Solid Solar Commissions 20 MWp Hilly-Terrain Solar Power Plant in Uttarakhand Using Gautam Solar TOPCon Bifacial Modules

Solid Solar Pvt. Ltd. has commissioned a nearly 20 MWp solar power project in Malna/Patara village of Uttarkashi district, Uttarakhand. Described as one of India’s largest solar plants developed on hilly terrain, the project has been constructed across a single hill at an elevation of more than 5,000 feet above sea level. The plant is powered by Gautam Solar’s n-type TOPCon bifacial modules.

Developing a solar power plant of this scale on a single hill presented several engineering and logistical challenges compared to conventional flat-terrain installations. The steep, rocky and uneven landscape, remote Himalayan location and limited accessibility required Solid Solar to adopt innovative construction methods to address challenging terrain, harsh climatic conditions, wildlife risks, logistical constraints and manpower limitations.

One of the primary challenges involved designing the plant layout to accommodate significant variations in elevation and terrain. To address this, Solid Solar developed a detailed 3D model of the entire hill, enabling its design and engineering teams to plan the placement of solar modules and supporting structures according to the site’s actual contours. This approach helped optimize the available space and sunlight while ensuring a precise layout.

Construction activities presented additional difficulties, as conventional vehicles could not access most sections of the hill. Solid Solar developed several cost-effective and innovative solutions to overcome these limitations, including a ropeway system for transporting materials and solar modules across difficult sections of the site.

According to the company, relying entirely on manual material handling or conventional ropeway systems would have resulted in significantly higher costs and longer construction timelines. In areas where the ropeway was not feasible, the project teams adopted alternative methods, including a controlled sliding mechanism, a manpower-based chain-link system and the use of kachhars (mules) to transport materials across particularly challenging stretches of the hill.

The rocky terrain also complicated piling and foundation work, as conventional heavy machinery could not be deployed across most of the site. Solid Solar used portable handheld equipment for rock breaking and drilling, allowing construction teams to operate in locations inaccessible to larger machinery. The project also incorporated chemical grouting to secure columns, adapting a technique more commonly associated with rooftop solar installations to the specific requirements of the rocky hillside.

Gautam Solar’s n-type TOPCon bifacial modules have been installed across the project. These modules are designed to generate electricity using sunlight received on both sides of the panel. Their deployment brings advanced solar technology to a project requiring equipment suited to demanding geographical and operating conditions.

The plant has reportedly demonstrated stronger performance than several other solar installations in the surrounding region. However, actual generation performance depends on various site-specific and operational factors.

Mukesh Agrawal, Managing Director, Solid Solar Pvt. Ltd., said, “Building a plant of this scale on a single hill required meticulous planning, innovative thinking to develop out-of-the-box solutions and close coordination between the design and site engineering teams. The successful commissioning of our 20 MWp Solar PV Plant in Malna/Patara village is an important milestone for us and reflects the engineering effort that went into its execution. As the project neared completion, its scale and complexity attracted several visitors who came to see the solar plant, with some describing it as an ‘engineering marvel’ underscoring the exceptional complexity of developing a large-scale solar plant across a single, highly uneven hill.”

Gautam Mohanka, Managing Director, Gautam Solar Pvt. Ltd., said, “The Uttarkashi project demonstrates the potential for advanced solar technology to be deployed in challenging geographical conditions. Our TOPCon bifacial modules powering this project are part of an approach that combines technology with site-specific engineering and meticulous execution.”

The commissioning of the Uttarkashi solar project represents a significant development in the deployment of renewable energy infrastructure across challenging geographical locations in India. Beyond its nearly 20 MWp capacity, the project highlights how site-specific engineering, innovative construction techniques and advanced solar technologies can support large-scale solar power development in mountainous regions where conventional construction approaches may not be practical.