Module Mounting Structure (MMS) Installation SOP

Standard Operating Procedure for the installation of Module Mounting Structures in utility-scale solar PV projects, ensuring structural integrity, optimal energy capture, and long-term system durability for ground-mounted solar power plants.

Duration: 10-15 days Team: 8-15 workers Risk Level: Medium-High

1. Purpose

To establish a structured procedure for the installation of Module Mounting Structures (MMS) in solar photovoltaic projects to ensure structural integrity, optimum solar energy capture, and long-term durability.

2. Scope

This SOP applies to all MMS installation activities in utility-scale solar PV projects, including foundation works, structure assembly, alignment, and quality control. It covers both fixed-tilt and single-axis tracker systems from site preparation through final commissioning.

3. Responsibilities

Project Manager

Ensures adherence to design and scheduling parameters

Site Engineer

Supervises technical aspects and quality control

MMS Installation Lead

Manages daily operations and team coordination

Mechanical Team

Executes structure assembly and alignment

Quality Inspector

Verifies structural integrity and specification compliance

HSE Officer

Enforces safety protocols and hazard prevention

4. Materials & Tools Required

Structural Components

Posts, Purlins, Rafters, Torque Tubes

Fasteners

Bolts, Nuts, Washers, Clamps

Foundation Materials

Piles, Concrete, Rebar, Foundation Caps

Surveying Equipment

Total Station, DGPS, Measuring Tapes

Hand Tools

Wrenches, Torque Wrench, Hammers, Levels

Heavy Equipment

Pile Drivers, Excavators, Cranes, Forklifts

Testing Equipment

Pull-Out Testers, Torque Testers, Inclinometers

Safety Equipment

PPE, Fall Protection, Barricades

5. Procedure

1
Site Preparation & Layout
  • Conduct detailed topographical survey of installation area
  • Clear vegetation and level ground as per design requirements
  • Mark pile locations according to approved layout drawings
  • Verify row-to-row spacing and table dimensions
  • Establish reference points and benchmarks for alignment
  • Conduct underground utility detection before excavation
2
Foundation Installation
  • Perform soil testing to confirm foundation design parameters
  • Install piles (driven/ramming/pre-drilling) as per geotechnical recommendations
  • Ensure proper pile depth and verticality (max deviation: ±2°)
  • Conduct pull-out tests on sample piles to verify load-bearing capacity
  • For concrete foundations, ensure proper curing time before loading
  • Verify foundation elevation and alignment with surveying equipment
  • Apply anti-corrosion treatment to exposed foundation elements
3
Primary Structure Assembly
  • Inspect all structural components for damage before assembly
  • Install post adapters or caps on foundation elements
  • Mount primary support posts ensuring proper orientation
  • For trackers, install torque tubes with bearings and drives
  • Install cross bracing and diagonal supports for stability
  • Ensure proper torque values for all bolted connections
  • Verify alignment of primary structure both vertically and horizontally
4
Secondary Structure Assembly
  • Install purlins/rafters perpendicular to primary supports
  • Ensure proper spacing for module mounting as per design
  • Mount module rail systems and connecting hardware
  • Install end clamps and mid clamps for module securing
  • Verify proper alignment of rails for smooth module installation
  • Check and adjust tilt angle according to design specifications
  • Ensure all components are properly secured with specified torque
5
Final Adjustments & Quality Checks
  • Fine-tune table height and slope to meet design parameters
  • Verify row-to-row spacing and east-west alignment
  • Check all fasteners for proper torque values
  • For trackers, test drive systems and control units
  • Conduct structural stability tests under simulated wind loads
  • Install grounding systems and lightning protection
  • Document all measurements and quality checks

6. Quality Checks

Verify foundation depth and verticality (max deviation: ±2°)
Ensure proper torque values for all structural connections (±5% tolerance)
Verify MMS tilt angle accuracy (±1° tolerance)
Check horizontal alignment between tables (±10mm tolerance)
Validate row-to-row spacing (±30mm tolerance)
Inspect all welds for defects and galvanizing integrity
Test tracking system functionality (for tracker systems)
Verify grounding continuity and resistance values

7. Safety Measures

Personal Protection

Use appropriate PPE: hard hat, safety shoes, gloves, eye protection

Material Handling

Use proper lifting techniques and equipment for heavy components

Electrical Safety

Ensure proper grounding of all metallic components

Weather Monitoring

Halt operations during high winds (>40 km/h) or lightning

Work Zones

Establish clear barricades around active pile driving areas

Tool Safety

Inspect all tools and equipment before use

First Aid

Maintain first aid kits at strategic locations

Visual Alerts

Use high-visibility marking for trip hazards and equipment

8. Documentation & Approval

Daily installation progress reports with quantities and locations
Pull-out test results for foundation strength verification
Torque value verification records for all critical connections
Quality inspection reports and non-conformance records
Photographic documentation of each installation phase
Material inspection and testing certificates
Site engineer approval for completed MMS tables
Tracker calibration and commissioning records

9. Troubleshooting Common Issues

Pile Driving Difficulties

Problem: Hard strata or refusal during pile driving operations

Solution: Pre-drill pile locations to required depth and backfill with suitable material. Alternatively, consider concrete foundations as per engineer's approval.

Alignment Discrepancies

Problem: Misalignment between piles affecting secondary structure installation

Solution: Use adjustable connectors or custom spacers to compensate for misalignment within allowable tolerance. For severe cases, reinstall affected piles after engineer review.

Galvanization Damage

Problem: Damaged zinc coating on structural components

Solution: Apply zinc-rich cold galvanizing paint on minor damages. For major damages, replace the component and document the non-conformance.

Tracker Binding/Stiction

Problem: Tracker movement not smooth or binding during rotation

Solution: Check bearing alignment, lubricate moving parts, verify torque tube straightness, and ensure proper drive system calibration.

10. Pro Tips

Pre-Assembly

Pre-assemble smaller components at staging area to reduce field installation time

Reference Tables

Create reference tables for each block to establish alignment benchmarks

Sequential Installation

Follow block-by-block installation sequence to optimize resource utilization

Tool Management

Establish dedicated tool stations with calibrated equipment at strategic locations

Weather Planning

Schedule critical alignment activities during early morning to avoid thermal expansion effects

Mapping Progress

Maintain digital layout maps color-coded by installation status

11. Environmental Considerations

  • Implement erosion control measures during foundation installation
  • Avoid excessive soil disturbance and preserve topsoil when possible
  • Properly dispose of packaging materials and construction waste
  • Establish designated areas for hazardous material storage
  • Consider wildlife corridors and habitat preservation in layout design
  • Implement dust control measures during dry conditions
  • Restore vegetation in disturbed areas after construction completion

12. References and Standards

MNRE Guidelines for Solar Structure Installation
IS 800:2007 - General Construction in Steel
IS 875 (Part 3):2015 - Wind Loads on Buildings and Structures
ASTM F1554 - Standard Specification for Anchor Bolts
Solar Project Design Specification Document
IEC 62446 - Grid Connected Photovoltaic Systems
ASTM D1143 - Standard Test Methods for Deep Foundations Under Static Axial Load
Solar Energy Corporation of India (SECI) Technical Specifications for Ground Mounted Solar Projects

13. Conclusion

Proper installation of Module Mounting Structures is critical to the long-term success of solar PV projects. By following this Standard Operating Procedure, teams can ensure structural integrity, optimal energy production, and enhanced system longevity. The MMS serves as the backbone of the solar array and must withstand decades of environmental exposure while maintaining precise alignment. Regular quality checks, documentation, and adherence to safety protocols throughout the installation process are essential to project success.

Remember that even minor deviations in alignment can compound across the solar field, potentially affecting energy yield over the project's lifespan. Therefore, maintaining precision and quality control throughout the process is essential for the overall success of the solar energy project.

Download PDF
×

Thank You!

Thanks for your feedback Karthik. We'll review your suggestions.