PowerFlex Solves for Site Complexities During 1.8-MW Solar Buildout at Lumentum Headquarters

Lumentum is a global leader in photonics, designing and manufacturing optical and laser solutions that enable next‑generation communications and industrial applications. Headquartered in San Jose, California, Lumentum combines advanced engineering with a commitment to operational excellence and sustainability, aiming for net-zero Scope 1 and 2 emissions by 2030.

The Challenge

Deploy Solar Across Multi-Building Campus Despite Uncertain Site Conditions

Lumentum partnered with PowerFlex to install a large-scale solar panel system at its San Jose headquarters, aiming to generate clean energy and improve the employee experience with shaded parking and future EV charging readiness. The campus layout presented complexities, with three buildings requiring separate rooftop systems, two primary electrical tie‑in locations to coordinate, and carports distributed across multiple parking areas around an irregular property line.

Underground anomalies compounded the challenge. Ground-penetrating radar proved ineffective in the local sandy and clay soils, which meant buried utilities and building infrastructure, such as undocumented water and electrical lines, were frequently encountered during trenching and foundation work.

Variations in seasonal groundwater levels introduced another roadblock, causing drilled carport foundations to flood as soon as they were opened. All of this had to be managed without disrupting daily campus operations and while maintaining strict safety and schedule discipline.

PowerFlex’s Solution

An Agile Installation Strategy That Turned Uncertainty Into Success

INSTALLATION TYPE

Solar Rooftop & Carport

INSTALLATION SIZE

1.8 MW

LOCATION

San Jose, CA

ANNUAL ENERGY PRODUCTION

2,638,054 kWh

INCENTIVE

Investment Tax Credit (ITC)

PowerFlex engineered and delivered a 1.8-megawatt (MW) solar solution at Lumentum’s headquarters that combines three rooftop systems with campus‑wide solar carports, totaling 3,384 modules and 21 inverters with an expected annual production of 2,638,054 kilowatt-hours (kWh). The design consolidated electrical interconnections, tying two of the rooftop systems into a single location and a third into another, while routing carport infrastructure efficiently across the campus to minimize disruption and preserve parking availability.

To overcome unknowns during the construction process, PowerFlex implemented a solutions-focused installation plan to quickly identify and mitigate challenges as they arose. When trenching encountered utilities that didn’t appear on site plans or underground scans, crews shifted from standard excavation to careful hand‑digging to protect lines and maintain safety, coordinating rapid repairs as needed to restore water or power. Because the elevated water table caused instant flooding of drilled foundations during rainy-season work, the team deployed hydro‑vacuum trucks to continuously remove water while reinforcing rebar cages and pouring concrete, ensuring structural integrity despite saturated conditions.

Throughout the project, PowerFlex maintained a weekly meeting cadence with Lumentum’s assigned project manager, facilities lead, and an executive contact, providing regular updates and aligning on field decisions to keep the build moving.

In addition to solving immediate challenges during installation, PowerFlex also considered future site needs. The final carport buildout included make‑ready infrastructure for EV charging that enables Lumentum to add chargers down the line, without major rework.

By utilizing clean energy generated by the combined solar rooftop and carport, Lumentum is able to reduce its reliance on price-volatile electricity from the grid, creating operational savings. The project also leveraged the federal Investment Tax Credit (ITC), further strengthening project economics by managing upfront installation costs.