Aldoga Solar Farm, Queensland, Australia

The Challenge

The site used a mini trunk bus system on a specific tracker variation which meant the use of traditional cable routing was not a viable option       as it created significant pinch points and abrasion risks. These challenges we're discovered late in the programme, risking delays, added costs, and damage to key infrastructure if not resolved quickly. 

Full commissioning is expected for November 2025 - 14 months ahead of schedule.

The Solution

At this critical stage in the project, Gripple was brought on board to resolve the issues and worked closely with both the OEM, NexTracker, and the contractor to develop a bespoke mounting system that effectively addressed the problems.

Following a comprehensive quantity take-off and taking into consideration the 820,000 solar modules requiring support, Gripple supplied 1.1 million metres of messenger wire and 980,000 Cable Mini Hangers. Collaborating closely with NexTracker, Gripple identified these hangers as the optimal solution to accomodate the site-specific design loads on structure, ensuring secure pile support while eliminating any risk of overload.

In addition, 123,000 custom L-Brackets we're precisely engineered with specific hole sizing and spacing to integrate with the pre-punched NexTracker pile structure using rivet fixings. This adaptation allowed for rapid, low-labour installation that dramatically reduced complexity on-site.

Multiple site visits from Gripple engineers and hands-on troubleshooting with contractors ensured a smooth installation and timely delivery.

Outcome

Thanks to the bespoke L-Brackets and the simplicity of installing the Cable Mini Hangers, the completed installation in just 10 months - a full 14 months ahead of the original schedule. 

The electrical contractor often completed half-day work shifts to avoid overtaking the mechanical teams, highlighting the rapid speed of the solution. The simplicity of the system was such that a backpacker labour was successfully used at times during installation, showcasing its ease of use and minimal training requirements.

Despite a significant budget uplift for cable management (due to underestimated complexity at the early design stage prior to Gripple's involvement), the project came in under total budget thanks to accelerated timelines and efficient labour deployment.