The 50+ mph winds that rushed through the canyons of Emery County, Utah the previous evening meant Sundt Field Engineer Sam Cooper spent his morning fixing a snapped fence post. The fence belongs to a neighbor of the nearly seven-mile-long D.E. Shaw Renewable Investments (DESRI) Hornshadow 398MW Solar Photovoltaic (PV) Plant. It wasn’t how Sam expected to start his day, but the ability to adjust in the face of nature has proven essential in keeping this monumental renewable energy project on schedule and online in an unprecedented 13 months.
From the beginning, the Hornshadow Solar Plant required a very aggressive schedule for its size. The project required months of meticulous planning, permitting and prep for the approximately 3,000-acre site.
“It was an all-hands-on-deck situation,” Cooper said. “Superintendents and project leaders walked side by side with the crews every day, helping minimize mistakes and maximizing efficiency.”
The panels used on this project are a new iteration of frameless solar panels made by First Solar called the Series 7. They are thin film modules, essentially a mixture of chemicals that are turned into a gel and placed between two pieces of glass.
“The panels generate up to around 540 watts. It’s their highest producing panel, but they are fragile as a potato chip is what people will tell you,” said Cooper.
Due to the fragile nature of the panels, installation requires extra care and usually at least two people to avoid damaging them. Even the panels themselves can adjust for the notorious high winds that move through the site’s location. The team installed smart tracking systems for the solar panels, designed to automatically pivot into a protective “wind stow” position at a 60-degree angle to prevent damage from high winds.
The Dawn of a New Solar Plant
Despite the fast-paced schedule and delicate panels, the team stayed positive and found solutions. Working with the client and partners, the team moved almost 20 megawatts worth of panels and fit them into the site while staying on schedule.
“The deck was definitely stacked against this project,” said Steves. “In nearly two decades of my construction experience, this was one of the toughest projects. But we rose to the challenge.”
As Hornshadow Solar moves toward full operation, it stands as a testament to Sundt’s commitment to excellence. With future renewable projects already underway nearby, the team continues to build on this momentum.
It shows how crucial an experienced, resilient team capable of adjusting to unexpected conditions can be to ensure project success. No matter what winds or other obstacles come up, the Sundt team stayed positive and brought energy to ensure a job well done.
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