The installation of solar panels on industrial, commercial, and logistics roofs continues to grow in Spain. However, many companies still focus solely on the photovoltaic modules and the inverter, neglecting a critical element: the solar roof structure.
A poorly designed photovoltaic system not only reduces the lifespan of the installation, but can also lead to safety problems, workplace hazards, leaks, overloads, and even serious structural failures in the building.
In this article we analyze the main risks of installing solar panels without a suitable roof structure and why structural and aerodynamic calculations are fundamental in any professional photovoltaic project.
Why is the solar structure a critical element?
The structure is the system that transmits all the loads from the solar panels to the roof of the building.
This includes:
- Self-weight of the modules
- Wind overloads
- Thermal expansion
- Vibrations
- Maintenance loads
- Extreme climate actions
If the structure is not correctly designed, calculated and adapted to the roof, the entire installation is compromised.
A photovoltaic installation is an added structural load
Many industrial roofs in Spain were designed decades ago and did not always take into account additional loads such as a solar plant.
Therefore, it is essential to verify:
- Roof load-bearing capacity
- Type of sheet metal or sandwich panel
- Existing straps
- State of conservation
- Wind zone
- Overloads according to regulations
The most common mistake is installing standard structures without adapting the system to the actual behavior of the roof.
Main safety problems without good solar structures
1. Risk of landslides due to wind
Wind is one of the main causes of failure in rooftop solar installations.
The gusts generate:
-
- Suction
- Negative pressures
- Candle effect
- Mechanical fatigue
If the structure has not been calculated according to the wind zone and the geometry of the building, the panels may shift or detach.
In large industrial roofs, this risk increases especially in:
-
- Corners
- Perimeters
- High roofs
- Isolated buildings
- Coastal areas
Applicable regulations in Spain
The calculation must take into account:
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- Technical Building Code (CTE)
- Structural Eurocode
- Wind actions
- Safety against variable loads
Furthermore, the aerodynamics of the structure directly influence the transmitted loads. Discover the wind zones in Spain according to Eurocode here.
2. Roof overload
One of the biggest risks is adding excessive weight to decks that were not designed to support it.
This can cause:
-
- Excessive arrows
- Deformations
- Sagging
- Damage to straps
- Partial collapse
Especially problematic in:
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- Old roofs
- damaged sandwich panel
- Asbestos cement
- Thin sheet metal
- Ships with corrosion
The problem of oversized structures
Some structures add unnecessary weight because:
-
- Excess material
- Poorly calculated ballast
- Non-optimized systems
Good engineering seeks to balance:
-
- Endurance
- Reduced weight
- Security
- Economic optimization
3. Leaks and damage to the roof
Poorly executed drilling is another frequent cause of problems.
Incorrect fastening can cause:
-
- Water inlet
- Corrosion
- Dampness
- Loss of watertightness
- Damage to insulation
This worsens over time and with thermal cycles. Discover our ballasted systems here.
The importance of systems compatible with the roof
Each roof needs a specific solution:
-
- Trapezoidal sheet
- Sandwich panel
- Deck cover
- Metal cover
- Sloping roof
Not all fixings are suitable for all types of roofing.
4. Occupational risks during maintenance
Poorly designed facilities make it difficult to safely access the panels.
This increases the risk of:
-
- Falls
- Module treading
- Breakages
- Workplace accidents
Many solar power plants lack:
-
- Technical walkways
- Accessible areas
- Secure distribution
- Maintenance spaces
This is where systems like CAREX help improve safety and accessibility on solar rooftops.
5. Structural fatigue and long-term problems
Although the installation may initially seem stable, problems usually appear over the years.
Factors such as:
-
- Vibrations
- Thermal expansion
- Metal fatigue
- Corrosion
- Micro movements
they can end up weakening the installation.
A poorly designed structure significantly reduces the lifespan of a photovoltaic system. Discover the benefits of preventative maintenance here.
How to avoid these problems in a solar installation?
1. Perform professional structural calculations
Before installing, the following should be analyzed:
-
- Load capacity
- Wind
- Type of cover
- Structural state
- Applicable regulations
2. Design structures adapted to the project
There is no universal structure valid for all covers.
Each project should consider:
-
- Location
- Building height
- Orientation
- Geometry
- Module type
3. Prioritize aerodynamic systems
Aerodynamic optimization allows:
-
- Reduce wind loads
- Lose weight
- Improve stability
- Reduce effort
4. Incorporate safety and maintenance from the design stage
A solar cover should allow:
-
- Secure access
- Inspections
- Cleaning
- Preventive maintenance
Security should not be added later: it should be integrated from the beginning of the project.
The solar structure is not an accessory: it is a safety feature
In many photovoltaic projects the cost of the structure represents a small part of the total investment, but its impact on safety is enormous.
A poorly designed structure can compromise:
- The solar installation
- The roof of the building
- Worker safety
- The company’s operational continuity
That’s why more and more engineering firms and companies are looking for optimized, lightweight, and technically verified structural solutions.
Frequently asked questions about safety in solar structures
Can an industrial roof support solar panels?
It depends on the structural condition, the allowable loads, and the system used. A prior structural verification must always be carried out.
What risks does wind pose to solar installations?
Wind can generate very high suction forces. Miscalculations can cause panels to shift or detach.
Is it mandatory to calculate the solar structure?
Yes. The facilities must comply with applicable structural and safety regulations in Spain.
Which tires present the most risks?
Especially:
- Asbestos cement
- Old roofs
- damaged sandwich panel
- Corroded lightweight sheet metal
Why is aerodynamics important?
Good aerodynamics reduces the loads transmitted to the cover and improves the stability of the system.
