Solar Farm UPS Foundations Re-levelled Without Disruption

A number of UPS foundations across the solar farm had experienced subsidence of up to 100 mm, creating uneven support beneath critical renewable energy infrastructure. The issue required a solution that could re-level the affected foundations while improve the underlying ground conditions to provide long-term support.

The project presented several challenges. Underground cables beneath each foundation had to be accurately identified before drilling could begin, and the UPS panels needed to remain fully operational throughout the works. In addition, site conditions included uncontrolled fill and loose sandy material, which required careful management to achieve consistent ground improvement and controlled lifting.

Mainmark reviewed cable layout drawings to confirm the location of underground services and establish safe drilling positions beneath each footing, which ensured the lifting works could be carried out safely and precisely. The works were also coordinated with two members of the client’s electrical team, who assisted with loosening cable connections and verifying cable locations to help minimise the risk of damage during the lifting process.

Baseline level readings were then taken at the four corners of each foundation to determine the extent of subsidence and identify the lowest points requiring correction. Based on these survey results, angleddrilling was carried out to target approximately 600 mm below the  underside of each footing.

Teretek® was then injected in a controlled sequence at the four corners of each of the 61 UPS foundations, with each foundation measuring approximately 1.5 m x 1.5 m and 300 mm deep. As the engineered resin expanded, it filled voids, improved the bearing capacity of the underlying soils and delivered controlled lift to re-level each footing.

Due to the presence of uncontrolled fill and loose sandy material, injection rates and volumes were carefully managed to achieve consistent ground improvement and uniform lifting performance across the site.

Following completion of the injection works, post-treatment level surveys were undertaken to verify that the required level correction had been successfully achieved across all foundations.

In addition to achieving the required level correction, the Teretek® treatment improved ground bearing capacity beneath the foundations, providing a long-term remediation solution.

The works were delivered without compromising the underlying cable network or interrupting the live UPS systems, allowing the client to maintain full operational continuity throughout the project.

Completed ahead of schedule, the project highlighted the speed, precision and effectiveness of Mainmark’s remediation approach, delivering the required ground improvement and re-levelling outcomes with minimal disruption to site operations.