Geno - Roof

Searching the literature and inventory of existing aluminum constructions and detection of damages on fasteners:

Different working groups for solar panel roof installations have carried out a preliminary feasibility study by examining some engineering/technical parameters that will add a new concept to the literature and the state of the art. Within the scope of this study, firstly, the preferred panel sub-constructions for different types of roof coverings that will be used for roof solar power plant (GES) applications were classified and an inventory of the mounting systems used in existing applications was made.

The list of activities based on working groups carried out within the scope of the work package is as follows:

1-Defining the general concepts related to renewable energy sources

2-Listing the general structures of roof solar power plant (GES) systems

3-Doing literature research on panel sub-construction types

5- Classification of the panel sub-constructions preferred for the area where the roof GES application will be made, according to the roof covering type

6-Determining the software to be used for finite element analysis

7-Making scans to select the appropriate mesh geometry related to the finite element technique

Damages and weaknesses in the existing aluminum construction and fasteners, for which inventory work was carried out, were determined. Depending on the load transfer mechanism of the carrier system, the elements and regions where the damage is concentrated have been determined.

Two commercial applications have been applied on all roof coverings of two facilities whose solar panel mounting construction is still in progress. As a result of the tensile tests, the force values are determined for the existing roof covering. The determined force values are the force value that will occur when the self-tapping screw (ejot screw) is stripped from the roof covering. The spacing and number of self-tapping screws (ejot screw) on which the solar panel sub-construction elements are supported are calculated based on the determined force values. In this way, the optimum number of smart screws (ejot screws) can be selected and extra screws are avoided. The application cost can be reduced by using the optimum number of screws.

Figure 4. Tensile Test Sample Application Images for Different Types of Roof Coverings

Development of solar panel mounting construction for terrace roofs:

In Tükiye, solar panel mounting construction is generally supported on the roof by using additional weights (concrete curbstones, etc.) on the terrace (flat) roofs. This application both extends the assembly time and creates additional costs for the project.

Solar panel mounting construction development studies were carried out for terrace (flat) roofs. For solar power plants to be installed on terrace roofs, the product was developed by modeling and designing blocks made of concrete material, which will serve as both weights and construction. The developed concrete blocks consist of 3 separate parts and by changing the weight of one of the pieces, concrete blocks with the required weight can be produced for each GES project. These developed concrete blocks both reduce the installation time of the plant and reduce the installation cost of the plant by replacing the additional weight used to support the aluminum construction in existing applications.

Figure 5. Developed Concrete Block (GENOBLOK) Construction Image-1

Development of solar panel mounting construction for terrace roofs

Figure 6. Developed Concrete Block (GENOBLOK) Construction

Development of solar panel mounting construction for terrace roofs

Figure 7. Developed Concrete Block (GENOBLOK) Construction

Figure 8. Developed Concrete Block (GENOBLOK) Construction

Project R&D Gains

  1. Based on the TS-EN-1991-1-4, TS-EN-1990-1-3 regulations, spreadsheets that perform analysis and verifications of the structural system according to the calculated loads have been created, and thus the construction selection can be created according to the optimum conditions. With the sections selected/determined according to engineering calculations, savings in construction costs are achieved.
  2. The strength properties of the roof hook developed for tile roof types are higher when compared to its equivalents. The high strength of these roof hooks, which act as a support for the Solar Power Plant (GES) carrier system, extends the economic life of the facility and prevents additional costs by preventing possible damages.
  3. GES construction systems that will create optimum cost can be designed and applied with the construction types (long profile, short profile, etc.) and support conditions (number of screws, screw spacing, etc.) to be determined based on the strength values of the roof covering determined as a result of the tensile tests. In this way, unnecessary profiles, screws, etc. saving in project cost is achieved by preventing the use of
  4. Determining the strength of the roof covering by tensile tests allows the establishment of a panel sub-construction system specific to each roof and increases the number of roofs that can be installed.
  5. Concrete blocks developed for terrace roofs (flat roofs) both reduce the installation time of the plant and reduce the installation cost of the plant as they can be produced at the weights determined as a result of static calculations. In addition, it is produced at the desired weight, preventing the use of extra concrete. In this way, the carbon footprint of the facility is also reduced.

Project Outcomes

  1. Engineering services to EPC (Engineering Procurement and Construction) companies that install GES on roofs with spreadsheets that perform structural analysis and verifications according to the loads calculated with reference to TS-EN-1991-1-4, TS-EN-1990-1-3 regulations and counseling is provided.
  2. Roof hooks developed for tile roof types were used in the roof GES project, where we carried out the static project, panel and panel sub-construction supply and on-site assembly/application commercial project. With this application, a new sector was entered and the project outputs were commercialized.
  3. Commercial service studies were carried out to provide the investors with the tensile test device provided within the scope of the project and the coating strength information of the roofs they plan to install the GES. With this service innovation, a new sector was entered and the project outputs were commercialized.
  4. During the development phase of the project, two sales engineers and one R&D engineer joined the project team to promote and sell the project outputs both in Turkey and abroad, and additional employment was created.
  5. Concrete blocks, which are an R&D qualified product developed for terrace type roofs, are suitable for sales and marketing. This product was introduced to existing electrical contractor companies at fairs.
  6. This completed project has enabled our company to diagnose the deficiencies and problems in the SPP sector, enabling the development of new R&D projects and ideas.
  7. The completed project is a project developed within the framework of our company’s product-oriented service strategy, and the project outputs were commercialized and new sectors were entered.