be visible, noisy, or otherwise disruptive to neighbors or public space?

Permitting reviewers aren’t looking to stall projects, but they need confidence that a system is safe, compliant, and appropriately documented.

“AHJs want to know that your system is safe and built to code, but most importantly, they want to see that the PE takes responsibility for it.”

The layout is then returned to the racking vendor, who uses it to generate structural requirements for the pile plans. Pile plans inform civil engineering work—such as hydrology (H&H) and stormwater (SWPPP) studies—which ultimately shapes the full site design. Each step needs verification from the other disciplines to ensure feasibility.

What Developers Need for Permitting

While every AHJ may have its own requirements, certain elements come up repeatedly. Developers should coordinate with their engineering team to produce the following:

• Site Plan with Dimensions: Showing array layout, setbacks, property lines, and access points.
• Glare Studies: Determining if sunlight reflected off solar panels could cause a safety hazard.
• Structural Analysis: For rooftop systems, confirming the building can handle the additional load.
• Electrical Diagram: A clear and code-compliant representation of the system’s electrical layout.
• Trenching & Conduit Routing Plan: Required for ground-mounted systems and often scrutinized for safety.
• Fire Code Compliance: This includes setbacks and pathways as required by IFC or local fire codes.
• Zoning Requirements: Some AHJ require specific lighting or have ADA requirements depending on the project. 
• Flood Zone Identification: Projects in FEMA floodplains may require additional documentation or adjustments.
• Environmental Impact Info: In some areas, solar projects trigger environmental review or mitigation steps.
• Equipment Spec Sheets: For modules, inverters, racking, batteries, and combiners.

Avoiding Interconnection Delays

Smart planning and engineering will set up utility interconnection for success. However, every utility operates differently; they all have their own standards for protective equipment, metering, and transformer configuration. As a distributed generation developer, you can’t afford to submit applications that require major redesigns after utility review.

At Pure Power, the interconnection application process begins with a thorough feasibility analysis. We ask:

• What equipment does the utility expect?
• How should the project be grounded?
• Are there special protection requirements?
  

It takes a proactive engineering team that communicates directly with the utility when needed. A phone call to clarify a diagram or spec may prevent weeks of delays. Having the personal contact and technical credibility helps, of course, especially when discussing complex protection schemes or transformer configurations.

“We make sure the design is bulletproof—one look and the utility can understand it. That keeps the project moving.”

Top 5 Tips for Developers

To avoid painful permitting or interconnection delays, consider these best practices:

•    Engage engineering early. Don’t wait until construction drawings are completed. 
•    Know your AHJ and utility. Requirements and expectations vary widely. Local knowledge saves time.
•    Submit complete, tailored packages. Boilerplate drawings won’t cut it. Anticipate reviewers’ questions.
•    Maintain relationships. AHJs and utilities move faster when they know and trust your team.
•    Follow up strategically. A well-timed check-in can prevent a small issue from snowballing into weeks of delay.

Choose an Engineering Partner to Gain Local Expertise 

In both permitting and interconnection, delays are common, but not always inevitable. 
Getting submissions right requires technical rigor, documentation finesse, and strong stakeholder communication. Developers and EPCs who treat them as strategic phases—not afterthoughts—will see smoother projects, faster approvals, and fewer budget surprises.

While the challenges are real, so is the opportunity: With the right engineering partner, even the most demanding permitting and interconnection processes can become a well-practiced routine. Pure Power Engineering has assisted over 15,000 solar projects and has 12 highly experienced Senior Project Managers to help you navigate permitting and interconnection. For more information on our engineering services please contact Pure Power Engineering at info@PurePower.com.