How Coordination Between Electrical, Civil, and Racking Determines Utility-Scale Project Success

Well-executed utility-scale solar projects follow a specific pattern, allowing for completion on time and without additional cost. Arguably one of the most critical factors in the development is managing the intersection of electrical, civil, and racking. Invisible gaps between these disciplines can quickly turn into problems once construction begins. But what does state-of-the-art coordination look like? As a leading engineering provider, Pure Power Engineering has had the opportunity to accumulate wide-ranging experience with utility-scale systems. This article shares the crucial insights that constitute the difference between on-time delivery and costly delays, between a fully optimized layout and a system that underperforms from day one. 

The Coordination Challenge

Most utility-scale projects begin with optimistic layouts using approximated tracker dimensions. These early-stage designs often rely on generic CAD blocks that don’t reflect the actual racking equipment or electrical system needs. When developers use such arbitrary CAD blocks to estimate system capacity, the physical dimensions often don’t line up. Suddenly, the system doesn’t fit within the permitted limits of disturbance (LOD) or buildable area. Land use permitting must be revisited. Schedules slip. Costs rise.

“Sequencing of the coordination is critical to the success of the project. Once the module is selected, analysis is performed to determine string size, then the racking manufacturer is contacted to develop the actual CAD blocks for use in the design.”, says Benjamin Ahles, Senior Project Manager at Pure Power.

Another frequent breakdown occurs when different parties make conflicting assumptions. Civil engineers might approve a table layout across a drainage ditch, only for the racking manufacturer to later reject it due to structural pile design constraints. Or the electrical team might design an above ground cable messenger system layout without a clear pile plan, forcing redesigns downstream.

Envisioning A Better Process for Utility-Scale Solar

The obvious solution lies in deliberate, structured coordination. Ideally, it begins when the electrical team calculates the string size and coordinates directly with the racking manufacturer to generate an accurate CAD block. The goal is to avoid projects moving too far ahead with design assumptions that don’t reflect the reality on the ground. 

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.

Cost Runaways are the Major Culprit

Without proper coordination, even small discrepancies can have massive cost implications. Ironically, it is often cost considerations that drive developers to choose the most inexpensive available racking equipment with specs that don’t necessarily align with the system design.

"We often get layouts that just aren't physically representative of what needs to be built. And then, it's on us to fix it without the cost getting out of hand."

• Delayed permitting: When electrical and civil work move ahead based on uncoordinated assumptions, the permitting process can become a game of catch-up. LODs and fence lines may need to be revised, delaying timelines and risking noncompliance with regulatory requirements.
  
  
• Overpromised capacity: In a likely scenario, the developer oversells a site’s production capacity based on an inaccurate layout. Once the real equipment dimensions are factored in, the site can’t physically accommodate the needed modules. The owner will be forced to reset expectations and the developer will have to come up with solutions that will ultimately delay the project and increase design costs.
  
  
• Survey Mismatches: A CAD file built in one coordinate system and interpreted in another can throw off entire rows by dozens of feet. One such error can lead to an array being installed away from its intended actual location, requiring removal and costing hundreds of thousands of dollars.
  

What Good Project Coordination Looks Like

A strong process avoids most of these pitfalls. Our best practices when it comes to coordination of utility-scale solar projects follow these guidelines:

1. Start with real equipment specs. Engage with racking vendors early. Don’t rely on guesswork blocks.
2. Calculate string sizes first. Electrical leads the process, informing layout geometry.
3. Generate a layout, then verify. Get feedback from racking and civil on whether pile plans and drainage constraints align.
4. Standardize CAD practices. Ensure everyone is using the same coordinate system and file standards.
5. Drive layout ownership. Empower the electrical team to lead layout creation with constant feedback loops from civil, structural, and the racking vendor. 

"We drive coordination for the client. That means asking the right questions at the right time, getting accurate files, and verifying that everything aligns before anything gets built."

Why it Matters: Avoiding Costly Project Delays

Coordination isn’t just a design best practice—it’s a risk management strategy. In utility-scale solar engineering, the cost of error is too high to leave layout assumptions unvalidated. Developers and EPCs who prioritize a seamless interaction between electrical, civil, and racking partners gain a real edge: faster schedules, fewer redesigns, and layouts that actually reflect the system being built.

"These projects are complex jobs at heart, and if electrical doesn't understand civil, the whole thing falls apart. That's why we took it upon ourselves to learn both."

The best outcomes emerge when teams are aligned from the start. That doesn’t happen by accident. It requires process, discipline, and partners who know how to bring the pieces together.

About Pure Power Engineering

Pure Power is a national engineering firm specializing in solar and energy storage. Our utility-scale team bridges the gap between electrical, civil, and racking fostering project success through proactive coordination.

For further insight and expert guidance on coordination between these parties, get in touch with Pure Power Engineering—your partner in effective, code-compliant Utility-Scale solar and storage engineering solutions.