Lightsource bp's NextGen Solar and construction at scale

At gigawatt scale, construction is repetition. Lightsource bp released the investigation phase of its NextGen Solar Programme: automated piling, steel instead of aluminium frames, press-fit bolt-free mounting and on-site pre-assembly could, combined, cut direct installation costs by around 22% and installation time by up to 30%.

One change touches the supply chain. NREL's July 2019 report on the US PV supply chain estimated aluminium frames at about 10% of module mass and concluded that, with most modules imported, that aluminium was likely imported too. For steel, the study saw no significant supply constraint.

In the US, a steel frame moves closer to a chain with domestic headroom. Its cost was not disclosed, citing confidentiality, and the 22% applies to direct installation, not the whole project.

Trials in the United States and Australia, with results targeted within 18 months, will validate supplier data for use from 2028. Until then, the gain is an estimate. If confirmed, it changes the numbers for anyone building at scale.