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  • Protected PV roof energises savings

    Introduction

    A.V. Dawson was investing in a steel storage facility for automotive and earth moving equipment manufacturers in the North East. Designed to provide optimum storage conditions for Tata Steel products, the 9,000m2 store uses solar photovoltaic (PV) roof panels to provide an innovative and energy-efficient solution for internal climate control.

    Detailed Information

    Summary

    Summary

    • New Confidex®  Guarantee

      Protects pre-finished steel beneath solar panels

    • 1,000+ PV panels installed

      Roof cladding underneath had to combine strength, performance and aesthetics

    • 105 tonnes of CO2 saved annually

      A payback period of under six years

    • Maximum return on investment

      Solar PV system designed to generate 194,250 kWh in 12 months

    Close collaboration with Tata Steel meant we were able to develop and prove a PV array solution that delivers cost savings for the client whilst ensuring that the roofing material performs at its best. Our partnership approach means we can combine and optimise building envelope and solar PV designs to suit a range of client needs.

    Steven Jones, director, Redsky Solar


    Bolstered by growing demand and volumes for Tata Steel products in the automotive market, multi-modal logistics company, A.V. Dawson looked to invest in a new £6.5m steel store for its automotive and earth moving equipment clients in the North East of the UK.

    The store would be served by rail links direct from Tata Steel’s production facility in Port Talbot, Wales, providing additional flexibility and security of supply for customers. At the same time, the new storage facility needed to provide the optimum storage conditions for the products stored within it, while remaining energy efficient and controlling costs.

    With these considerations in mind, A.V. Dawson opted for an efficient, renewable energy system – combining a ground source heat system with solar PV panels on the warehouse roof.

    Tata Steel worked with specialist roofing contractor Chemplas and supply chain partner Redsky Solar, as well as A.V. Dawson, to deliver a roof design, using Trisomet® insulated panels, that combined strength, performance and efficiency, with exceptional aesthetics.

    It was also the first building in the UK to benefit from the added reassurance of Tata Steel’s revised Confidex® Guarantee that protects the Colorcoat HPS200 Ultra® pre-finished steel beneath the solar panels.
     

    The buildability and speed of installation was one of the reasons we chose this composite panel system from Tata Steel. Using the Trisomet® System also meant we could select the optimum insulation thickness for enabling control of the internal climate of the building.

    Gary Dawson, managing director, A.V. Dawson

    Challenge

    Challenge

    The main challenges for this project were the specific requirements and choice of cladding for the steel-frame. The new store needed to provide optimum storage conditions for steel products used by the automotive industry, particularly steel coil. It was therefore essential that the internal temperature and relative humidity could be conditioned and maintained to ensure that the steel remained in prime condition.

     When designing the new steel-framed facility, A.V. Dawson selected an efficient, renewable energy system that combined a ground source heat system with solar PV panels on the store’s roof.

    The choice of cladding was critical to achieve the necessary insulation and air-tightness levels, while the roof had to be strong enough to support a 1,000+ panel solar PV array.

    A. V. Dawson also required assurance that the weathering performance of the whole roof could be guaranteed, including critical areas such as beneath the solar panels themselves.

    Ease of installation and aesthetics were two more important considerations. The build needed to be fast and efficient. Plus, as the building would be visited by prestigious customers such as Nissan, the new facility needed to look crisp, professional and smart.

    Solution

    Solution

    Working closely with the client, specialist roofing contractors Chemplas and with supply chain partner Redsky Solar, Tata Steel’s expert construction team helped to develop a cost-effective design for the building envelope. The team also provided the wind load and air-tightness calculations for the 10,000m2 design, helping to secure the maximum return on investment for the PV array.

    Tata Steel’s Trisomet® and Trimapanel® insulated panels were specificed to meet the project’s demanding cladding requirements. Through close collaboration with Tata Steel’s technical experts at design stage, A.V. Dawson was able to select the optimum insulation thickness to control heat and humidity, while still meeting the stringent requirements of the local area’s building control officer.

    Tata Steel’s tested panel joints and recommended junction details provided additional confidence value of 3m3/m2/h.

    The fixings securing the PV panels to the Trisomet® roof coverings were a particular focus for Tata Steel and its supply chain partner, Redsky Solar. Consequently, fixings were developed that would not compromise the weathering performance of the roof. 

    There were also concerns that the installation of the solar panels could affect the integrity and warranties of the roof cladding. As such, the enhanced Confidex® Guarantee for Colorcoat HPS200 Ultra®, newly extended to cover areas situated under photovoltaic (PV) frame modules, was a key benefit for A.V. Dawson. It provides confidence that installing a PV array will not have a detrimental effect on the performance of the pre-finished steel, and guarantees performance of the entire roof for up to 40 years.

    The solar PV system itself comprised over 1,000 PV panels. It was designed to generate 194,250 kWh in its first year. This saves over 105 tonnes of carbon dioxide and reduces A.V Dawson’s  energy bills by around 60% in the first year alone, thereby accruing savings of more than £800,000 over the next 20 years.

    Gallery

    Gallery

    Summary

    • New Confidex®  Guarantee

      Protects pre-finished steel beneath solar panels

    • 1,000+ PV panels installed

      Roof cladding underneath had to combine strength, performance and aesthetics

    • 105 tonnes of CO2 saved annually

      A payback period of under six years

    • Maximum return on investment

      Solar PV system designed to generate 194,250 kWh in 12 months

    Close collaboration with Tata Steel meant we were able to develop and prove a PV array solution that delivers cost savings for the client whilst ensuring that the roofing material performs at its best. Our partnership approach means we can combine and optimise building envelope and solar PV designs to suit a range of client needs.

    Steven Jones, director, Redsky Solar


    Bolstered by growing demand and volumes for Tata Steel products in the automotive market, multi-modal logistics company, A.V. Dawson looked to invest in a new £6.5m steel store for its automotive and earth moving equipment clients in the North East of the UK.

    The store would be served by rail links direct from Tata Steel’s production facility in Port Talbot, Wales, providing additional flexibility and security of supply for customers. At the same time, the new storage facility needed to provide the optimum storage conditions for the products stored within it, while remaining energy efficient and controlling costs.

    With these considerations in mind, A.V. Dawson opted for an efficient, renewable energy system – combining a ground source heat system with solar PV panels on the warehouse roof.

    Tata Steel worked with specialist roofing contractor Chemplas and supply chain partner Redsky Solar, as well as A.V. Dawson, to deliver a roof design, using Trisomet® insulated panels, that combined strength, performance and efficiency, with exceptional aesthetics.

    It was also the first building in the UK to benefit from the added reassurance of Tata Steel’s revised Confidex® Guarantee that protects the Colorcoat HPS200 Ultra® pre-finished steel beneath the solar panels.
     

    The buildability and speed of installation was one of the reasons we chose this composite panel system from Tata Steel. Using the Trisomet® System also meant we could select the optimum insulation thickness for enabling control of the internal climate of the building.

    Gary Dawson, managing director, A.V. Dawson

    Challenge

    The main challenges for this project were the specific requirements and choice of cladding for the steel-frame. The new store needed to provide optimum storage conditions for steel products used by the automotive industry, particularly steel coil. It was therefore essential that the internal temperature and relative humidity could be conditioned and maintained to ensure that the steel remained in prime condition.

     When designing the new steel-framed facility, A.V. Dawson selected an efficient, renewable energy system that combined a ground source heat system with solar PV panels on the store’s roof.

    The choice of cladding was critical to achieve the necessary insulation and air-tightness levels, while the roof had to be strong enough to support a 1,000+ panel solar PV array.

    A. V. Dawson also required assurance that the weathering performance of the whole roof could be guaranteed, including critical areas such as beneath the solar panels themselves.

    Ease of installation and aesthetics were two more important considerations. The build needed to be fast and efficient. Plus, as the building would be visited by prestigious customers such as Nissan, the new facility needed to look crisp, professional and smart.

    Solution

    Working closely with the client, specialist roofing contractors Chemplas and with supply chain partner Redsky Solar, Tata Steel’s expert construction team helped to develop a cost-effective design for the building envelope. The team also provided the wind load and air-tightness calculations for the 10,000m2 design, helping to secure the maximum return on investment for the PV array.

    Tata Steel’s Trisomet® and Trimapanel® insulated panels were specificed to meet the project’s demanding cladding requirements. Through close collaboration with Tata Steel’s technical experts at design stage, A.V. Dawson was able to select the optimum insulation thickness to control heat and humidity, while still meeting the stringent requirements of the local area’s building control officer.

    Tata Steel’s tested panel joints and recommended junction details provided additional confidence value of 3m3/m2/h.

    The fixings securing the PV panels to the Trisomet® roof coverings were a particular focus for Tata Steel and its supply chain partner, Redsky Solar. Consequently, fixings were developed that would not compromise the weathering performance of the roof. 

    There were also concerns that the installation of the solar panels could affect the integrity and warranties of the roof cladding. As such, the enhanced Confidex® Guarantee for Colorcoat HPS200 Ultra®, newly extended to cover areas situated under photovoltaic (PV) frame modules, was a key benefit for A.V. Dawson. It provides confidence that installing a PV array will not have a detrimental effect on the performance of the pre-finished steel, and guarantees performance of the entire roof for up to 40 years.

    The solar PV system itself comprised over 1,000 PV panels. It was designed to generate 194,250 kWh in its first year. This saves over 105 tonnes of carbon dioxide and reduces A.V Dawson’s  energy bills by around 60% in the first year alone, thereby accruing savings of more than £800,000 over the next 20 years.

    Gallery