Coles Facility Roof Solar

Introduction

Incon was engaged to undertake structural assessment and certification for a large-scale rooftop solar installation at the Coles Food Processing and Packaging Facility in Erskine Park, New South Wales. The project involved evaluating the structural capacity of an existing industrial building to support extensive photovoltaic (PV) infrastructure.

Project
description

The project comprised structural assessment of an existing large-span industrial facility (~105m x 155m, 11m high) to accommodate maximum rooftop solar coverage .

Key elements included:

Assessment of roof structure supporting flush-mounted PV panels in landscape configuration
Structural evaluation of a portal frame building with multiple grid variations (~20 configurations)
Analysis of existing roof loads, including:

Air Handling Units (AHUs)
Suspended gantry walkways
Cold-room panel systems supported by purlins

Development of structural zones across the roof to reflect varying capacities and configurations
Integration with PV layout design to optimise panel distribution and fixing systems

Challenge

The project required detailed engineering analysis due to:

Highly variable structural system, with different portal frame configurations across the building
Significant existing roof loads, including mechanical equipment and suspended systems impacting available capacity
Maximising PV coverage, requiring optimisation without overstressing existing structural elements
Complex load combinations, including dead load, wind uplift, and localised fixing forces
Zonal structural behaviour, requiring differentiation of roof areas based on capacity and configuration
Coordination with evolving PV layout design, requiring iterative engineering input

Solution

We delivered a practical and optimised engineering solution through:

Detailed roof capacity assessment, identifying allowable PV load densities across different structural zones
Development of zone-based design approach, enabling efficient allocation of PV modules without overloading critical areas
Calculation of wind pressures and uplift forces, ensuring compliance with relevant standards and safe fixing design
Optimisation of PV mounting systems (rails, clamps, screw fixings) to minimise additional loads on the structure
Close coordination with the PV designer (Solgen) to refine layout and maximise usable roof area

Key Engineering Highlights

Assessment of ~16,000 m² industrial roof structure
Integration of PV system with existing heavy roof loads (AHUs, walkways)
Development of zone-based structural capacity model
Optimisation of PV fixing systems for minimal structural impact
Rapid turnaround for assessment and certification delivery

Other Projects

We deliver project success and technical excellence.

We take pride in delivering innovative and practical solutions which adds real value to our clients and the community. We strive for better outcomes that delivers a best possible solution by employing our technical expertise. We believe the real value in good engineering is breaking down a complex problem into a simple solution which underpins our philosophy of ‘do it right – the first time’.