Comprehensive SWMS for Large-Scale Ground-Mounted Solar Photovoltaic Systems

Ground-Based Solar Farm Installation Safe Work Method Statement

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Ground-based solar farm installation involves the large-scale deployment of photovoltaic panel arrays mounted on ground-fixed racking systems, typically spanning multiple hectares for commercial energy generation. This work encompasses civil preparation, pile driving for racking foundations, extensive DC and AC electrical installations, inverter commissioning, and grid connection infrastructure across expansive rural or industrial sites. The unique hazards include working near overhead transmission lines, managing high-voltage DC systems, operating mobile plant across uneven terrain, heat stress in exposed locations, and coordinating multiple trades across vast construction zones. This SWMS addresses the specific safety requirements for ground-based solar farm construction in accordance with Australian WHS legislation and Clean Energy Council guidelines.

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Overview

What this SWMS covers

Ground-based solar farm installation represents one of the fastest-growing sectors in Australian renewable energy construction, with projects ranging from 5MW community-scale installations to utility-scale farms exceeding 100MW capacity. Unlike rooftop solar installations, ground-mounted solar farms involve extensive civil works, pile driving operations, large-scale racking assembly, and electrical infrastructure across sites spanning tens to hundreds of hectares. These projects typically occur in rural locations with challenging site conditions including uneven terrain, exposure to weather extremes, potential proximity to existing overhead transmission lines, and limited access to emergency services. The installation process begins with site preparation including vegetation clearing, access road construction, and establishment of laydown areas for materials storage. Foundation works involve driving or augering thousands of steel piles to support racking structures, using specialised pile-driving equipment or hydraulic post drivers mounted on excavators or dedicated tracked vehicles. Site conditions vary from flat agricultural land to undulating terrain requiring careful survey and pile positioning to maintain panel array alignment and optimise solar exposure. Racking installation involves assembling galvanised steel frames that support multiple rows of solar panels at optimised tilt angles, typically 20-30 degrees for Australian latitudes. Racking components are delivered in bulk and assembled on-site, requiring coordination of materials handling, team assembly work, and quality control to ensure structural adequacy for wind loads and panel weight. Solar panels, often 72-cell commercial modules weighing 25-30kg each, are installed in portrait or landscape orientation and secured to racking with specialised clamps. A typical utility-scale solar farm may install 100,000 to 500,000 individual panels. Electrical installation encompasses DC string wiring connecting panel arrays in series, inverter installation and commissioning, medium-voltage AC reticulation to the site substation, and grid connection infrastructure coordinating with network operators. DC voltages in large string configurations can exceed 1500V, presenting serious electrocution and arc flash hazards requiring specialised training and strict isolation procedures. The scale of solar farm projects demands careful traffic management, mobile plant coordination, and segregation of work zones to prevent interactions between heavy machinery and electrical installation personnel.

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Why this SWMS matters

Ground-based solar farm construction presents unique electrical hazards not encountered in conventional building electrical work. DC electrical systems cannot be isolated by switching off supply as solar panels continuously generate voltage whenever exposed to light. String voltages exceeding 1000V create serious electrocution risk and arc flash potential during connection work, fault conditions, or accidental contact. Unlike AC systems where residual current devices provide automatic disconnection, DC systems lack equivalent earth fault protection, meaning sustained earth faults can occur without circuit interruption. The scale of installations, with thousands of DC circuits operating simultaneously, multiplies exposure risk for electrical workers. Proximity to overhead transmission lines represents a critical hazard in solar farm construction. Many solar farm sites locate near existing transmission infrastructure to minimise grid connection costs, creating scenarios where mobile plant, materials handling, and panel installation occur within exclusion zones of high-voltage overhead lines carrying 66kV to 330kV. Contact or electrical flashover from mobile plant such as excavators, cranes, or elevated work platforms causes immediate electrocution and catastrophic burns. Australian Standard AS/NZS 4836 establishes minimum approach distances, but site-specific Safe Work Procedures and continual monitoring are essential given the dynamic nature of construction activities across large sites. Heat stress affects solar farm workers significantly due to exposed site locations with minimal shade, reflective heat from ground surfaces and installed panels, and physically demanding installation work. Australian summer conditions in rural locations can see ambient temperatures exceeding 40°C, with radiant heat from panel surfaces adding further thermal load. Workers performing pile driving, racking assembly, or panel installation maintain high work rates over extended shifts. Without adequate heat stress management including hydration protocols, scheduled rest breaks in shaded areas, and work-rest cycles adjusted for temperature, heat exhaustion and heat stroke risks escalate. These conditions can also impair worker judgement, increasing other hazards such as electrical errors or mobile plant incidents. Mobile plant operations across uneven terrain create collision, rollover, and crush hazards. Solar farms under construction involve simultaneous operation of excavators for pile driving, telehandlers for materials distribution, cranes for inverter installation, elevated work platforms for high DC bus work, and utility vehicles for personnel and equipment transport. Coordinating these activities across sites potentially spanning hundreds of hectares, often with limited formed roadways, demands robust traffic management and exclusion zone protocols. Vehicle-pedestrian interactions, particularly in congested laydown areas or active installation zones, create serious crush injury risk. The scale and remoteness of sites can delay emergency response, making prevention of serious incidents critical.

Reinforce licensing, insurance, and regulator expectations for Ground-Based Solar Farm Installation Safe Work Method Statement crews before they mobilise.

Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Electrocution from High-Voltage DC Systems

High

Solar panel strings generate DC voltages continuously when exposed to light, with utility-scale configurations exceeding 1500V DC. Unlike AC systems that can be switched off at the source, DC systems remain energised whenever light reaches panels. Connection of DC strings, combiner box wiring, and inverter input work occurs on live circuits. Arc flash incidents can occur during connection of energised circuits, from insulation failures, or when isolating faulty strings. DC arcs are more difficult to extinguish than AC arcs and can sustain for longer durations. Workers may also contact energised conductors during cable pulling, termination, or troubleshooting if isolation procedures are not strictly followed.

Consequence: Electrocution causing cardiac arrest and death, severe electrical burns requiring extensive grafting or amputation, arc flash burns from DC arc events, and long-term neurological effects from electric shock exposure.

Working Near Overhead High-Voltage Transmission Lines

High

Many solar farm sites locate adjacent to existing transmission lines for grid connection. Construction activities including pile driving, racking installation, panel lifting with cranes or telehandlers, and use of elevated work platforms may occur within or near exclusion zones of overhead lines carrying 66kV to 330kV. Electricity can arc across air gaps if minimum clearances are breached. Mobile plant booms, extending racking components, or lifted panel assemblies can inadvertently approach lines. Electrical flashover does not require direct contact - electricity arcs through air when clearances reduce below safe distances. Metallic equipment provides conductive paths causing instant electrocution.

Consequence: Instant electrocution causing death, catastrophic electrical burns covering large body surface areas, secondary injuries from falls if working at height when contact occurs, and thermal trauma from arc flash temperatures exceeding 10,000°C.

Heat Stress in Exposed Installation Environments

High

Solar farms install in open rural locations with minimal natural shade. Workers perform physically demanding manual handling of panels, racking components, and tools under direct sun exposure for extended shifts during construction schedules. Reflective heat from installed panel surfaces and bare ground compounds ambient temperature effects. Australian summer temperatures frequently exceed 35-40°C in solar farm regions. PPE including safety boots, long sleeves for sun protection, hard hats, and electrical arc-rated clothing for DC work increases thermal load. High work rates to meet installation schedules reduce opportunity for adequate heat acclimatisation and recovery.

Consequence: Heat exhaustion causing weakness, headache, nausea, and reduced work capacity; heat stroke causing core temperature elevation above 40°C with potential for organ failure, neurological damage, and death; dehydration affecting cognitive function and increasing error rates in electrical work.

Mobile Plant Collisions and Rollover on Uneven Terrain

High

Ground-based solar farm construction involves simultaneous operation of excavators for pile driving, telehandlers for racking and panel distribution, all-terrain vehicles for site transport, elevated work platforms for electrical work at height, and cranes for inverter installation. These machines operate across uneven ground with varying load-bearing capacity, temporary access tracks, and around installed infrastructure creating obstacles. Sites under construction lack formed roads and designated traffic routes. Collision risk exists between mobile plant items and between plant and workers on foot. Rollover hazard arises from soft ground, sloping terrain, and operation near excavations or pile installation areas. Limited visibility for operators due to dust, solar panel glare, or site congestion increases incident likelihood.

Consequence: Crush injuries causing death or permanent disability, fractures and internal injuries from vehicle impacts, traumatic amputation if caught in plant movements, rollover causing operator injuries or ejection from equipment, and secondary hazards from fuel spills or equipment damage.

Manual Handling of Solar Panels and Racking Components

Medium

Commercial solar panels used in ground-mounted arrays typically weigh 25-30kg each with dimensions of approximately 2000mm x 1000mm, creating awkward manual handling due to size and wind loading. Workers lift and position hundreds of panels daily during installation phases. Racking components including posts, rails, and bracing members are delivered in bulk and manually handled during assembly. Wind conditions on exposed sites can suddenly load panels during handling creating unexpected forces. Repetitive bending, lifting, and overhead positioning of panels onto racking causes cumulative musculoskeletal strain. Ground conditions may be uneven, requiring workers to maintain balance while handling loads.

Consequence: Acute lower back injuries including muscle strain and disc herniation, chronic musculoskeletal disorders from repetitive loading, shoulder and upper limb injuries from overhead panel positioning, and soft tissue injuries from sudden loading if wind catches panels during handling.

Pile Driving Noise and Vibration Exposure

Medium

Foundation pile installation uses hydraulic pile drivers or impact hammers generating sustained high noise levels exceeding 110dB(A) at operator position and extending to surrounding work areas. Workers operating pile driving equipment endure continuous noise exposure over full shifts. Vibration transmitted through equipment controls affects operators of pile driving plant and hand-held hydraulic breakers if ground requires preparation. Sites may involve installation of thousands to tens of thousands of piles over project duration, creating extended noise exposure for site personnel. Noise also impairs communication increasing coordination risks around mobile plant and electrical work areas.

Consequence: Noise-induced hearing loss developing over weeks to months of exposure, tinnitus affecting quality of life, vibration white finger syndrome from sustained vibration exposure, reduced communication ability increasing other hazards, and fatigue from sustained noise stress.

Arc Flash During DC System Commissioning and Fault Investigation

High

Commissioning of DC electrical systems involves energisation of string circuits and connection to inverters under controlled procedures. Fault conditions including insulation failures, incorrect polarity connections, or short circuits can generate arc flash incidents releasing intense thermal energy. Unlike AC systems where fault current is limited by source impedance, DC systems connected to large photovoltaic arrays can supply sustained fault current maintaining arcs. Investigation of string faults requires testing of potentially energised circuits to identify issues. Working on combiner boxes, DC isolators, or inverter inputs presents arc flash exposure if procedures are not strictly followed or if equipment fails during operation.

Consequence: Severe thermal burns requiring prolonged hospitalisation and skin grafting, ignition of arc-rated clothing if not adequately specified, eye damage from intense light and UV radiation, pressure wave injuries to hearing and internal organs, and inhalation injuries from vaporised conductor material and toxic gases.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

DC Electrical Isolation Procedures and Light Exclusion

Engineering Control

Implement comprehensive DC isolation procedures recognising that panels generate voltage whenever exposed to light. Use opaque covers to exclude light from panel surfaces when work on DC circuits is required. Install and verify operation of DC isolators at string level and combiner box level before commencing electrical work. Use lockable DC isolators that can be individually secured to prevent unauthorised re-energisation. Verify isolation using appropriate DC voltage testers rated for system voltage before commencing work on cables or terminations.

Implementation

1. Install opaque light-blocking covers on all panels in the string requiring isolation work, securing covers to prevent wind displacement 2. Open and lock DC string isolators at combiner box location using personal safety locks 3. Open and lock DC input isolators at inverter or centralised DC switching location 4. Wait minimum 5 minutes after isolation for residual voltage in cables to dissipate to safe levels 5. Test DC circuits using voltage tester rated minimum 2000V DC to verify absence of voltage 6. Apply 'DANGER - DO NOT OPERATE' tags to all isolation points with worker name and contact details 7. Treat all circuits as potentially live until proven otherwise with testing equipment

Overhead Line Exclusion Zones and Spotter Protocols

Engineering Control

Establish physical exclusion zones around overhead transmission lines according to AS/NZS 4836 minimum approach distances for voltage rating. Use highly visible barrier tape, fencing, or delineation to mark exclusion boundaries. Prohibit entry of mobile plant, materials, or workers into exclusion zones. Engage trained spotters to monitor all mobile plant operations and elevated work within 15 metres of overhead lines. Maintain continuous communication between operators and spotters using two-way radio. Coordinate any required work near lines through formal High Voltage Safety Observer procedures with electricity network operator approval.

Implementation

1. Identify all overhead power lines on site and determine voltage rating from network operator records 2. Calculate minimum approach distances: 3 metres for <33kV, 6 metres for 33-132kV, 8 metres for >132kV plus safety margin 3. Mark exclusion zones on ground using highly visible barrier fencing or marked tape visible from 50 metres 4. Conduct toolbox meeting with all mobile plant operators identifying line locations and exclusion requirements 5. Assign dedicated High Voltage Spotter when any work occurs within 15 metres of overhead lines 6. Equip spotter with air horn or other audible warning device to immediately alert operators if approach distances reduce 7. Maintain spotter at all times when plant operates - if spotter must leave position for any reason, plant operations cease

Heat Stress Management Program

Administrative Control

Implement comprehensive heat stress management recognising extreme conditions in solar farm environments. Establish work-rest cycles adjusted for ambient temperature and humidity using heat stress monitoring tools. Provide shaded rest areas and ensure unlimited access to cool drinking water. Schedule highest-intensity work during cooler morning hours. Monitor workers for heat stress symptoms and empower all personnel to cease work if experiencing heat illness. Provide heat stress training for all site personnel including symptom recognition and first aid response.

Implementation

1. Monitor site ambient temperature and humidity using weather station or portable thermometer at 2-hour intervals 2. Implement staged work-rest cycles: 45 minutes work/15 minutes rest when temperature exceeds 32°C; 30 minutes work/30 minutes rest when temperature exceeds 38°C 3. Establish shaded rest areas using marquees or shade structures positioned throughout site to minimise travel distance 4. Provide insulated water stations with ice-cooled drinking water at 200-metre intervals across active work zones 5. Schedule pile driving, racking assembly, and manual handling during cooler morning hours before 12pm 6. Conduct daily toolbox meetings including heat stress symptom recognition: headache, dizziness, nausea, confusion, lack of sweating 7. Appoint heat stress monitors to observe workers and intervene if symptoms evident - immediate work cessation and first aid response

Traffic Management Plan for Mobile Plant Operations

Administrative Control

Develop and implement site-specific Traffic Management Plan designating access routes, speed limits, parking areas, and work zone demarcation. Establish separation between mobile plant operating areas and pedestrian zones using physical barriers or clearly marked exclusion tape. Conduct daily pre-start meetings communicating plant movements and work zone locations. Implement two-way radio communication for all plant operators and supervisors. Use high-visibility clothing and signage to alert operators to worker presence. Install reversing cameras and proximity alarms on all mobile plant operating in congested areas.

Implementation

1. Prepare site plan showing designated access tracks, laydown areas, plant operating zones, and pedestrian routes 2. Mark main access routes using marker posts or delineation visible in dusty conditions 3. Establish 10km/h maximum speed limit for all vehicles operating in active work zones 4. Conduct daily pre-start meeting at 7:00am with all plant operators and work crews communicating planned activities and locations 5. Issue two-way radios to all plant operators, supervisors, and work crew leaders with designated radio channel for site communications 6. Require all site personnel to wear Class D high-visibility vests during all hours on site 7. Prohibit pedestrian entry to active pile driving areas or racking installation zones when mobile plant operating

Manual Handling Aids and Team Lifting Protocols

Engineering Control

Provide mechanical panel installation aids including vacuum lifters, panel trolleys, and mobile conveyors to eliminate manual carrying of panels across installation areas. Mandate team lifting protocols requiring minimum two workers for all panel installation to racking. Use panel gripper tools to improve hand position and reduce grip force requirements. Plan materials distribution to minimise carrying distances from delivery points to installation location. Provide training in correct manual handling techniques specific to panel installation including wind awareness and coordinated team lifting.

Implementation

1. Provide vacuum panel lifters (rated minimum 50kg capacity) for teams installing panels on ground-level arrays 2. Position panel deliveries at maximum 30-metre intervals along array rows to minimise carrying distance 3. Mandate two-person team for all panel installation - one worker secures panel to racking while second guides positioning 4. Use panel gripper handles that attach to panel frames providing ergonomic lift points 5. Train all installers in coordinated lift technique including verbal count-down (3-2-1-lift) and maintaining synchronised movement 6. Cease panel installation work when wind speeds exceed 30km/h due to wind loading on panels during handling 7. Rotate workers between panel installation and other tasks at 2-hour intervals to vary muscle group loading

Hearing Protection and Noise Exclusion Zones

Personal Protective Equipment

Mandate Class 5 hearing protection for all workers operating pile driving equipment or working within 20 metres of pile installation operations. Establish noise exclusion zones marked with signage prohibiting entry without appropriate hearing protection. Rotate pile driving operators to limit individual daily exposure duration. Implement engineering controls including use of hydraulic pile drivers rather than impact hammers where site conditions permit. Conduct noise monitoring and audiometric testing for personnel with sustained exposure to pile driving operations.

Implementation

1. Issue Class 5 earmuffs rated minimum 30dB attenuation to all pile driving operators and support crew 2. Mark 20-metre exclusion zones around active pile driving operations using visible barrier tape and signage: 'HEARING PROTECTION MANDATORY BEYOND THIS POINT' 3. Rotate pile driving machine operators at maximum 4-hour intervals to limit individual exposure duration 4. Schedule pile driving operations for limited daily duration where practical to reduce site-wide exposure 5. Conduct noise monitoring using calibrated sound level meter at operator position and 10-metre intervals from pile driving 6. Provide annual audiometric hearing tests for all personnel with regular exposure to pile driving operations 7. Investigate use of hydraulic or vibratory pile drivers in preference to impact hammers where ground conditions allow

Arc-Rated PPE for DC Electrical Work

Personal Protective Equipment

Provide and mandate arc-rated PPE for all personnel performing DC electrical work including string connections, combiner box wiring, and inverter commissioning. Specify arc rating based on incident energy calculations for maximum available fault current from photovoltaic array. Include arc-rated long-sleeve shirts and trousers, arc-rated face shields, leather gloves over electrical insulating gloves, and leather safety boots. Prohibit synthetic clothing that can melt onto skin during arc flash events. Store arc-rated PPE separately and inspect regularly for contamination or damage that reduces protective capability.

Implementation

1. Conduct arc flash hazard analysis to determine maximum incident energy levels at DC combiner boxes and inverter inputs 2. Provide arc-rated PPE minimum 8 cal/cm² rating for DC connection work (higher rating if analysis indicates greater exposure) 3. Issue complete arc-rated PPE kit to electricians including long-sleeve shirt, trousers, arc-rated face shield with hardhat attachment 4. Require Class 0 electrical insulating gloves (rated 1000V) with leather protector gloves when working on DC circuits 5. Prohibit wearing of synthetic underwear or base layers that could melt in arc flash - require natural fibre garments 6. Inspect arc-rated clothing monthly for contamination from oils or fuels that reduce flame resistance; launder using manufacturer specifications 7. Replace arc-rated PPE immediately if exposed to arc flash event or if damaged/contaminated beyond effective cleaning

Download complete control procedures

Personal protective equipment

Requirement: Minimum 8 cal/cm² arc thermal performance value (ATPV)

When: Required for all DC electrical connection work, combiner box wiring, inverter commissioning, and fault investigation on energised circuits

Requirement: Class 0 rated to 1000V AC/1500V DC per AS/IEC 60903

When: When performing any work on potentially energised DC circuits, string terminations, or testing of electrical systems

Requirement: Minimum 30dB attenuation per AS/NZS 1270

When: Required when operating pile driving equipment or working within 20 metres of pile installation operations

Requirement: Class D day/night per AS/NZS 4602.1

When: Required at all times when on solar farm construction site due to mobile plant operations and site scale

Requirement: Medium impact rated per AS/NZS 1337

When: During all site activities including installation work, plant operations, and site inspection to protect from flying debris and solar panel glare

Requirement: Electrical hazard rated per AS/NZS 2210.3 with Category 1 impact protection

When: Throughout all solar farm activities due to electrical hazards, heavy materials, and mobile plant operations

Requirement: UPF 50+ sun protective clothing

When: During all outdoor work in solar farm environment with minimal shade and extended sun exposure

Inspections & checks

Before work starts

✓Verify overhead transmission line locations and ensure exclusion zones are clearly marked with barrier fencing or highly visible delineation
✓Inspect all DC isolation equipment including string isolators and combiner box disconnects for correct operation before commencing electrical work
✓Check weather forecast for ambient temperature, wind speed, and storm activity; postpone work if conditions unsafe for exposed installation
✓Verify mobile plant has current inspection records, functional reversing alarms and cameras, and two-way radio communication systems operative
✓Confirm heat stress management provisions including shaded rest areas, adequate water supply, and heat monitoring equipment available on site
✓Inspect solar panels for shipping damage or cell defects before installation; reject damaged units to prevent safety and performance issues
✓Verify pile driving equipment including hydraulic systems, noise dampening, and operator hearing protection is serviceable
✓Conduct site toolbox meeting communicating daily work zones, mobile plant movements, electrical work areas, and emergency assembly points

During work

✓Monitor all mobile plant operations for compliance with exclusion zones around overhead power lines using dedicated spotters where required
✓Verify DC isolation procedures are followed before any work on electrical circuits; test circuits to confirm de-energisation before commencing work
✓Monitor ambient temperature and humidity at 2-hour intervals; adjust work-rest cycles and ensure workers taking scheduled breaks in shade
✓Observe workers for heat stress symptoms including headache, dizziness, nausea, or confusion; immediate work cessation if symptoms evident
✓Check panel installation teams are using two-person lifting protocols and ceasing work when wind speeds exceed safe handling limits
✓Verify traffic management controls including speed limits, designated routes, and radio communication are maintained during plant operations
✓Monitor noise levels in pile driving exclusion zones and verify all personnel within area are wearing required Class 5 hearing protection
✓Inspect arc-rated PPE is being worn correctly by electricians performing DC connection work with no skin exposure through gaps

After work

✓Inspect all DC electrical connections for correct polarity, secure terminations, and appropriate cable management before energisation
✓Test DC isolation equipment functionality after installation ensuring smooth operation and positive lock-off capability
✓Conduct thermal imaging inspection of completed DC combiner boxes and inverter connections to identify loose connections or hotspots
✓Verify all pile installation locations match design survey coordinates and racking alignment is within tolerance for panel installation
✓Document any incidents, near-misses, or safety concerns in daily site diary including heat stress cases, plant interactions, or electrical issues
✓Clean and inspect all tools and equipment used during shift; remove damaged items from service with clear 'DO NOT USE' tagging
✓Review heat stress monitoring data for day's work; adjust work-rest cycles for following day if required based on temperature trends
✓Debrief daily activities identifying any safety improvements required for following day; communicate changes at next morning's toolbox meeting

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Site Establishment and Overhead Line Identification

Commence with comprehensive site establishment identifying all hazards and establishing control infrastructure. Walk entire site perimeter and internal areas to locate and document all overhead power lines, underground services, waterways, environmentally sensitive areas, and existing infrastructure. Contact relevant electricity network operator to confirm voltage ratings of all overhead lines and obtain network operator approval for work near assets. Survey site topography and soil conditions to identify areas of soft ground, steep slopes, or poor load-bearing capacity affecting mobile plant operations. Establish site access points, laydown areas for materials storage, parking areas for light vehicles, and designated routes for mobile plant movements. Install site amenities including offices, toilet facilities, first aid station, and emergency assembly point. Erect highly visible exclusion zone barriers around all overhead power lines at minimum safe approach distances plus additional safety margin. Install site signage at entry points identifying speed limits, PPE requirements, emergency contacts, and site rules. Conduct initial site safety inspection documenting hazards and verifying control measures are operative before commencing construction activities.

Safety considerations

Verify overhead line exclusion zones are marked before any mobile plant enters site. Ensure first aid facilities and emergency communications are operational before workforce arrives. Identify nearest hospital and emergency services contact information. Brief all personnel on emergency assembly point location and evacuation procedures.

Pile Foundation Installation for Racking Support

Install foundation piles according to engineering design using hydraulic pile drivers or augering equipment. Load pile installation coordinates into GPS-guided positioning system or mark pile locations using survey stakes at design spacing. Position pile driving machine at first pile location ensuring stable ground conditions and safe clearance from overhead power lines and underground services. Drive galvanised steel posts to design depth using hydraulic ram force, monitoring driving resistance to verify adequate ground penetration and load-bearing capacity. For poor ground conditions, pre-drill pilot holes or use larger diameter piles as specified by geotechnical engineer. Check pile vertical alignment using digital level during driving, adjusting pile orientation if deviation exceeds tolerance before pile is fully driven. Install thousands of piles across site following systematic row-by-row sequence, maintaining quality control records of pile driving depth and any installation anomalies. Conduct pull-out testing on sample piles at specified frequency to verify ground holding capacity meets engineering design loads. Mark any piles requiring remediation including re-driving, additional piles, or structural bracing to achieve load capacity. Schedule pile installation work to minimise crew exposure to extreme heat by working early morning shifts during high temperature periods.

Safety considerations

Maintain Class 5 hearing protection for all personnel within 20 metres of pile driving operations. Rotate machine operators every 4 hours to limit noise and vibration exposure. Monitor pile driving equipment for hydraulic leaks, loose components, or abnormal operation. Cease operations if mobile plant approaches overhead line exclusion zones. Ensure spotter maintains visual contact with overhead lines at all times during pile installation near transmission infrastructure.

Racking Structure Assembly and Installation

Assemble galvanised steel racking structures connecting horizontal rails to driven piles at specified tilt angle for solar panel mounting. Distribute racking components along array rows using telehandlers or all-terrain vehicles equipped with trailers, positioning materials at intervals to minimise manual carrying. Assemble racking following manufacturer instructions, typically involving connection of horizontal purlins to pile tops using clamp assemblies or bolt connections. Ensure all connections are tightened to specified torque values using calibrated torque wrenches to prevent loosening under wind loading. Install diagonal bracing between racking rows as specified by structural engineer to provide lateral stability and wind resistance. Verify racking alignment using laser levels or string lines, ensuring panel mounting surfaces are aligned within tolerance to prevent panel installation difficulties and optimise solar exposure. Check racking levelness across rows to ensure water drainage and prevent panel pooling that reduces performance. Complete racking installation systematically across site, coordinating with pile driving to maintain continuous workflow. Inspect completed racking for secure connections, correct alignment, and absence of damage from handling or installation. Address any non-conformances before proceeding to panel installation phase.

Safety considerations

Use two-person teams for racking assembly to manage component weight and awkward dimensions. Wear cut-resistant gloves when handling galvanised steel components with sharp edges. Cease racking installation when wind speeds exceed 40km/h due to wind loading on partially installed structures. Maintain awareness of mobile plant delivering materials to work area - establish exclusion zones preventing vehicle-pedestrian interactions. Ensure adequate hydration during racking work involving sustained manual handling in exposed conditions.

Solar Panel Installation to Racking Arrays

Install photovoltaic panels to completed racking structures using coordinated team installation. Deliver panel deliveries to installation areas using telehandlers or cranes, positioning pallets at maximum 30-metre intervals along array rows to minimise carrying distance. Unpack panels inspecting for shipping damage or cell defects before installation. Assign two-person teams for all panel installation - teams work systematically along rows installing panels to racking clamps in specified orientation (portrait or landscape). Use panel gripper handles attached to panel frames providing ergonomic lift points and reducing grip force requirements. Position panel on racking structure, align mounting holes with clamp positions, and secure using stainless steel bolts and clamps torqued to specification. Maintain consistent gap spacing between adjacent panels (typically 15-20mm) for thermal expansion. Install panels row by row, completing full strings before commencing adjacent rows to enable progression of electrical installation work. Monitor wind conditions continuously - cease panel installation immediately when wind speeds exceed 30km/h as panels act as sails during handling creating sudden loading and control difficulty. Rotate installation teams at 2-hour intervals to vary muscle group loading and prevent fatigue. Implement staged work-rest cycles adjusted for ambient temperature ensuring workers access shaded rest areas and hydration.

Safety considerations

Mandate two-person teams for all panel installation without exception. Monitor wind speed using anemometer or weather station - stop work immediately if gusts exceed 30km/h. Ensure workers wear high-visibility vests at all times due to simultaneous mobile plant operations. Provide adequate water stations at 200-metre intervals across active installation zones. Enforce scheduled rest breaks in shaded areas every 60-90 minutes depending on temperature. Train workers to recognise heat stress symptoms in themselves and co-workers.

DC String Wiring and Combiner Box Installation

Install DC electrical wiring connecting solar panels in series to form strings, and connect strings to combiner boxes for parallel connection. This work involves handling live DC circuits as panels generate voltage whenever exposed to light. Wire panels within each string in series using DC-rated cable (typically 4mm² or 6mm² photovoltaic cable) with weatherproof MC4 connectors at panel junction boxes. Route cables using cable management clips attached to racking structure maintaining neat runs and UV protection. Calculate maximum string voltage based on panel specification and number of series-connected panels (typical utility-scale strings operate 1000-1500V DC). Install DC combiner boxes at designated locations housing string fusing or circuit breakers, monitoring equipment, and parallel connection to DC main cables. Wire strings to combiner box maintaining correct polarity - positive conductors to positive bus, negative to negative. Label all cables clearly identifying string number and polarity to facilitate troubleshooting. Install lockable DC isolators at combiner boxes enabling individual string isolation. Test each string for correct voltage and polarity using DC voltmeter rated for system voltage before making combiner box connections. Verify all connections are secure, correctly terminated, and have appropriate ingress protection rating (minimum IP65 for outdoor installation).

Safety considerations

Treat all DC circuits as energised at all times during daylight hours. Wear electrical insulating gloves with leather protectors when making DC connections. Use voltage testers rated minimum 2000V DC to verify voltage before touching conductors. Wear arc-rated PPE when working in energised combiner boxes. Cover panels with opaque material if isolation required for remedial work. Never short-circuit DC strings to test for current - use appropriate clamp meters. Verify correct polarity before connecting strings to combiner boxes - reverse polarity can damage equipment and create arc flash hazard. Do not work alone on DC electrical installation - minimum two qualified electricians must be present.

Inverter Installation and DC Connection

Install inverters converting DC power from solar arrays to AC power for grid connection. Position inverters on prepared foundations or mounting structures at locations specified in electrical design. Large central inverters may weigh several tonnes requiring crane lifting, while smaller string inverters mount to racking structures. Install DC cabling from combiner boxes to inverter DC input terminals following cable schedules and maintaining correct polarity. Terminate DC cables at inverter input using appropriate cable glands, lugs, and torque specifications per manufacturer instructions. Verify DC input voltage matches inverter rating and does not exceed maximum input voltage specified. Install DC isolation switches at inverter inputs enabling complete inverter isolation for maintenance. Connect inverter AC output cabling to site AC reticulation system following separately documented AC electrical installation procedures. Install inverter earthing and lightning protection systems according to AS/NZS 5033 requirements. Program inverter parameters including grid connection settings, power factor, and monitoring system integration. Commission inverters following manufacturer procedures and Clean Energy Council guidelines. Conduct insulation resistance testing on DC circuits, continuity testing of earthing systems, and functional testing of isolation equipment before energising inverters. Monitor inverter operation during initial start-up for abnormal voltages, currents, temperatures, or fault indications.

Safety considerations

Crane lifting of large inverters requires exclusion zones around lift area preventing personnel access during lifts. Verify DC cable polarity before connecting to inverter inputs - incorrect polarity causes immediate failure and potential arc flash. Wear arc-rated PPE rated for calculated arc flash incident energy when making connections to energised inverter inputs. Ensure inverter is properly earthed before energisation. Only qualified electricians with Clean Energy Council accreditation shall perform inverter commissioning. Test inverter shutdown systems and verify emergency stop functions operate correctly. Conduct thermal imaging inspection of DC connections after initial energisation to identify hotspots indicating loose connections.

System Testing and Commissioning Verification

Conduct comprehensive testing and commissioning of completed solar farm installation verifying electrical safety, performance, and compliance with connection agreement. Test DC string voltages and currents under various irradiance conditions confirming panel performance matches specifications. Conduct insulation resistance testing on all DC circuits between conductors and to earth, verifying minimum 1 megohm insulation resistance. Test operation of all DC isolation devices under load to verify adequate interrupting capacity and positive isolation. Conduct earth fault loop impedance testing on AC electrical systems verifying protective device coordination. Test inverter response to grid fault conditions including over/under voltage and frequency, confirming compliant disconnection times. Verify monitoring systems are recording data correctly including string performance, inverter output, and site meteorological conditions. Conduct infrared thermal imaging inspection of all DC connections, combiner boxes, and inverter terminations identifying any hotspots indicating high resistance connections requiring remediation. Test emergency shutdown systems verifying solar farm can be safely isolated in emergency situations. Compile commissioning documentation including test results, as-built drawings, and compliance certifications. Obtain network operator approval for grid connection and energisation to utility network. Conduct final site inspection addressing any defects or non-conformances before handover to asset owner.

Safety considerations

Testing of energised DC systems requires arc-rated PPE rated for maximum available arc flash incident energy. Verify isolation equipment operates correctly under load - do not operate isolators under full load conditions without appropriate arc fault protection. Conduct thermal imaging from safe distances using appropriate infrared cameras - do not approach energised equipment to temperatures exceeding safe limits. If remedial work is required, implement full isolation procedures including light exclusion before accessing DC circuits. Only allow qualified personnel with appropriate training and Clean Energy Council accreditation to perform commissioning testing. Maintain test documentation for future reference and regulatory compliance verification.

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Frequently asked questions

How do I safely work on DC electrical systems that cannot be switched off like AC systems?

DC electrical systems in solar installations generate voltage whenever light reaches the photovoltaic panels, meaning circuits remain energised during all daylight hours. Safe work requires strict isolation procedures including use of opaque light-blocking covers secured over panel surfaces to eliminate voltage generation, opening and locking all DC isolators at string and combiner box levels, waiting minimum 5 minutes for residual voltage in cables to dissipate, and testing circuits with voltage meters rated for system voltage to verify absence of voltage before commencing work. All workers must treat DC circuits as potentially live until proven otherwise through testing. Lock-out/tag-out procedures must be implemented with personal safety locks preventing unauthorised re-energisation. When work on energised DC circuits is unavoidable, workers must wear appropriate arc-rated PPE rated for calculated incident energy levels, use insulated tools rated for system voltage, and work with a qualified assistant maintaining visual contact. Only electricians with specific training in DC electrical systems and Clean Energy Council accreditation should perform solar farm electrical work.

What are the minimum safe approach distances for working near overhead transmission lines?

Minimum safe approach distances are specified in AS/NZS 4836 based on overhead line voltage rating. For lines up to 33kV, maintain minimum 3 metres clearance from any energised conductor. For 33kV to 132kV systems, maintain minimum 6 metres clearance. For transmission lines above 132kV, maintain minimum 8 metres clearance. These distances apply to any part of workers' bodies, tools, equipment, or mobile plant including elevated booms, lifted loads, or extended racking components. Add safety margin to minimum distances accounting for equipment movement, load swing, or unexpected factors. Establish physical exclusion zones marked with highly visible barriers preventing inadvertent approach. Engage trained High Voltage Safety Observers (spotters) to monitor all work within 15 metres of overhead lines, maintaining constant visual observation and equipped with air horns to immediately alert workers if clearances reduce. For any work requiring approach closer than minimum safe distances, contact the network operator to arrange line de-energisation or installation of temporary insulating covers. Never assume lines are de-energised - always treat overhead lines as live at maximum voltage rating.

How should heat stress be managed during solar farm installation in Australian summer conditions?

Heat stress management requires multi-faceted controls recognising extreme conditions in solar farm environments. Monitor ambient temperature and humidity at regular intervals using weather stations or portable thermometers. Implement staged work-rest cycles adjusted for conditions: when temperature exceeds 32°C, implement 45 minutes work with 15 minutes rest; when temperature exceeds 38°C, implement 30 minutes work with 30 minutes rest. Establish shaded rest areas using marquees or shade structures positioned throughout site to minimise travel distance - workers must be able to access shade within 100 metres of work location. Provide unlimited access to ice-cooled drinking water with insulated water stations at 200-metre intervals encouraging workers to drink minimum 250ml every 15-20 minutes. Schedule highest-intensity work including manual handling and racking assembly during cooler morning hours before 12pm. Provide heat stress training for all personnel including symptom recognition (headache, dizziness, nausea, confusion, lack of sweating) and first aid response. Appoint heat stress monitors to observe workers and intervene if symptoms evident, with immediate work cessation and cooling measures. Allow adequate heat acclimatisation period for workers new to site or returning after extended absence. Never rush work to meet schedules if heat conditions require extended rest periods - heat stroke can be fatal.

What specific PPE is required for DC electrical work on solar farms compared to standard AC electrical work?

DC electrical work requires arc-rated PPE not typically specified for conventional AC electrical installations due to higher incident energy levels and sustained arc duration in DC systems. Conduct arc flash hazard analysis calculating incident energy at DC combiner boxes and inverter inputs based on available fault current from photovoltaic arrays. Provide arc-rated long-sleeve shirts and trousers rated minimum 8 cal/cm² (higher if analysis indicates greater exposure) manufactured to AS/IEC 61482-2. Require arc-rated face shields worn with hard hat providing facial and neck protection. Electricians must wear Class 0 electrical insulating gloves rated minimum 1000V AC/1500V DC per AS/IEC 60903 with leather protector gloves worn over top. Prohibit wearing of synthetic underwear or base layers that could melt and adhere to skin in arc flash event - require natural fibre garments. Standard synthetic high-visibility vests must be removed during arc flash risk work and replaced with arc-rated high-visibility garments. Provide leather safety boots with electrical insulating soles rather than synthetic materials. Store arc-rated PPE separately from normal work clothing and inspect regularly for contamination from oils or fuels that degrade flame resistance. Replace immediately if damaged or exposed to arc flash event. Ensure all PPE is correct size with no gaps exposing skin particularly at wrist, ankle, and neck areas.

What are the traffic management requirements for large solar farm construction sites with multiple mobile plant operating simultaneously?

Solar farm sites require comprehensive traffic management plans due to site scale, unformed access routes, and simultaneous operation of multiple plant types including excavators, telehandlers, cranes, elevated work platforms, and light vehicles. Prepare site-specific traffic management plan showing designated access routes marked with visible delineation (posts or markers visible in dusty conditions), parking areas separated from active work zones, laydown areas for materials, and pedestrian routes separated from vehicle operating areas. Establish maximum 10km/h speed limit for all vehicles in active work zones. Conduct daily pre-start meetings at consistent time (typically 7:00am) communicating planned plant movements, work zone locations, and any exclusion areas. Issue two-way radios to all plant operators, supervisors, and work crew leaders with designated site channel for communication. Require all site personnel to wear Class D high-visibility vests at all times. Install reversing cameras and proximity alarms on all mobile plant operating in congested areas. Prohibit pedestrian entry to active pile driving or panel installation zones when plant operating. Appoint traffic controllers at site entry points during peak delivery periods managing heavy vehicle access. For work near overhead power lines, assign High Voltage Spotters maintaining visual observation of plant clearances. Review traffic management effectiveness daily and adjust controls if near-misses or coordination issues arise. Brief all new personnel on site traffic rules before allowing site access.

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After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Ground-Based Solar Farm Installation Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Electrocution from High-Voltage DC Systems

Working Near Overhead High-Voltage Transmission Lines

Heat Stress in Exposed Installation Environments

Mobile Plant Collisions and Rollover on Uneven Terrain

Manual Handling of Solar Panels and Racking Components

Pile Driving Noise and Vibration Exposure

Arc Flash During DC System Commissioning and Fault Investigation

Control measures

DC Electrical Isolation Procedures and Light Exclusion

Overhead Line Exclusion Zones and Spotter Protocols

Heat Stress Management Program

Traffic Management Plan for Mobile Plant Operations

Manual Handling Aids and Team Lifting Protocols

Hearing Protection and Noise Exclusion Zones

Arc-Rated PPE for DC Electrical Work

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Site Establishment and Overhead Line Identification

Pile Foundation Installation for Racking Support

Racking Structure Assembly and Installation

Solar Panel Installation to Racking Arrays

DC String Wiring and Combiner Box Installation

Inverter Installation and DC Connection

System Testing and Commissioning Verification

Frequently asked questions

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