Solar Panel Ballast Blocks for Lamby Way Solar Farm
Delivering 4,000 precast units for a 42-acre renewable energy project
Supporting a major solar installation with a precast foundation system
When ELMYA started work on a new solar farm at Lamby Way, Cardiff, the site presented unique challenges. Built on a 42-acre former landfill, the ground conditions were less than ideal for traditional foundations. The solution had to provide stability for the photovoltaic (PV) panels without invasive piling or in-situ works.
We manufactured and delivered 4,000 precast solar panel ballast blocks, providing a fast, flexible, and non-penetrating foundation system to secure the array in exposed conditions.
Project Overview
- Client – ELMYA
- Location – Cardiff
- Sector – Renewable Energy
- Services Provided – Design, manufacture & delivery
- Project – Lamby Way Solar Farm
- Products Supplied – Solar Panel Ballast Blocks
- Installation Duration – Coordinated multi-load delivery schedule
Project Background
The Lamby Way project is a flagship renewable energy scheme in Wales, built on a capped landfill site that has been repurposed for green infrastructure. Traditional piling or cast foundations would have been expensive, disruptive, and unsuitable for the conditions.
ELMYA required a foundation solution that was:
- Heavy enough to resist uplift in high winds
- Adaptable to different panel orientations
- Quick to install across a large site footprint
- Non-invasive, protecting the integrity of the landfill cap
Our Solution
Why Solar Panel Ballast Blocks
Our solar ballast system has a larger footprint than standard concrete blocks, making it particularly effective in poor ground conditions. The modular units can be cast in various sizes, providing engineers with flexibility in layout and load management.
We manufactured and delivered 4,000 units measuring 3m × 0.5m × 180mm, each weighing 635kg. Logistics were carefully organised to ensure a continuous supply to the site, with deliveries sequenced to align with the client’s installation programme.
Key benefits for this project included:
- Non-penetrating foundation – no drilling or piling into the landfill cap
- Fast, safe installation – blocks lifted directly into position
- Flexibility in PV panel placement and orientation
- Large surface area for stability on challenging ground
- Fully reusable if arrays need to be reconfigured in future
The Results
The solar farm was completed successfully, with ballast blocks providing a stable foundation system that ensures the long-term security of the PV arrays. The use of precast elements also meant fewer delays, reduced ground disturbance, and easier coordination on a large, complex site.
Products Used In This Project
Precast ballast blocks provide a proven foundation system for solar farms of all sizes. Without the need for invasive foundations, they’re ideal for brownfield sites, capped landfills, or areas with variable ground conditions.
- Concrete strength: C50 prestressed
- Chamfered edges, smooth mould finish
- Tongue-and-groove interlock for alignment
- Flexible dimensions: 500mm–1.5m wide, 3–6m long, 150–280mm thick
- Handling: 2 × M16 swivel lifting eyes
- Unit weight: ~635kg (standard 3m × 0.5m × 180mm)