Installing photovoltaic systems on industrial roofs is an efficient solution for generating renewable energy across large areas. However, one of the main challenges is managing the structural loads on the roof. Reducing loads on industrial facilities allows for avoiding costly reinforcements, optimizing costs, and ensuring the safety of the existing structure.
In this article you will learn techniques to reduce loads on industrial roofs , practical solutions and how to optimize the calculation of ballast in solar installations .
Importance of reducing loads on industrial roofs
Industrial roofs are typically designed to support limited loads. Adding a photovoltaic system increases the load due to:
- Weight of solar modules
- Weight of the support structure
- Ballast needed to withstand the wind
- Maintenance overloads
If these loads exceed the roof’s capacity, problems such as the following may arise:
- Need for costly structural reinforcements
- Installation size limitation
- Risk of structural deformation or fatigue
- Increased project execution time
Therefore, optimizing the design and reducing loads is essential for successful industrial solar installations .
Types of loads in solar installations
Permanent loads
They are constant and depend on the weight of the system:
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- Photovoltaic modules
- Support structure
- Ballast (in systems not directly fixed)
Variable loads
They depend on environmental and usage conditions:
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- Wind load
- Maintenance overload
- Thermal actions
In lightweight industrial roofs , the permissible additional load is usually between 10 and 20 kg/m² , which requires optimization of the design.
Techniques for reducing loads in industrial photovoltaic installations
Use of lightweight aluminum structures
Aluminum structures offer an excellent strength-to-weight ratio, reducing the permanent load on the roof.
Advantages:
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- Lower overall system weight
- Greater durability against corrosion
- Quick and safe installation
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Ideal for deck, sheet metal or sandwich panel roofs .
Aerodynamic optimization of the system
An aerodynamic design decreases wind pressures , reducing the need for ballast.
Strategies:
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- Profiles with a low drag coefficient
- Wind deflectors or anti-wind systems
- Optimized module row layout
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With this technique, ballast can be reduced by between 20% and 50% depending on the wind zone.
Ballasted systems: fixing + ballast
Combining structural fixing points with reduced ballast allows for stability without overloading the deck.
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- Useful on roofs where minimizing perforations in the waterproofing is desired.
- Optimize wind safety and reduce costs
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Strategic ballast distribution
The ballast is not distributed evenly; it is concentrated in critical areas such as:
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- Perimeters
- Corners
- Cover edges
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The central areas can carry less ballast , reducing the overall load on the structure.
Ballast calculation in industrial solar installations
The calculation of ballast must consider structural regulations and environmental factors:
- Wind zone of the site
- Building height and terrain roughness
- Geometry and inclination of the panels
- Row spacing
Basic steps:
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- Calculate wind pressures according to regulations
- Determine lifting forces on the deck
- Determine the amount of ballast needed to ensure stability
- Optimize load distribution to minimize total weight
With a suitable design, the load is reduced without compromising structural safety .
Benefits of optimizing loads in industrial solar projects
- Greater technical feasibility on existing roofs
- Reduction of structural costs
- Faster and more efficient installations
- Less impact on the building structure
- Maximizing the performance of the solar installation
These strategies allow making the most of the available surface area without exceeding structural limits .
Alusin solar and load calculations to reduce loads in photovoltaic installations
Reducing loads on industrial installations is key to the success of rooftop photovoltaic projects. Through lightweight structures, aerodynamic optimization, and precise ballast calculations , a safe, efficient, and cost-effective system can be designed. Our rooftop systems include all the necessary calculations, and our Picos Ballasted System is a prime example .
Optimizing loads not only ensures safety, but also maximizes the performance and profitability of solar installations in large industrial areas .
