Agrovoltaics—also known as agrivoltaics or dual-use PV systems—refers to the integrated use of land for both agricultural production and solar energy generation. By strategically combining photovoltaic (PV) panels with crop cultivation or livestock grazing, agrovoltaics enables sustainable energy development without compromising agricultural output. In fact, when designed effectively, these systems can enhance overall land productivity and contribute to more resilient farming practices, positioning agrovoltaics as a cornerstone of climate-smart agriculture.

European countries such as Italy and Spain are at the forefront of agrovoltaic adoption, incorporating it into broader renewable energy and rural development policies. For instance, in 2021, Italy committed €1.1 billion to support the installation of approximately 2 GW of agrovoltaic capacity, promoting hybrid agriculture-energy models that reinforce farm sustainability and energy independence. This growing support across the EU reflects agrovoltaics’ strategic importance in the region’s green transition and its push toward carbon neutrality.

As a trusted EPC contractor in the European renewable energy sector, Voltage Group recognizes both the potential and the engineering complexity of agrovoltaic projects. With extensive experience in solar power plant construction, Voltage Group is well-positioned to address the technical demands of dual-use systems. This article delves into the key challenges of electrical installation and metal structure assembly in agrovoltaic applications—and highlights how Voltage Group’s integrated design and construction capabilities make it a reliable partner for delivering future-ready agrovoltaic solutions across Europe.

Electrical Installation Challenges in Agrovoltaic (Dual-Use PV) Systems

Designing and installing the electrical infrastructure for agrovoltaic (dual-use PV) systems presents unique technical challenges that go beyond those of conventional solar farms. In agrivoltaics, photovoltaic panels are integrated directly into active farmland, where they must coexist with crops, agricultural machinery, and sometimes grazing livestock. This proximity significantly raises the stakes for electrical safety and reliability.

Unlike standard utility-scale solar arrays, which are typically fenced off and isolated from public access, agrovoltaic systems remain open and accessible to farmers and animals. Tractors and harvesters may operate directly beneath elevated PV structures, and animals may graze in the same fields. As a result, the risk of accidental contact with electrical components is much higher. If a machine snags an exposed cable or livestock damage occurs, it could lead to electric shock, fire, or system failure—posing serious safety and liability risks, while potentially undermining public confidence in this emerging field.

Designing for Safety in an Agricultural Context

Ensuring a robust and secure electrical design is therefore a top priority. One of the primary challenges is effective cable routing in a dynamic, dual-use environment. Agrovoltaic systems typically position PV modules higher than in conventional installations to accommodate machinery and crops, resulting in longer cable runs that must be carefully managed.

In such systems, loose or surface-laid cables are unacceptable. Farming activities like plowing, tilling, or irrigation make exposed cables vulnerable to mechanical damage and environmental wear. To mitigate these risks, best practices in agrovoltaic engineering recommend that all DC and AC wiring be either:

• Buried in conduit at depths exceeding typical tillage zones (e.g., at least 18 inches or 45 cm below surface level), or

• Securely routed along racking systems or within steel mounting poles to protect against weather and mechanical impact.

In specific environments such as orchards or vineyards, trenching may not be viable due to the risk of damaging root systems. In these cases, above-ground cable trays or overhead suspension systems may be used—provided that the cables are securely fastened and shielded from animals and equipment.

Cable Protection and Material Considerations

All cable connectors, junction boxes, and enclosures should meet at least IP65 rating standards, ensuring full protection against dust ingress, rainfall, and potential exposure to agricultural spraying systems. Materials must also be corrosion-resistant, as they will endure moisture, fertilizers, and frequent temperature variations.

Moreover, installations should incorporate lightning protection and proper grounding throughout the site. Tall metal structures on open farmland are natural lightning targets, making grounding and surge protection non-negotiable safety requirements.

Animal Interaction and Farm Machinery Risks

Special attention should be given to areas where animals graze. Even small livestock like goats or sheep can chew through or dislodge cables, so any exposed wiring must be mechanically protected and installed well out of reach. Similarly, farm equipment such as plows or harvesters should never risk entanglement with live circuits. Using vertical support poles as cable conduits, or embedding conduits within panel structures, can effectively safeguard the system.

Coordination with Agricultural Practices

Electrical design must harmonize with farm workflows. This includes:

• Locating inverters and distribution equipment at the field perimeter for easy technician access without disrupting crop zones.

• Elevating enclosures above flood irrigation levels and animal pathways.

• Clearly marking and shielding all electrical components to avoid collisions with vehicles or missteps during planting and harvesting.

• Including emergency shutoff systems that farmers are trained to operate if needed.

Agrovoltaic projects often also require enhanced monitoring systems that go beyond standard PV installations. These systems may integrate sensors for soil moisture, air temperature, or automated tilt adjustments to optimize both crop yield and energy generation.

Metal Structure Assembly Challenges for Agrivoltaic Projects

Designing and assembling the metal support structures for agrivoltaic (dual-use PV) systems requires careful coordination between the demands of solar engineering and the realities of active farming. Unlike conventional solar farms, which use relatively simple and standardized racking systems, agrivoltaic installations must function as a hybrid: part solar infrastructure, part farm-access framework.

Elevated Design for Agricultural Compatibility

One of the defining challenges is height. Agrivoltaic systems often mount PV modules at elevations of 4–5 meters (14–16 feet) above ground, using robust steel poles or trellis systems. This clearance allows large agricultural machinery—such as tractors, combine harvesters, and sprayers—to operate freely underneath the panels. In Spain, for instance, some agrivoltaic projects feature 10% of land reserved for agriculture, with wide panel spacing designed specifically to allow passage of heavy equipment.

Horizontal spacing is equally critical. Row distances between structures often range from 15 to 25 meters (50–80 feet), depending on crop type and machinery width. These wide spans create an open, canopy-like layout, more reminiscent of pergolas than dense panel arrays, ensuring minimal interference with farming.

Foundation Engineering Without Soil Disruption

Every steel support post must be securely anchored to withstand wind loads and environmental stress. However, traditional concrete foundations are often unsuitable, as they disturb the soil profile and can negatively impact farmland productivity. To preserve topsoil and support sustainable land use, Voltage Group engineers favor low-impact foundation systems such as:

• Helical piles

• Ground screws

• Ballasted footings

These alternatives minimize grading and excavation, reduce environmental disruption, and accelerate installation timelines. Where possible, sourcing adjustable mounting systems that adapt to existing land contours helps avoid the need for terrain flattening.

Adapting to Terrain and Crop Variability

Agricultural land is rarely flat or uniform. Slopes, furrows, and irregular field shapes require metal structures that can adapt dynamically while maintaining consistent panel alignment. Modular racking systems with telescopic posts and adjustable brackets offer the necessary flexibility.

Precision surveying, combined with real-time on-site adjustments, enables Voltage Group construction teams to deliver consistent tilt and array height even on uneven ground. Moreover, the system must account for future changes in farming activity. Over a 25+ year operational life, a field may switch from vegetables to hay or grain. Thus, structures should be designed to support evolving crop patterns and harvesting techniques.

Structural Durability and Weather Resilience

High-clearance PV structures present a larger surface area to wind, increasing the structural load. This demands heavy-duty materials, over-engineered joints, and deeper anchoring systems. Designs must account for:

• Wind speeds up to 120 km/h or more (per Eurocode standards)

• Snow loading in colder climates

• Vibration and impact from nearby farm operations

Steel components are typically galvanized or stainless to resist corrosion from moisture, fertilizers, and routine irrigation. Given the exposure to both weather and mechanical activity, structural robustness is a fundamental requirement.

Smart Design for Agricultural Operations

Dual-use structures must be as practical for farmers as they are efficient for power generation. Key features that enhance field operations include:

• Rounded edges and protective guards to prevent damage from contact with machinery

• Removable sections or gates for seasonal access with large equipment

• Adjustable tilt modules that can be rotated to vertical to maximize crop sunlight or create clearance for specific farm tasks

Though not standard on every project, such flexibility can significantly increase site usability. At a minimum, no structural element should obstruct regular farming routines beyond acceptable thresholds.

Efficient Assembly and Long-Term Maintainability

Building steel support structures several meters high requires professional assembly crews with experience in industrial steelwork. The process involves:

• Coordinated sequencing of foundations, posts, and panel mounting

• Heavy lifting equipment and alignment tools

• Strict adherence to safety protocols

Voltage Group oversees this process from start to finish, ensuring that solar installation progresses smoothly without disrupting agricultural cycles such as planting or harvest.

To minimize long-term maintenance costs, designs emphasize:

• Bolted over welded connections for easier replacement

• Standardized structural components to simplify part replacement

• Routine visual inspection routines that align with farm schedules (e.g., checking bolts, corrosion points, and alignment outside critical crop periods)