tec 3.11

0211TECpC1:0211TECpC1 3/2/11 2:49 PM Page C1

Visit us at: www.haticonsolar.com

0211TECpFPads:0211TECpFPads 2/28/11 2:31 PM Page C2

Visit us at: www.legrand.us/cablofil

0211TECpFPads:0211TECpFPads 3/2/11 9:36 AM Page 1

Visit us at: SEDPV.com

0211TECpFPads:0211TECpFPads 2/28/11 2:25 PM Page 2

Visit us at: www.norenproducts.com


4 The Electric Current March 2011

Contents +

PRESIDENT/PUBLISHERGlen Hobson - 205-733-1341SALES DEVELOPMENT MANAGERHank Underwood - 205-733-1343NATIONAL SALES MANAGERRick Harless - 205-733-1324CIRCULATION DIRECTOR/WEB DESIGNJacklyn HobsonCREATIVE DIRECTORDerek GaylardART DIRECTORDavid Todd

Executive and Advertising Offices2070 Valleydale Rd,Suite # 6 Hoover, AL 35244toll free: 866.981.4511phone: 205-733-1341fax: 205-733-1344www.theelectriccurrent.com

The Electric Current is distributed free to qualified sub-scribers. U.S. Postage paid at Birmingham, Alabama andadditional mailing offices.

The Electric Current is distributed to to qualified ownersand managers in the electrical industry. Publisher is not li-able for all content (including editorial and illustrationsprovided by advertisers) of advertisements published anddoes not accept responsibility for any claims made againstthe publisher. It is the advertiser’s or agency’s responsi-bility to obtain appropriate releases on any item or indi-viduals pictured in an advertisement. Reproduction ofthis magazine in whole or in part is prohibited withoutprior written permission from the publisher.

POSTMASTER: Send address changes toThe Electric Current 2070 Valleydale Rd.,Suite #6 Hoover, AL 35244

P R I N T E D I N T H E U S A

2644

06Stetson Wind ProjectStetson Mountain, Maine

10Getting to know North America’s Leading Geotechnical Contractor

20MV/HV Cable Testing – VLF Technology

26From Electrical Contracting to Solar Installation:Knowing What You Need To Know

34NABCEP Alternative ExperiencePathway for Qualified Electricians

40Multi-Contact, serving some of the world’s mostdemanding applications.

44Finding your place in the sun

0211TECp04:0211TECp04 3/1/11 12:22 PM Page 4

Visit us at: www.hiokiusa.com



Feature +

0211TECp06-48:0211TECp06-48 3/1/11 12:26 PM Page 6

Visit us at: www.jonasconstruction.com



Feature +

0211TECp06-48:0211TECp06-48 3/1/11 12:26 PM Page 8

Visit us at: www.zistos.com/EC.htm


Industry News +

Hayward Baker Inc. (HBI) is NorthAmerica’s leading geotechnical contractor,offering the full range of pre and post con-struction services for foundation rehabilitation,settlement control, liquefaction mitigation, soilstabilization, groundwater control, slope sta-bility, excavation support, and underpinning.They are ranked #1 Specialty Excava-tion/Foundation Contractor by EngineeringNews-Record, year after year.

Among the specialty techniques offered byHBI are cement, chemical, compaction, jet, ure-thane, and soil fracture grouting; dry and wetsoil mixing, dynamic compaction, injection sys-tems for expansive soils, rapid impact com-paction, rigid inclusions, Vibro systems, VibroPiersTM, augercast piles, driven piles, Frankipiles (PIFs), helical piles, jacked piers,MacropilesTM, micropiles, pit underpinning,soil and rock anchors, anchor block slope sta-bilization, Gabion systems, Micropile Slide Sta-bilization (MS3), sheet piles, soil nailing, soldierpiles and lagging, polyurethane injection, slabjacking, slurry walls, TRD Walls, and wickdrains.

Over the past 30 years, HBI’s techniqueshave been applied to numerous projects,ranging from dam rehabilitation to soil stabi-lization for major subway construction to seis-mic retrofit to sinkhole remediation. HBI alsohas extensive experience with power projects,having performed services for power gener-ating stations of all types. Many ground im-provement techniques saw their first use in theUnited States by HBI. Whatever the geotech-nical challenge, chances are that HBI hassolved a similar one before.

Headquartered in Odenton, Maryland,HBI has over 20 offices across the UnitedStates, as well as locations in Mexico, andCanada. Since its inception, HBI has es-tablished itself in the forefront of geotech-nical specialty contracting, evolving andexpanding to meet the increasingly com-plex needs of the construction community.They are capable of offering full Design-Build services for virtually any geotechnicalconstruction application, and are able todesign and fabricate equipment for specificapplications.


Getting to know NorthAmerica’s Leading

Geotechnical Contractor

Wet soil mixing and jet grouting to create a bottom seal to allow the installation of aprecast conveyor tunnel below the water table at the Mirant Morgantown coal-firedplant in Newburg, MD.

0211TECp06-48:0211TECp06-48 3/1/11 12:26 PM Page 10

Visit us at: www.dhsolar.net


Visit us at: www.nabcep.com


Visit us at: www.pelsue.com



or driven piles may be the solution. However,often the poor soils can be strengthened andstiffened economically to enable the structureto be constructed on a shallow foundation.Ground improvement and grouting techniquescan effectively address a variety of weak soilconditions. Whether designing a foundationprior to construction or a remedial solution toan existing foundation experiencing unac-ceptable performance, the goal is to identifythe most economical foundation system thatwill provide acceptable performance.

What follows is a brief explanation ofmany of the ground improvement, grouting,and deep foundation techniques that can ef-fectively be employed for power sites to al-low construction on shallow foundations,correct settlement issues, or transfer founda-tion loads to a competent bearing stratum.

GROUND IMPROVEMENTGround improvement methods modify the

in situ soil matrix to increase bearing capacityand/or reduce the risk of liquefaction of gran-ular soils during a seismic event. Some meth-ods use energy (vibratory or impact) tostrengthen the soil, while others use cementi-tious binders to strengthen the soil.

VIBRO PIERSTM (AGGREGATE PIERS)Vibro PiersTM, also known as aggregate

piers, are short, stiff aggregate piers con-structed to reinforce fine grained soils and areonly used prior to construction of the founda-tion. The pier location is initially predrilled forsoils in which the hole will remain open. In

HBI belongs to the internationally recog-nized Keller Group, which provides specialtygeotechnical contracting services worldwide.German affiliate Keller Grundbau developedthe technology and equipment for the deepvibratory techniques of Vibro Compactionand Vibro Replacement that have been in-strumental in site improvement both in NorthAmerica and overseas.

All of HBI’s work is conducted in the safestmanner possible. Their accident incident sta-tistics are well below the national average asdictated by the Bureau of Labor Statistics. Acomprehensive safety awareness and train-ing program for employees, and regular eval-uation of job site procedures helps to ensureminimum risk. To their client’s benefit, a safework environment for their staff and their sur-roundings is a more efficient one for the job.

HBI’s depth of experience and expertise,range of techniques, and the international re-sources of the Keller Group ensure that clients re-ceive the highest level of quality, service, safetyand value available anywhere in the industry.

GEOTECHNICAL CONSTRUCTIONTECHNIQUES FOR POWERGENERATION FACILITIES

Foundation design can pose challengeswhich are generally addressed during designand construction; however, problematic sub-surface conditions can go initially undetected,only to be discovered when they are manifestedas foundation problems during construction op-erations, or after the structures are constructed.

Initial design for any project should includea geotechnical exploration by a geotechnicalengineering consultant. The geotechnical re-port should include an evaluation of the sitegeological history, soil engineering proper-ties (including density, gradation, and mois-ture content), and the in situ strength,permeability, and compressibility character-istics of each stratum within the influence ofthe planned foundation. When problems oc-cur with an existing structure, a similar ex-ploration is required to determine the causeand remediation options.

Weak or loose soils can result in a numberof foundation performance problems, includ-ing insufficient bearing capacity, excessive totalor differential (tilting) settlement, or unaccept-able performance during a seismic event (liq-uefaction or excessive dynamic settlement).When the geotechnical exploration at aplanned facility location reveals that the sub-surface conditions are weak and compressible,a deep foundation system consisting of drilled

soils that cave or collapse, a bottom feed vi-brator can be employed. The downhole vi-brator is lowered vertically to the designedtip of the pier, typically with a standard crane.Aggregate (new crushed stone or recycledconcrete) is then introduced into the hole andis compacted in lifts by repeated penetrationswith the vibrator. The vibratory energy fromthe vibrator densifies the aggregate and anysurrounding granular soil. The high moduluspier reinforces the treatment zone. The tech-nique increases bearing capacity and de-crease settlement for planned structures.

VIBRO COMPACTIONVibro compaction densifies granular soils

using a downhole vibrator probe and is a pre-construction technique. The probe is loweredvertically into the soil, typically with a stan-dard crane. After reaching the bottom of thetreatment zone, the soils are densified as theprobe is raised. The vibratory energy allowsthe soil particles to move into a denser con-figuration. The densification results in a de-pression at the ground surface unless granularbackfill is added during the densificationprocess. The treated soils have increased den-sity, friction angle and stiffness. The techniquehas been used to increase bearing capacity,decrease settlement and mitigate liquefaction.

DYNAMIC COMPACTIONDynamic compaction densifies soils and

fills by using a drop weight on a grid patternand is a preconstruction technique. The dropweight, typically a hardened steel plate, is

Industry News + Dynamic compaction forground improvement forplanned wind towers atStoney Corners wind farmin McBain, MI.

0211TECp06-48:0211TECp06-48 3/1/11 12:26 PM Page 14

Visit us at: www.meproducts.net



bearing capacity or be the cause of excessivesettlement.

A closed-end mandrel is advanced to theunderlying firm soils. The pipe is then filledwith a concrete mix with a high internal fric-tion. The end of the mandrel is opened andthe mandrel is extracted. The concrete fills thevoid created by the mandrel during extraction,and terminates in an upper strong stratum or issubsequently overlain by a fill relieving platform.The improved performance results from the re-inforcement of the compressible strata with thehigh modulus columns. The technique has beenused to increase allowable bearing pressureand decrease settlement for planned structures.

GROUTINGGrouting techniques strengthen weak soils

by the introduction of grout mixtures into thesoil with special tooling. The appropriatemethod is chosen based on the soil proper-ties and specified requirements.

JET GROUTINGJet grouting creates in situ geometries of

soil and cement, known as ‘soilcrete’, using agrouting monitor attached to the end of a drillstem, and can be used as a preconstructiontechnique or for remedial situations. The soil-crete is significantly stronger than the in situsoil, and increases the bearing capacity andshear resistance. The grouting monitor is ad-vanced to the maximum treatment depth. Highvelocity fluid jets are then initiated from portsin the side of the monitor. The jets erode and

lifted by a crane and repeatedly dropped onthe ground surface. The drop locations aretypically located on a grid pattern, the spac-ing of which is determined by the subsurfaceconditions and foundation loading and geom-etry. Treated granular soils and fills have in-creased density, friction angle and stiffness.The technique has been used to increase bear-ing capacity, and decrease settlement and liq-uefaction potential for planned structures. Inshallow Karstic geologies, it has been usedto collapse voids prior to construction, therebyreducing sinkhole potential. Although theprocess appears simple, experience is re-quired to understand the capabilities, limita-tions, and risk factors associated with thedynamic compaction technique.

SOIL MIXINGSoil mixing techniques mechanically blend

soils in place with cementitious material to im-prove soil engineering properties such asstrength and compressibility, and is a pre-construction technique. Soil mixing increasesbearing capacity, decreases settlement andincrease global stability for planned structures.

There are two types of soil mixing: Wetand Dry. Wet soil mixing uses binder slurry totreat soils that have low water content. Drysoil mixing uses binder delivered in powderform to treat soils with high water content.The binder material is introduced to the soilthrough a hollow rotating pipe that isequipped with cutting and mixing blades. Thesoil mix product can take the form of individ-ual columns of various sizes, typically in therange of 2.5 to 8 feet in diameter. Columnscan be installed as individual elements, asoverlapping multiple elements installed with amultiaxis mixing tool, or in the form of a massstabilization, installed with a specializedblending tool attached to an excavator arm.

Because mixed soil provides enhancedbearing capacity and reduced compressibility,the use of the soil mixing technique allows fora reduction in size of the foundation, often re-ducing the overall construction cost and time.

RIGID INCLUSIONSRigid inclusions is a ground improvement

technique that transfers loads through weakstrata to a firm underlying stratum, using highmodulus concrete columns, and is a precon-struction technique.. Planned power sites mayappear firm on the surface, only to conceal aburied weak soil stratum. Depending on thedepth and thickness of the weak layer, it mayprovide the planned structures with insufficient

mix the in situ soil as the drillstem and grouting monitor arerotated and raised. Excess soil-crete rises to the surfacethrough the borehole annulus

where it is contained. Depend-ing on the application and soils to be treated,one of three variations is used: the single fluidsystem (slurry grout jet), the double fluid system(slurry grout jet surrounded by an air jet) andthe triple fluid system (water jet surroundedby an air jet, with a lower grout jet). Jet grout-ing can underpin existing foundations andprovide groundwater cutoff.

CEMENT GROUTINGCement grouting, also known as slurry

grouting or high mobility grouting, is a grout-ing technique that fills pores in granular soil orvoids in rock or soil with flowable particulategrouts. Depending on the application, Port-land cement or microfine cement grout is in-jected under pressure at strategic locationseither through single port or multiple portpipes. The grout particle size and soil/rockvoid size must be properly matched to permitthe grout to enter the pores or voids. Thegrouted mass has an increased strength andstiffness, and reduced permeability. The tech-nique has been used to reduce water flowthrough rock formations beneath hydroelec-tric dams and to cement coarse granular soilsto underpin foundations or for support prior toan adjacent excavation.

CHEMICAL GROUTINGChemical grouting transforms granular soils

into sandstone-like masses, by permeationwith a low viscosity grout, and can be used asa preconstruction technique or for remedialsituations. Typically, a sleeve port pipe is firstgrouted into a predrilled hole. The grout is in-jected under pressure through the ports on thepipe. The grout permeates the soil and solidi-fies it into a sandstone-like mass. The groutedsoil has increased strength and stiffness, andreduced permeability. The technique under-pins existing foundations where granular soilshave resulted in excessive settlements or forsupport prior to an adjacent excavation.

COMPACTION GROUTINGCompaction grouting, also known as Low

Mobility Grouting, is a grouting technique thatdisplaces and densifies loose granular soils, re-inforces soils and stabilizes subsurface voids orsinkholes, by the staged injection of low-slump,low mobility aggregate grout. Compaction

Feature Story + Jet grouting to construct a60-ft-deep by 60-ft-widecutoff wall to prevent thePéribonka River fromseeping into a diversiontunnel for the new earthembankment hydroelectricdam in Péribonka, Quebec,Canada.

0211TECp06-48:0211TECp06-48 3/1/11 12:26 PM Page 16

Visit us at: www.surgesuppression.com



ditions. Micropiles can be in-stalled through holes coredthrough an existing foundation.After installation the micropilesare bonded or mechanically at-tached to the foundation. Alter-nately, micropiles can beinstalled around the perimeter ofthe foundation, after which theconnection is achieved by en-larging the foundation. Althoughthe highest capacity micropilestypically develop their capacityby bonding into bedrock, significant capaci-ties are achievable by friction bonding intosoils. Micropiles are often combined with avariety of grouting or ground treatment tomaximize capacities.

DRIVEN PILESDriven piles can be a cost-effective deep

foundation system for some sites underlain byloose or soft soils, or mine spoils, which canprovide insufficient bearing capacity and ex-cessive settlement. Types include timber, pre-cast concrete, steel H-piles, and pipe piles.The technique is most commonly used for newfoundations. The piles can resist compressionand tension loads. Driven piles may be slightlybattered outward to resist lateral loads. Sincedriven piles generally do not requirepredrilling, they can be driven into a contam-inated soil profile without producing spoil thatcan require costly removal.

AUGERCAST PILESAugercast piles, also known as continuous

flight auger piles (CFA), are deep foundationelements that are cast-in-place, using a hollowstem auger with continuous flights. The tech-nique is most commonly used for new founda-tions. The auger is drilled into the soil and/orrock to design depth. The auger is then slowlyextracted, removing the drilled soil/rock asconcrete or grout is pumped through the hol-low stem. The grout pressure and volume mustbe carefully controlled to construct a continuouspile without defects. Reinforcing steel is thenlowered into the wet concrete or grout. The fin-ished foundation element resists compressive,uplift and lateral loads.

ANCHORSSoil or rock anchors increase the uplift ca-

pacity of foundations. Structures subject tohigh lateral loads may experience a largeoverturning moment. This loading conditionresults in a downward load on the downwind

grouting can be used for both preconstructionand beneath an existing foundation. Typically,a pipe is first advanced to the maximum treat-ment depth. Mortar grout is then injected asthe pipe is slowly extracted in lifts, creating acolumn of overlapping grout bulbs. The ex-pansion of the grout bulbs displaces sur-rounding soils. The surrounding granular soilhas increased density, friction angle and stiff-ness. The high modulus grout column rein-forces the treatment zone. The technique hasbeen used to increase bearing capacity, anddecrease settlement and liquefaction potentialfor planned and existing structures. In Karsticgeologies, compaction grouting has beenused to treat existing sinkholes or to reducethe sinkhole potential in sinkhole prone areas.

FRACTURE GROUTINGFracture grouting, also known as compen-

sation grouting, hydrofractures in situ soil usingneat fluid grout. When excessive total or dif-ferential settlement occurs to structures foundedon fine-grained soils, soil fracture groutingmay be the correct solution for releveling andproviding long-term support. For foundationapplications, soil fracture grouting is most com-monly used as a remedial measure to coun-teract ongoing consolidation settlement infine-grained soils, or for the pretreatment ofmarginally stiff, fine-grained soils that mightotherwise require the use of deep foundations.A sleeve port pipe is grouted into a

predrilled hole beneath the foundation. Thegrout is injected under pressure at strategiclocations through the ports in the pipe. Oncethe hydrofracture pressure of the soil is ex-ceeded, fractures open up in the soil and areimmediately expanded by the subsequent in-flux of grout. The process results in controlledheave of the overlying soils and foundation.

DEEP FOUNDATIONSDeep foundations bypass unsuitable soils

and bear into deeper strata to provide the re-quired capacity. Deep foundation systems re-sist the moment couple by compression,tension, or bending of the deep foundationelements.

MICROPILESMicropiles, also known as minipiles, pin

piles, needle piles or root piles, can provideexceptional value, particularly in difficult ac-cess situations. In addition to new construc-tion, micropiles are often installed to remediateproblems with existing foundations, or retrofitexisting structures for changes in loading con-

edge of the foundation, and an upward loadon the windward edge. Seismic loading,where applicable, further increases theseoverturning loads.For shallow foundations, the downward

load bears on natural or improved soils. Theuplift load can be resisted by the weight ofthe foundation and additional surchargeplaced above the footing. Increasing the matdiameter can also increase the resistance tothe overturning moment. When individualpiles are utilized for deep foundations, thedownwind elements resist the moment loadin compression and the windward piles intension. Foundations supported by a drilledshaft or a concrete cylinder are designed towithstand the moment in bending.The uplift capacity of foundations can be

increased by incorporating soil or rock an-chors into the foundation system. Soil androck anchors are tension elements which de-velop their capacity by bonding into soil androck, respectively. Anchors are typically con-structed by first drilling a 6- to 12-inch di-ameter hole into a stable soil or rockformation. A high-strength steel bar or strand(cable) is then placed into the hole, and thehole is filled with a high strength cementi-tious grout. The top of the bar or strand isthen attached to the foundation. When thefoundation is subjected to an uplift load, theanchor resists the load by going into tensionand transferring the load to the stable soilor rock formation. Soon after construction ofan anchor, the soil-to-anchor or rock-to-an-chor bond can be enhanced by pressuregrouting the bond zone. For more informa-tion on geotechnical construction techniques, visitwww.haywardbaker.com. �

About the author:James Hussin is a director for Hayward

Baker Inc., the leading specialty foundationand ground improvement contractor. He canbe reached at [email protected] online to www.haywardbaker.com.

Industry News + Driven pipe pile foundations forsolar panels, Southeastern U.S.

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 18

Visit us at: www.phase-a-matic.com



Case Study +

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 20

Visit us at: www.conduitrepair.com



Case Study +

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 22

Visit us at: www.utlitymetals.com


Visit us at: www.hvinc.com


Visit us at: www.bierermeters.com


Case Study +From Electrical Contracting to Solar Installation:

Knowing What You Need To KnowBy Mike Bauer, SunWize Technologies

fering business mix means that the solar in-stallation business requires more outreach tobring a steady flow of new customers.Solar electric systems are “big ticket”, dis-

cretionary items. They are equivalent to a newcar purchase and usually undergo the samedegree of scrutiny, shopping or “tire kicking”.This is in contrast to an essential electrical re-pair, important upgrade or time critical workon a larger construction project. The upshotis that PV systems require a greater educa-tional and selling effort. Multiple visits to thebuyer are often required, competition can beheated and the sales cycle can be months. Inthe California market as few as one in six toeight leads turns into a contract and the cost ofthat sale can be over $1000 in marketing ex-pense. As a result, margins can be thinner than

M any electrical contractors con-template diversifying their busi-ness to include the design and

installation of solar electric systems. Of all theconstruction trades, electricians are the bestcandidates to make this move since photo-voltaics (PV) are electrical in nature and inter-connected with a household’s electricalsystem. However, there are important differ-ences between electrical contracting and solarinstallation businesses. This article discussesthose differences by first comparing and con-trasting a solar installation with a typical elec-trical contracting business in terms ofmarketing, sales, administration, operationsand finally the installation itself. Next, it de-scribes how the transition into solar can begreatly facilitated by aligning with a support-

ive, capable solar wholesale distributor andby utilizing pre-engineered system packages.

SOLAR IS MARKETINGAND SALES INTENSIVESolar installations require more sales and

marketing than the typical electrical installations.While both businesses are heavily dependenton referrals, solar customers rarely provide asource of repeat business. In addition, electri-cal contractors often get a significant portionof their jobs working for other contractors, sub-contracting on projects for general contrac-tors for example. Solar installerspredominately work directly for the end-user(home and business owners); they seldom ob-tain projects through ongoing relationshipswith other contractors. The net effect of the dif-


Solar mounting requires careful roof attachment and codecompliant flashing (photo courtesy of Quick Mount PV)

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 26

Visit us at: www.sunwize.com


on an electrical project.Unlike electric work, solar electric

systems require both consumer educa-tion and preparation of the owners totake over the operation of the system(people who lease a system or pur-chase power from a system installedon their rooftop are exempt from thisrequirement). They will need to under-stand the system sufficiently to deter-mine if it is performing properly and toprovide the minimal maintenance that itrequires (unless the installer providesthis as an added service). Finally, theworkmanship of solar electric systemsby law has to be guaranteed for tenyears in many areas. This means thatthe back-end support of the sale is oftenlonger than in the electrical trade.

SOLAR IS ADMINISTRATIVELYINTENSIVE

Solar installations encompass more paper-work than electrical contracting. While bothbusinesses involve proposals, contracts, draw-ings and permitting, these documents are gen-erally more involved in solar. For example,proposals contain calculations of estimatedenergy production, cost savings and financialreturn. Moreover, solar installation deals inadministrative aspects not found in electricalcontracting: rebate administration, financingand tax considerations. Many states or utili-ties have rebate incentive programs that of-ten have applications. In many cases,financing is involved and the installer has to fa-cilitate this process. In some cases, PACE(property assessed clean energy) programs forinstance, the solar installer needs to complete aportion of the application and often submitsthe entire package to the city or county imple-menting the tax-based financing program.While income tax issues involve no paper-work, the installer does need to understandFederal incentives like the 30% tax credit andwhatever State incentives apply (some stateslike Hawaii, Louisiana, North Carolina andOregon have their own tax credits).

SOLAR IS CASH INTENSIVESolar projects involve more cash outlay and

cash management than electrical contracting.

Modules are expensive (up to $500 each)and inverters cost between $2,000 and$4,000. Materials will comprise about 80-90% of the total job cost and can tie up tensof thousands of dollars. In contrast, electricalprojects have a much greater labor compo-nent, closer to 50% of the job cost. There maybe other variables that complicate the man-agement of the cash needed for any given in-stall. In some states like California, downpayment is limited by law to $1,000. To becompetitive, installers often have to carry therebate for the homeowner or provide bridge fi-nancing (usually through third parties) until taxrefunds arrive. Credit terms for materials aretypically limited to 30 days.

SOLAR IS LOGISTICALLY COMPLEXWhile most materials for an electrical pro-

ject are stocked at the local supply house orinvolve a very short lead time, solar equip-ment is different. The industry has been in aperiod of short supply for over a year andavailability of modules and inverters has beenan issue. This situation requires the solar in-staller to plan ahead. and work with a rep-utable solar distributor.. A national distributorwill ship from centralized warehouses in var-ious locations across the county. In addition tolead times, shipping costs and delivery timesare involved. JIT (just in time) job delivery is

therefore more involved.

SOLAR INVOLVES NON-ELECTRICAL TRADE SKILLS

The typical solar installation requiresroofing skills and specialty labor. Oneof the most critical aspects of a resi-dential or commercial rooftop applica-tion is the roof attachment andwaterproofing. Leaks due to improperflashing (or no flashing at all) are themost common liability in the industry.Sometimes roofing needs to removedand replaced to install the mountingsystem. A skilled roofer or someonetrained in roofing best practices is acritical member of the installation team.Typically a pair of skilled laborers isutilized to install the racking and mod-ules. When trained, they also do theroof attachments and flashing as well.

Commercial projects get more com-plex. Electrical engineers specializingin large scale PV systems are utilized.Structural engineers are also requiredbecause of roof loading. Licensed com-

mercial roofing contractors are regularlyinvolved because of the major liability of roofpenetrations.

SOLAR INVOLVES ONGOINGSERVICE AND SUPPORT

As mentioned earlier, solar installations re-quire more service and support than electri-cal work. Unlike an electrical system, whichseldom fails if installed properly, the invertersin solar electric systems contain complex elec-tronics with a life expectancy of about 15years (vs. 25-30 years for the modules). Thismeans that they will require replacing in the25 to 30 year life of a PV system. PV arraysare sometimes located in vulnerable areasand can be damaged by objects such asfalling tree branches. The need for serviceand support can provide an additionalstream of revenue; many installers are nowoffering optional monitoring and mainte-nance services (such as module cleaning)with the installation.

PARTNERING WITH A SOLARDISTRIBUTOR, A CRITICALSUCCESS FACTOR

The differences discussed above may ap-pear daunting but they can be significantlyalleviated by aligning with a supportive, ca-pable solar wholesale distributor. A solar dis-tributor’s business depends in part on new

Case Study +


Electricians will have to become familiarwith DC wiring and grounding as in thisdisconnect box(photo courtesy of Solar-Fit)

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 28

Visit us at: www.californiaturbo.com


Case Study +of trouble, insure a quality system for the endcustomer, and safeguard the reputation of theindustry. They represent the best formula forsuccess for electrical contractors new to thebusiness.

System packages also make sense for smalland/or low volume electrical contractors whohave solar experience. These contractors offera wide range of electrical contracting services,including solar electric. These businesses donot have the volume to warrant additionaloverheads in purchasing, engineering, inven-tory, and logistics. There are also a largenumber of small operations that operate fromtheir home or a small storefront with limitedshop space. These operations sometimes pick

up system packages right from the freight car-riers dock or have them drop -shipped to thecustomer. In short, system packages save ex-perienced electrical contractors time andmoney by simplifying their operations.

In summary, successful entry into solar in-stallation depends on fully understanding whatis involved, finding a good solar distributorpartner and easing into installations with pre-engineered system packages. �

entrants in the market; they are used to andwell equipped to support and nurture electricalcontractors getting into solar. It is critical topick the right distributor; at this initial stage,the ability to provide support and customerservice trumps price. Solar distributors deliverinvaluable pre-sales and post-sales technicalsupport and a range of training opportunities.After service and support, electrical contractorsneed to evaluate solar distributors in terms ofthe breadth and depth of their inventory.

Critical to success is developing a closeworking relationship with a single Sales Man-ager within the solar distributor’s organiza-tion. They will be able to utilize their manyyears of experience to provide guidance anddirection in such areas as system design,equipment selection and industry best prac-tices. They will also act effectively as an ex-tension of the electrical contractor’sorganization, managing many logistics, watch-ing over orders, networking, advocating andexpediting when necessary.

SYSTEM PACKAGES, THE BESTWAY TO GET STARTED

Once partnered with a solar distributor, thebest way to get started is by installing systempackages, sometimes referred to as kits. Sys-

tem packages are pre-engineered,documented, complete systems thatare ordered with a single part numberand available in a wide range of con-figurations. Pre-engineering means so-lar contractors are freed from thedetails of system design and are guar-anteed a reliable, proven system. Theinclusion of electrical and mechanicaldrawings translate to less time spentputting together a submittal packagefor the local building department or ob-taining interconnection. Ordering us-ing a single part number saves time inpurchasing while off-the-shelf avail-ability minimizes lead time and guar-antees everything will arrive at thesame time. Hundreds of available con-figurations assure that the requirements ofmost installations can be satisfied with a PVsystem package.

System packages are ideally suited to elec-trical contractors new to the solar installationbusiness. They embed the experience that thenovice solar contractor lacks. They allow con-tractors to focus on the areas where they dohave experience and can excel: selling and in-stalling jobs, particularly the electrical portion.System packages help keep contractors out


Select a solar distributor with depth and breadth of inventory

Grid-Tie Systems from SunWize Technologies:complete, pre-engineered solar electric systemsmake entry into solar easy

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 30

Visit us at: www.dexterchaney.com


Visit us at: www.cementexusa.com


Visit us at: www.ezmeter.com



In August of 2009 NAB-CEP announced a newprogram that would en-

able journeymen electriciansto gain the experience re-quired to sit for the NABCEPexam. This program wascalled the Alternative Experi-ence Pathway (AEP). Its guid-ing principle recognizes theextensive knowledge and skillthat it takes to earn journey-man electrician recognitionand provides a “fast track” ap-proach to these individualsgaining their PV installationexperience.In brief, this new pathway

allows teams of up to fourqualified electricians (jour-neymen) work together on aPV installation that is doneunder the supervision of aproctor. Each of the team members will get installation credit forthese installs that is unique in the NABCEPEligibility Requirements– in all other cases only a single individual can get credit for anygiven installation.At first the program met with some resistance, many seasoned

PV installers felt that the AEP would water down the eligibility re-quirements to take the exam. This is in fact no way the case. Theonly people who even qualify for this installation experience path-way must be journeymen electricians (or be recognized as a qual-ified electrician by their AHJ) and they must have a minimum of40 hours of PV specific training that includes the hands-on in-stallation of two distinctly different PV systems, plus the two sys-tem installs that are part of this Alternative Experience Pathway.This means that candidates qualifying to sit for this exam willhave participated in a minimum of four PV installs.Don Warfield, Chairperson of NABCEP says, “The Alternative

Experience Pathway program enables a large block of otherwisequalified craftsmen to qualify for certification and increase thesupply of Certified workers in markets which place high value oncertification”Chris LaForge, a veteran solar installer, electrican and ad-

vanced PV trainer who works with the non profit solar trainingorganization the Mid West Renewable Energy Association(MREA) agrees, he says; “At the MREA we find that qualified

electricians are buildingtheir skill sets quickly andfully meeting the goals out-lined in NABCEP’s taskanalysis. The new pathwaywill allow us to provide theopportunity for more of ourmost qualified students tomeet the experience re-quirements to sit for the PVCertification Exam. ”In the past year Alternative

Experience Pathway installa-tions have taken place inTexas andMontana. The firstround of candidates whocompleted their training andinstallations at the Austin JTCtook the NABCEP CertifiedPV Installer Exam in Sep-tember – and their passingscore percentage was higherthan the average.

In Texas the AEP program has been used in conjunction with aDepartment of Labor grant to train out of work or underemployedjourneymen electricians to play senior roles on PV installation pro-jects. The project is a joint venture between the Austin Texas JATC(Joint Apprenticeship and Training Center) and ImagineSolar – aprivate PV training company. This unique partnership brings to-gether the combined strengths of a nationally recognized PV cen-tric training organization and the outstanding facilities of a JATC.“We are proud that the solar training roadmap and the state-of-

the-art Solar Field Lab, designed by ImagineSolar, have enabled ourmembers to be approved to sit for the NABCEP Certified PV In-staller Exam,” stated Gilbert Ferrales, Training Director for the AE-JATC. “None of this would have been possible if not for theDepartment of Labor Green Jobs Training Grant we were awardedearlier this year. The grant awardwas the result of our close workingpartnership with the local workforce investment board, WorkforceSolutions Capitol Area, and ImagineSolar.”Response to this program from Electrical Contractors has been

equally positive. “ImagineSolar provided not only a pathway to theNABCEPCertification Exambut also in-depth installation experienceon cutting edge solar.” said Jack Payne, Owner, B.J. Electric, and amember of the AEJATCBoard of Trustees.ImagineSolar starts their students out in an extensive classroom

and laboratory based training program that runs 120 hours. In addition

NABCEP Alternative ExperiencePathway for Qualified Electricians

By – Ezra Auerbach

Feature +

0211TECp06-48:0211TECp06-48 3/1/11 12:27 PM Page 34

Visit us at: www.aetenergy.com



Feature +to theoretical learning the students participate in group installations thatincludes a wide variety of system types including; AC-coupled bi-modal systems, micro-inverters, dual-axis trackers, and cylindri-cal CIGS modules as well as traditional solar technology. In shortthe students are exposed to a very wide range of equipment andinstallation types. After completing the classroom and hands ontraining the students are broken into teams of four, as a team thecomplete two installations at the JATC. To ensure that the stu-dents are as close as possible to “real world” installation condi-tions the systems are all inspected and approved (or rejected) bythe AHJ.

In Austin, incentive payments for PV installations are tied to arequirement to have NABCEP Certified Installers on the job. Thisproject is helping ensure that there is a ready supply of well trainedand fully qualified available as solar electric installations becomeincreasingly prevalent.

The Montana Electrical Joint Apprenticeship and Training Com-mittee took a different approach to their implementation of the AEPprogram. Thanks to the dogged determination of Mitch Hegman, theAssistant Training Director at the JATC a community-based installa-tion was located. A team of four electricians, who took advanced PVtraining at the JATC, worked together to install a PV system on theEast Valley Middle School in East Helena, MT. This job provided theelectricians working on the project with valuable real-world PV in-stallation experience, which, of course, entailed the odd bit of difficulty– the wrong fasteners for the mounting frame slowed down progress

Visit us at: www.krenzvent.com Visit us at: www.arpiusa.com

0211TECp06-48:0211TECp06-48 3/1/11 12:28 PM Page 36

Visit us at: www.surgepure.ca



Feature +

while someone was dispatched to the nearest hardware supplier forthe correct length screw.

The “real world” intervened in the installation a second time.An is-sue with cabling arose when installing the monitoring system – toaddress the problem one of the installers had to interface with the ITperson at the school. Mitch Hegman says; “This issue is illustrative ofthe technical problems that can ‘haunt’ installers and lead to unantic-ipated expenditures of time. In that regard this problem was almostfortuitous with respect to the intent of this program to present someobstacles for the installers to solve.”

Mr. Hegman says. “I am very pleased with the performance ofthe installers. I think we can all agree that these candidates longago achieved ‘expert’ status in skills such as interpretation of theNEC, raceway installations, conductor sizing, etc. The trainingthroughout this venture however, has been remarkably produc-tive in bringing them to the front edge of PV design and installa-tion.” He continues; “The Middle School was actually the thirdsite selected for the PV system. Both previous locations failed to

progress beyond the permitting processdue to structural loading beyond existingroof design – all of this made for valuablelessons in site surveys, permitting andsystem design.”

This 4.48 kW installation of two stringsof ten 224 Watts Sharp PV modules is vir-

tually a letter perfect example of the intentof the AEP program because it provided value to multiple stake-holders. Not only did the candidates get the experience they neededto sit for the NABCEP exam they also made a lasting contribu-tion to their community. East Valley students, parents and schoolstaff will long see the benefits offered by solar electricity thanks tothis project.

The Alternative Experience Pathway installation opportunity isopen to all Joint Apprenticeship Training Centers. It offers a greatway for qualified electricians who take advanced training based onthe NABCEP PV Installer Job Task Analysis to get the experiencethey need to take the Certification Exam. It also presents a great op-portunity for training centers to work with their community andmake a positive contribution to the greening of the local electricalgrid. NABCEP strongly encourages collaboration between contrac-tors, JATCs, utilities and community groups to use lasting, real-world project for Alternative Experience Pathway installations. Formore information on this program readers should contact the authorat [email protected]. �

The Alternative Experience Pathway installationopportunity is open to all Joint ApprenticeshipTraining Centers.

Visit us at: www.udevices.com

0211TECp06-48:0211TECp06-48 3/1/11 12:28 PM Page 38

Visit us at: www.kvar.com


Multi-Contact is a well known manufacturer of preci-sion electrical and electronic connectors and interconnec-tion systems. Multi-Contact’s extensive history andexperience in creating cutting-edge electrical connectionsserves some of the world’s most demanding applications inrobotics, test and measurement, military, aerospace, medical,solar energy, power distribution, and many others. MC con-nectors are designed for high performance and high matingcycles, and they are ideally suited for high-current applica-tions. The renowned Multilam technology was created sixdecades ago and has been integrated into the complete connec-tor line that Multi-Contact continues to create today. All Multi-Contact products are built upon this timetested and provenMultilam band technology. The Multilam is unmatched in termsof low resistance, low insertion forces and reliability. Multi-Contact also offers both standard and custom connector solutionsfor all types of interconnect application.Multi-Contact takes great pride in focusing on emerging tech-nologies. MC‘s pioneering history within the solar industry iswell documented, mainly because the manufacturing back-ground allowed them to create the very first solar specificconnector, dating back to the 1980’s. Multi-Contact’s line ofplug connectors for data and power ranges from mini-sizedconnectors to high-current connectors that are more thancapable of carrying several thousand amperes. Thisbackground and experience allowed MC to naturally en-ter the photovoltaic sector, where the MC Solarline isone of the market leaders for connections in cablingsystems for all types of solar array systems (Multi-Contact was the first company to manufacture and of-fer such a photovoltaic connector product to anyonewho wanted one). As MC continued to be the only com-pany offering standard solar connector parts from inven-

tory, they saw the market go from very small specialized niche groupof people to inevitably, a huge political interest before any othercompany was even able to make their first solar connector.Multi-Contact has put forth great effort in making the most reli-able and precision quality solar connector possible. Its solar con-nectors are part of some of the longest standing Solar Arraysstill up and running to this day. The proprietary blend of metalalloys along with the Multilam technology, and quality assur-ance checks and balances, has made the MC Solarline of con-nectors (including both MC3’s and MC4’s) the solarindustry’s strongest and most reliable connectors. MC’s timetested track record speaks for itself.To ensure proper usage and installation practices of MC’s solar

Feature +

Multi-Contact, servingsome of the world’s mostdemanding applications.


0211TECp06-48:0211TECp06-48 3/1/11 12:28 PM Page 40

Visit us at: www.multi-contact.com



connectors, they offer many programs to solar professionals. MCwants to make every MC solar connection as concise and as easy aspossible, for the safety for everyone involved. Solar integrators andend users alike can count on MC connections being both reliable andheld to the highest safety standards in existence. MC offers an MC3connector certification program as well as an MC3 and MC4 tutorialvideo that serves as a step by step guide detailing all the instructionsneeded to make and assemble these simple yet powerful connections.With quality standard products and custom-designed solutions to meetcustomer needs, Multi-Contact has a proven track record as a reli-able business partner and design pioneer. Multi-Contact credits itscommitment to quality and reliability as the secret to its long-termcustomer relationships.The MC3 and MC4 connectors meet or exceed all county,

state, and federal regulatory building codes. Multi-Contacthas been certified according to the quality management stan-dard ISO 9001-2008. Multi-Contact’s products comply withcounty, state, and federal regulatory building mandates andare in compliance with many other safety standards and cer-tifications–notably UL, NEC, IEC and TÜV. Other productcertifications include cUL, RoHS, DIN EN, CTS, ESTI, VDE,and many more. Note that such compliance to codes are part

of the review and approval processes by government job inspectors.Multi-Contact has a very strong global presence; it is part of the

Stäubli Group, an international mechatronics solution provider. Be-ing involved with so many different types of innovative technologieshelps both establishments stay in tune as well as contribute to many oftoday’s emerging products. Multi-Contact’s headquarter is locatedin Switzerland and has sales offices globally, with new offices inMexico Russia and India. Multi-Contact’s North American Head-quarters is based North of San Francisco in Windsor, California. Fur-ther production sites are located in France, Germany, U.S.A., andChina. Business units operate across Europe, as well as in Asia andthroughout the Americas.

For further questions or inquiries please contact Brian Pfister at707-548-4780. �

Feature +

0211TECp06-48:0211TECp06-48 3/1/11 12:29 PM Page 42

Visit us at: www.solmetric.com



T horough site evaluation will notguarantee a successful solar in-stallation, but it can definitely in-

crease the chances.Solar site evaluation can be a key

success factor for solar installers. It re-quires a thorough knowledge of solarfundamentals as well as up-to-date in-formation on the latest tools and bestpractices. When performing site eval-uation, the solar professional needs togather data, including:• Roof orientation, including azimuthand tilt

• Roof area available for solar array• Shade measurements for energycalculations

• Conduit and inverter locationsIf this data is gathered quickly and

efficiently, then the time investment iskept to a reasonable level. Perhapseven more importantly, the client is leftwith a positive impression, and thechances of winning the business areimproved. The data must also be thor-ough, so that all information requiredto do a system design or proposal isavailable, without guesswork or with-out requiring a second site visit. In thisarticle we will discuss some of com-mon site evaluation challenges andsome new tools that can help improvethe accuracy and efficiency.

SHADE MEASUREMENT TOOLShade measurements are normally

performed using a manual reflectingglobe, or an integrated automatic ap-proach using a fisheye lens. The auto-matic fisheye lens approach is used by the Solmetric SunEye™,and can offer significant advantages in accuracy and time-savings. Shade readings are taken from a specific location onthe roof and processed immediately to show solar access per-centage, and also the time-of-shade, that is what months, andwhat time of day, surrounding obstructions will cause shade.

FINDING SHADE-FREE ZONESThe SunEye incorporates an electronic compass and level

for proper orientation during shade measurements. Direction

and tilt are measured continuously,and sun paths for the current locationare calculated and drawn on thescreen in “Live Preview” mode. As theoperator moves, the image updates.This function enables the operator tosee where obstructions (chimney, tree,other structure, etc.) will cause shade.By defining a desired “shade-free”window, such as 9am to 3pm year-round, the operator can move to theedge of a shade-free zone, and markthat location on the roof, for examplewith chalk. When completed, the usercan map out an array area that willassure shade free production in thistime window. The window can be de-fined with a start and stop time, and astart and stop month.

MEASURING WHEN METALINTERFERES WITH COMPASSA compass relies on the earth’s

magnetic field to its orientation read-ing. When using the compass nearmetal, readings can be distorted in anunpredictable way. In this case, Sun-Eye shade readings can still be takenusing a reference heading other thanthe compass, such as the seam of theroof, or the heading of a far away ob-ject. The user can enter the referencedirection, and the invalid compassreadings are over-ridden.

SOLAR ACCESS “UP THERE”In many situations, shade measure-

ments are required, but access is notavailable. For example, n many site

evaluations, it may be difficult to access the exact location ofthe solar array. For example, the roof access may not be au-thorized at the time of the evaluation or the proper safetyequipment may not be available. A new building or solar park-ing canopy may not be constructed yet, or step ladders maynot reach high enough and scissors lifts or boom lifts can be ex-pensive and complex.For these situations, the SunEye Extension Kit enables the

measurements from ground level up to 18 feet. The SunEye ismounted securely on a plate, then raised up on the telescoping

Feature +

Finding your place in the sunBy Peter Hoberg

Solmetric Corporation

Solmetric SunEye has integrated fisheyelens and touchscreen user interface.

0211TECp06-48:0211TECp06-48 3/1/11 12:29 PM Page 44

Visit us at: www.haywardbaker.com



pole to the desired level. Measure-ments are triggered by rotating thepole.

PREPARING FOR SITE VISITSAerial photography is freely

available from Google, Bing orother sources, and can be an ex-cellent way to prepare for a sitevisit. By inspecting both overheadand oblique (angled) views of thesite you can estimate the roof sizeand identify trees or buildings orother structures that may causeshading or roof access difficulty.However, care must be taken when using this information:• Make sure that you have zeroed in on the right building orsite. Address information alone cannot always assure thatthe right building or site is identified. I have heard stories ofcomplete solar proposals being prepared for a willing cus-tomer, but on the wrong house. Sometimes this requires aphone call or two, but it is definitely worth it to avoid theembarrassment.

•Beware that the images may beone to three years old. Structuresmay be missing, trees may havegrown, etc., both on the propertyand on neighboring properties.Images represent a useful snap-shot in time, but it is important toalso look for changes and newdevelopments.• Resolution may be limited. Thequality of imagery quality varies byregion and over time. Larger on-roof obstructions such as chimneysmay be visible but smaller ones,such as vent pipes, may not be.

Overall, aerial images provide a great way to prepare for asite evaluation. But they do not replace the need for on-sitevisual inspection.During a site visit, SunEye readings can be located on the

roof and afterwards viewed in Google Earth™.With the right tools and training, effective on-site evalua-

tion and shade measurements can help increase your chancesof success in solar. �

Feature +

SunEye Extension Kit enables measurementsup to 18 feet above ground level.

Identify shade-free areas using SunEye window.

0211TECp06-48:0211TECp06-48 3/1/11 12:30 PM Page 46

Visit us at: www.lappusa.com



Advertiser Index +AET Energy 35 www.aetenergy.comALCAN BC www.alcan.comARPI 36 www.arpiusa.comBierer & Associates 25 www.bierermeters.comCalifornia Turbo 29 www.californiaturbo.comCementex 32 www.cementexusa.comConduit Repair 21 www.conduitrepair.comDexter + Chaney 31 www.dexterchaney.comDH Solar 11 www.dhsolar.netE- Z Meter 33 www.ezmeter.comHatiCon Solar IFC www.haticonsolar.comHayward Baker 45 www.haywardbaker.comHigh Voltage 24 www.hvinc.comHioki USA 5 www.hiokiusa.comJonas Software 7 www.jonasconstruction.comKrenz Vent 36 www.krenzvent.comKVAR 39 www.kvar.comLapp U.S.A 47 www.lappusa.comLegrand/Cablofil 1 www.legrand.us/cablofilME Products 15 www.meproducts.netMulti - Contact 41 www.multi-contact.comNABCEP 12 www.nabcep.comNoren Products 3 www.norenproducts.comNorthwest Lighting Systems, Co. IBC www.northwestlightingsystems.comPelsue 13 www.pelsue.comPhase- A- Matic 19 www.phase-a-matic.comSED 2 www.SEDPV.comSolmetric 43 www.solmetric.comSun Wize 27 www.sunwize.comSurge Pure 37 www.surgepure.caSurge Suppression 17 www.surgesuppression.comUnderground Devices, Inc. 38 www.udevices.comUtlity Metals 23 www.utlitymetals.comZistos Portable Video Systems 9 www.zistos.com/EC.htm

Company Name Page Number Website

0211TECp06-48:0211TECp06-48 3/2/11 9:34 AM Page 48

Visit us at: www.northwestlightingsystems.com


Visit us at: www.alcan.com


tec 3.11

Documents

pm page c1visit

pm page c2visit

feature 0211tecp06

electrical industry

againstthe publisher

qualified ownersand

settlement control

groundwater control