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CC2530: Large network formation

Part Number: CC2530
Other Parts Discussed in Thread: Z-STACK

Hi,

We have a znp coordinator and around 100 routers.
the routers are installed on site and are in factory new state.

We need start the coordinator and add these routers to the network.
The coordinator is started in a particular channel and Pan.

The permit join is set for the coordinator.
Some routers join the network.Now we enable permit join for those routers and some more routers join...

after several iterations of this process we expected the network formation to be completed. But we faced the following problem:

After the no. of joined  routers exceed a certain threshold value the network gets flooded.
This happens because of the all routers( who are in network) responding to the beacon request of other routers (who want to join the network).

how can we control this flooding?
Is there a better way of forming a larger network?

*Note
The routers cannot be powered off.