Net Zero Agricultural Building | Normal, Illinois
216 kW | Net Zero Building | IBEW Union Installation
Key Highlights:
- Designed and installed to match architectural layout on mixed roof types (standing seam + flat)
- Zero roof penetrations across the entire 216 kW array
- Delivered under budget and on schedule for our scope, despite changing construction timelines and strict labor requirements
Project Overview
The Client
Heartland Community College – a new agricultural building on campus near Illinois State University in Normal, Illinois.
Project Type
Brand new construction, designed from the ground up as a net zero facility with sustainability at its core.
Our Role
Solar design-assist and turnkey commercial installation, working alongside the project’s electrical contractor.
Key Details
- Location: Normal, Illinois (Ameren territory)
- Building Type: Academic/Agricultural facility
- Scope: 216 kW rooftop solar PV, net zero design
System & Design Highlights
Roof & Mounting Strategy
- ~75% on pitched standing seam roof – Clip-on attachments with no penetrations
- ~25% on flat roof – Fully ballasted system with no penetrations
- Zero roof penetrations across the entire array, protecting the building envelope and roofing warranty
Architectural Alignment
The solar array was originally laid out in the architectural drawings, including a staggered/diagonal aesthetic on the standing seam roof. Windfree:
- Matched the design intent and aesthetic vision
- Adjusted for real-world spacing, roof vents, and code requirements
- Selected panel dimensions and racking that fit the drawings and structural constraints
- Worked collaboratively with the design team to ensure the final product met both form and function
Design Philosophy: Reality-Aware Engineering
We work from architectural plans and respect design intent. When specs call for products that are outdated, discontinued, or unavailable, we identify the closest viable alternatives and coordinate approvals—so the vision becomes a buildable, warrantable reality.
Equipment Strategy
Windfree is inverter-agnostic and equipment-agnostic. We source what’s specified when it’s available. When it’s not, we propose code-compliant alternatives that meet performance and aesthetic goals.
How This Project Was Delivered
Contracting & Coordination
This project was delivered through the electrical contractor as part of a larger new construction effort. Solar on new builds can be contracted in multiple ways:
- Through the general contractor
- Through the electrical contractor
- Directly by the owner
Windfree has experience working within all three structures and adapts to the project delivery method that makes sense for the team.
Labor Requirements & Flexibility
This project required union labor (IBEW). Midway through, a labor requirement surfaced that wasn’t originally communicated in the bid documents. We:
- Pivoted quickly from our non-union in-house crew to our union crew
- Remobilized with minimal downtime (~1–2 weeks)
- Kept the project on track and under budget for our scope
Our Labor Approach
Windfree maintains both in-house non-union teams and union teams (IBEW), allowing us to meet the specific requirements of each project—whether it’s a private commercial build, a public institution, or a faith-based facility. We’re deeply familiar with prevailing wage vs. union distinctions and the labor rules tied to Illinois solar incentives.
“Solar incentives in Illinois come with very specific labor rules. Project teams shouldn’t have to become experts in solar labor compliance—that’s our job.”
Financial & Performance Snapshot
Typical numbers for a similar 200–220 kW project in Illinois
What a 200–220 kW New Build Project Typically Looks Like
Approximate CapEx (Union, Public-Type Project): ~$600,000
Typical Incentive Stack (for projects that monetize RECs):
- 30% Federal ITC (Investment Tax Credit)
- +10% “Energy Community” Adder (applies to ~85% of Illinois sites)
- ~10% Utility Rebate (ComEd / Ameren)
- ~30% of project cost via SRECs (if customer sells their Renewable Energy Credits)
Typical Annual Energy Savings: ~$22,000/year (at current rates)
Typical Monthly Load Offset: ~$8,000–$9,000/month
Typical ROI (with full incentives): ~3 years
Note: Heartland College chose net zero status, so they retained their RECs rather than monetizing them. This gave them the sustainability credentials needed for net zero certification. Savings increase over time as utility rates rise—solar acts as a long-term hedge against future energy costs.
Common New Build Challenges & How We Address Them
New construction projects involve coordination across multiple trades, tight timelines, and evolving site conditions. Here’s how we help keep solar on track:
1. Labor & Incentive Compliance
The Challenge: Solar-specific labor requirements tied to state and federal incentives (union vs. prevailing wage, etc.) aren’t always well-understood early in the bidding process.
The Risk: Mis-specified labor in bids, last-minute union demands, incentive jeopardy, budget surprises.
Our Approach: We ask the right incentive and labor questions at the very beginning. We advise on whether the project should be union or non-union to keep incentives intact. We maintain both in-house and union crews, so we can pivot quickly if requirements change.
2. Product Availability vs. Architectural Specifications
The Challenge: Architectural specs sometimes call out panels, inverters, batteries, or racking that are outdated, no longer manufactured, not certified/available in the region, or not realistically priced.
The Risk: Delays, redesigns, last-minute substitutions, change orders.
Our Approach: We’re equipment-agnostic and deeply familiar with what’s actually on the market. We review the solar specs in the plans, identify what’s still available and viable, propose approved equivalents when needed, and align with the design team so aesthetics and performance goals are met.
3. Crane & Site Access on Finished Landscapes
The Challenge: Solar is often one of the last trades on site. By the time we arrive, landscaping, hardscaping, and finishes may already be in place—but we still need crane or scissor lift access.
The Risk: Tearing up new landscaping, hardscape damage, extra cost, and friction between trades.
Our Approach: We flag access needs early (crane paths, staging areas, lift access). We coordinate to schedule our heavy lifts before landscaping and final finishes whenever possible. Our experience helps avoid situations where access becomes impossible or damaging.
4. Conduit & Interior Routing During Construction
The Challenge: On new builds, solar conduits are sometimes treated as an afterthought.
The Risk: Walls closed, ceilings finished, then solar conduit needs to be run—forcing demo of brand-new work.
Our Approach: We plan interior conduit runs during rough-in, not after finishes. We coordinate to route conduit while walls and ceilings are open, avoiding rework, delays, and added cost while keeping the project clean and organized.
5. Roof Attachments & Roofing Warranties
The Challenge: Attachments on flat roofs can impact structural loads and roofing warranties if not coordinated properly.
The Risk: Warranty disputes, water intrusion issues, finger-pointing between the roofer and solar installer.
Our Approach: We use structural engineering to determine whether ballasted, attached, or hybrid mounting is appropriate. We coordinate closely with the roofing contractor during roof installation—not after. Whenever possible, we use clip-on or non-penetrating solutions (as we did at Heartland).
6. Utility Interconnection (Ameren, ComEd, etc.)
The Challenge: Utilities like Ameren can be time-consuming and exacting with interconnection requirements.
The Risk: Delays in permission to operate (PTO) and project close-out.
Our Approach: We handle the back-and-forth with utilities. We test and commission systems to the utility’s satisfaction, even when that involves multiple rounds of review. Our experience with both ComEd and Ameren across Illinois reduces surprises and keeps projects moving toward PTO.
Timeline: When to Bring Solar Into a New Build
(Hint: Not at the End)
Typical overall project timeline: 10–18 months from bid to permission to operate (PTO)—because the building itself takes time.
Solar is often one of the last trades to physically touch the building, but should be contracted at the beginning alongside other major trades.
Suggested Project Phases:
- Concept & Design (Pre-Bid)
Owner and design team target net zero or net positive performance. Solar layout, structural considerations, and electrical concepts are reviewed early. - Bid & Contract Award
Solar contractor selected based on experience and pricing. Labor requirements and incentive strategy confirmed. - Construction Phase Coordination
Roof structure and membrane scheduled with solar coordination in mind. Interior conduit runs planned and installed during rough-in. Paths for crane/lift access reserved. - Solar Installation
Racking, modules, and inverters installed. Roof and building finishes protected throughout. - Commissioning & Interconnection
Testing, inspections, and utility permission to operate. Building achieves net zero or net positive goal.
“We can physically install faster—but the best results come when we’re involved from day one so everything is coordinated around the build sequence.”
Results & Outcomes
For Heartland College:
- New net zero agricultural building with a 216 kW rooftop system
- No roof penetrations across the entire array
- Solar layout aligned with architectural intent
- Installed under budget and on schedule for our scope, even with labor pivots and utility complexities
- Building achieved net zero status with retained RECs
For Similar Projects:
- ~3-year payback with full incentive stack
- ~$8–9k/month typical load offset on similar-sized facilities
- Long-term hedge against rising utility rates
- Sustainability credentials for LEED, net zero, or net positive certification
Why Project Teams Choose Windfree for New Builds
- We’ve delivered numerous new build projects on public and private facilities across Illinois and the Midwest
- We’re experienced working within multiple contracting structures (owner-direct, through the GC, or through the electrical contractor)
- We understand union vs. non-union vs. prevailing wage requirements, complex incentive stacks, and how to protect project schedules and budgets from solar-related surprises
- We act as the solar specialist on the team:
- We check architectural solar specs for real-world viability
- We coordinate with roofers, electricians, and site supervisors
- We keep utilities like Ameren and ComEd moving toward permission to operate
- Since 2009, we’ve been helping customers save money and harness clean energy—with over $1.4 million in savings delivered to residential customers alone in 2024
“If you already know you want solar on your new building, our job isn’t to convince you—it’s to deliver a gold-standard system and make the process seamless for the entire project team.”
Planning a Net Zero or Net Positive New Build?
If you’re working on a new build with ambitious sustainability goals, bring Windfree Solar in early.
We’ll review your plans, flag any potential issues with materials, labor, and incentives, and help you design a solar scope that actually works in the real world.
Windfree Solar
Chicago, Illinois
Certified Minority Owned Business (MBE) | Equity Eligible Contractor (EEC)
Serving Illinois and the Midwest since 2009