Tag Archive for: PV Installation

Vertical Solar Is Changing the Game: Smarter Design, Real Results for Commercial Projects

What if your business or facility could generate solar power all day long—even in snow-heavy regions, tight urban sites, or areas with limited rooftop availability?

That’s exactly what vertical solar installations are making possible.

In a new YouTube breakdown, DIY solar enthusiast Projects With Everyday Dave explores how vertical solar setups—especially when paired with bifacial panels—are transforming solar efficiency in real-world environments. While his findings are residential in scale, the underlying data offers compelling insights for commercial developers, infrastructure planners, and large-scale property owners exploring smarter, space-efficient solar solutions.

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The Sunstall Way in Action: My Two Weeks On-Site

The Sunstall Way in Action: My Two Weeks On-Site

☀️ The Sunstall Way

One thing that sets Sunstall apart is its approach to training.

Most companies onboard you with a few Zoom calls, a handbook, and maybe a slide deck from a past project. As a new Assistant Project Manager(APM) at Sunstall, I wasn’t sure what to expect. Most APMs in office-based roles don’t typically head straight to the field. But Sunstall does something different. They bring you to the heart of the work.

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Sunzaun on Track: Vertical Bifacial Solar PV for Railways

As railroads intersect countries and connect cities, they offer a unique opportunity for energy generation. Vertical bifacial solar systems are well-suited to turn these corridors into high-efficiency, low-footprint power sources—without interfering with train operations or requiring additional land.

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Sunstalling the future

For over 10 years, California-based Sunstall has been building clean and efficient solar energy solutions for their clients. With a business model based on continuous improvement, sustainability, and streamlining of our work processes we were able to quickly expand from a West Coast startup to an industry leader.

We are focusing on the mechanical installation of ground mount solar arrays and all the add-on services like re-powering and repairing to maintain the assets over their lifetime. Now only a little more than a decade and 450 MW later, Sunstall’s team has had their boots on the ground in more than half of the US – from Hawaii to Massachusetts and everywhere in between.

We have installed systems of these manufacturers: Schletter, Solar Flexrack, MSI, Schueco, Cooper, Haticon, Legrand, First Solar, Creotecc, Shoals, RBI, GameChange, Unirac, Omcosolar, PLP, DCE, APA and more. At the same time, we have installed single-axis trackers from ATI, TerraFix, Clavijo, Nextracker, Exosun, Sunfolding, Soltec, RBI, FTC, and Archtech. We also worked on Ecolibrium, Aerocompact, Sollega, S5 and Erthos!

We are happy to support your project – get in touch with us!

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Solar Fastening Dilemma- Part2!

Our solar fastening Dilemma – Where are we coming from?

The global solar market is growing and so is the pain of dealing with nuts and bolts as the standard method to connect an assembly. To review why Nuts & Bolts are holding the solar industry back visit : Torquing – the Solar Installation Mystery!

It’s been almost 5 years since I wrote this article being frustrated with the lack of quality and other related issues, such as:

  • supply chain issues – procuring nuts and bolts in bulk guarantees inventory issues
  • manufacturing issues- ordering an M10 and getting an DIN M10 bolt are two different things – oh – and btw the nut should match the bolt.
  • losing nuts and bolts in harsh conditions is a given! Try installing them with gloves in NY at 20 degrees Fahrenheit.
  • and then you have the discussion about the torque – if interested read my first article. See video below and you see what I am referring to.

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Shoutout from Omco Solar

We at OMCO Solar want to give our partner Sunstall Inc. a shoutout!

Partnership with Omco Solar

After multiple project completions, and many more on the way, we know how the #powerofpartnerships can expedite projects and build a strong team. The first project was a 1.5 MW solar project, and was a huge success for both companies and the end-customer. OMCO Solar and Sunstall Inc. have installed over 30 MW of clean solar energy together, spanning 25 project sites that ranged from dairy farms to food and beverage facilities to retail power entities. Thank you to Helge Biernath, CEO of Sunstall Inc. for this winning partnership!
#OMCOSolar #SolarPower #PowerofPartnerships #Shoutout #Cleanenergy
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Sunstall’s Pile-Driving Fundamentals: Steel Piles and Corrosion

Having many other uses, steel piles are often used to build the foundations for utility-scale PV applications. In use, they become exposed to different types of corrosion of various extents. Some of the main elements that impact the level of corrosion are pile shape, driving method and the type of material. Common shapes include H-piles, pipe-piles, screw piles and disc piles  – all of which can have different material types. H-piles have become the most used for solar structures, because they have very good structural characteristics. This allows them to be well-suited for the loads seen in solar installations.

In general, corrosion takes place when two different metals come into contact with a conductive liquid, resulting in a flow of DC electricity. Pile corrosion can be divided into two groups: Atmospheric and soil corrosion.

Sunstallers positioning I-Beams
Sunstallers positioning I-Beams
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Cost Reduction, State of the Art and Trends of Structural Solar BoS

From the perspective of an installer the better the planning and the better the execution matches the planning the better the end result and the less likely it is that CO’s will be issued! Sounds easy – should be easy, but in reality….. it is not that easy!

If a project is executed on the fly – the costs have to be higher than well planned & executed projects so therefore the contingency has to be higher!

Check out the presentation to get some ideas how to reduce costs & call us to discuss and support your project!

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Toyota Production System (TPS) & $1/Watt PV System Challenge

$1/Watt PV System – BoS /Installation Challenges for Ground Mounted Systems

The $1/watt White Paper from the U.S. Department of Energy was a great start to kickoff discussions and movements towards the goal of making solar power competitive without any incentives. To achieve this goal, the cost of an installed PV system would break down into the following components:

•    $.50/watt for Modules

•    $.40/watt for BoS/Installation

•    $.10/watt for Power Electronics

Module Prices and Power Electronics are Getting There

With new production capacities going online almost every week and new players consistently entering the global market, it seems that the question is not if, but when the module prices will hit the $.50/watt. Innovation, scale of production and fierce competition will lead the way to the defined goal, not only for the modules, but also for power electronics.

BoS/Installation

Currently, physical system costs, including labor, are accounting for about 75% of BoS costs for a ground-mounted installation. These costs are divided between structural components and the electrical system.

How can these costs be driven down to the $.40/watt goal? A 2010 Rocky Mountain Institute (RMI) workshop suggested the following steps:

•    Reduce forces at work – such as reduction of the wind load

•    Optimize structural form and materials

•    Design for low-cost installation

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Tag Archive for: PV Installation