IntegratedSolar Solutions

Roof MountedPV System

Solar Photovoltaic Solutions

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Roof MountedPV System

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Contents

Introduction 4

Benefits of Solar PV 5

Put Your Roof To Work 6

How Solar PV Works 7

2 Steps to Maximise the Income 8

Product Range 10

Installation Process Map 12

Solar Radiation Map 13

Case Studies 14

Kingspan’s Journey to Carbon Neutrality 18

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Kingspan Roof Mounted PV System is aversatile solar photovoltaic system that issuitable for pitched and flat roof applicationson new build or refurbishment projects.

Initial enquiry with our specialist in-housedesign team, and installation and gridconnection are all part of Kingspan’s offering.

Generate clean, inflation-proof electricity– reduce operational energy costs

Zero CO2 emissions

Value engineered systems for quickand easy installation

PIR insulation core– excellent U-values

Closed cell insulation eliminates moistureingress and performance failure

Insulated Panel and PV system covered by theKingspan Total Guarantee for up to 25 years.

Roof Mounted PV System Features� Single source building envelope (roof, wall & façade) and solar

PV provider.

� PV fixing systems for the majority of Kingspan’s insulated

roof panels.

� Structural assurance on PV system and building envelope product.

� Full turn-key service; feasibility analysis, detailed design, product

supply, installation, system testing/commissioning and project

handover.

� Reduced build programme and site attendance costs due to the

PV system being installed in-conjunction with the roof panel.

� Annual operation and maintenance (O&M) contracts

offered with the Roof Mounted PV System.

Introduction

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� Generate energy even in low light (overcast / cloudy) conditions.

� Produce zero CO2 emissions.

� Has proven operational life in excess of 40 years.

� Is the only cost-effective, widely accepted renewable technology

that guarantees on-site green electricity production in an urban

environment.

Benefits ofSolar PV

The benefits of using a Solar PV System

� Reduce on-site electrical load / requirements.

� Generate electricity that offsets peak cost.

� Provide a hedge against rapidly increasing electricity prices.

� Increase asset / rentable value of a building by improving the

Energy Performance Certificate (EPC) rating.

� Meet Corporate Social Responsibility (CSR) needs.

� Electrical production is non-dependant on fossil or nuclear fuels.

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Generate your own power and benefit fromsignificant energy cost savings.

On account of the significant electricity rises experienced over the

past three years, there is no better time to invest in solar PV

technology to secure your energy future.

� FREE ENERGY.

� Enhance property value.

� Reduce impact of rising energy costs.

� Reduce associated carbon footprint of property / business.

� 7-10 years payback.

� Approximately 14% internal rate of return (IRR) on a 20 year

investment.

Put YourRoof to Work

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Cell

Module

PV String:Modulesconnectedin series

PV Array:Strings connectedin parallel

Modules, Strings & Arrays

Grid connection

Kilowatt-hourmeter

Solar PVmodules

Ampmeter

Interactiveinverter

Electricityload

A solar PV cell is a semi-conductor devicewhich converts solar energy into electricity.

PV Technologies� Crystalline PV – Monocrystalline or Polycrystalline.

Modules, Strings & Arrays� The multiple PV Cells are interconnected and encapsulated

to produce a PV Module.

� The modules are connected in series to form a string,

(Series connections increase the system voltage).

� A PV array is made up of a number of module strings connected

in parallel (Parallel connections increase the current in the system).

InvertersAn inverter is used to convert the direct current generated

(electricity) from the PV array to an alternative current (AC) for use

on site or for exporting to the grid.

� Stand alone inverters are used for off grid systems.

� Grid tie inverters are used when the installation is connected to a

utility supply. The grid tie inverter also synchronises the PV

generator with the grid.

How SolarPV Works

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2 Steps toMaximise the Income

Step 1Insulate

Over the past 50 years, insulated panels have evolved as a

particularly thermally efficient and economic method of

construction. They have been extensively used in refurbishment as

they are ideal for re-cladding walls and roofs. Insulated panels offer

the best long term guaranteed thermal performance and can

improve the energy efficiency of a building up to 44%, producing an

immediate payback on investment.

As single component, single-fix systems they provide a quick and

easy installation, saving up to 50% on construction time.

They are highly effective; they offer high performance insulation with

excellent guaranteed U-values. For example, many older buildings

have U-values of 0.6 W/m²K or worse, so over-cladding with an

insulated panel system that provides a U-value of 0.18 W/m²K, will

offer a huge energy saving. Furthermore it will improve the

aesthetics of the building and provide a more economic and

environmentally sound solution than demolition.

The first step is to reduce the energy demandand one of the simplest ways to do this, for bothnew build and refurbishment projects, is to useinsulated panel systems which offer guaranteedhigh thermal performance and low air leakageover the lifetime of the building.

Image courtesy of Gazeley and Central Photography

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Step 2Generate

2 Steps toMaximise the Income

The current climate of escalating electricity costs represents the

ideal opportunity for businesses to embrace renewable energy.

Furthermore the integration of renewable energy into your

businesses energy mix will aid in the ability to meet energy

efficiency and carbon reduction targets.

One of the key aspects for the success of including sources of

renewable energy will be the ease with which they can be

incorporated into buildings. Kingspan Insulated Panels has a

number of solutions which meet this criteria.

The development of sources of renewableenergy is a crucial part of the strategy toimprove energy efficiency and cut carbonemissions.

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ProductRange

Roof Mounted PV Systems RangeThe PV modules can be mounted onto a range of Kingspan

Insulated Roof Panels:

� Trapezoidal KS1000 RW

� Kingzip® Standing Seam

� Lo-Pitch KS1000 LP

� Curved Roof KS1000 CR

� Slate and Tile Support KS1000 TS

� Kingspan Topdek

� BENCHMARK Topspan

� BENCHMARK Envirodek

The PV system has been structurally tested in conjunction

with all above insulated panel profiles. It is a top sheet mounted

system, negating the need for through fixing, therefore eliminating

cold bridging.

On flat roofs with up to a 3° incline, a lightweight, non ballasted

mounting system is also available. The A-frame system requires no

module row connectors, allows for effective roof drainage and is

quick and easy to install. The system is patch welded to the

existing membrane thus negating the requirement for through fixing

or heavy weight ballasting.

The PV system can be installed on a wide range of roof systems

and can be tailored accordingly.

Lightweight flat roof mounting system

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PV modules installed on the Kingspan KS1000 RW Trapezoidal insulated roof panel

235m

mto495m

m235m

mto495m

mDistancedependantonwind

load

andsize

ofmodule

TypicalDetail

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InstallationProcess Map

A Kingspan installation will give you...

6 OFGEMRegistration 7 Renewable

Energy Schemes 8 Maintenance& Monitoring

1 ProjectFeasibilityStudy

2 Design &Cost Proposal 3 Finance

Package 4 Installation

5 Grid Connection,Commissioning& Handover

RenewableEnergySchemes

Feed-in TariffScheme (FIT)

RenewableObligationCertificates(ROC)

Renewable Energy SchemesThe Government has created a series of renewable energy

schemes designed to accelerate the UK’s development and use of

renewable energy to achieve the UK’s 2020 target of 15%

renewable energy supply.

� The Feed in tariff (FiT) was introduced in 2010 to encourage

small-scale (<5MW) low carbon electricity generation amongst

businesses, communities and individuals.

� The renewable obligation certificate (ROC) was introduced in

2002 to incentivise the deployment of large-scale renewable

electricity generation, providing a 20 year guaranteed revenue

linked to the retail price index (RPI).

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5 Usable roofspace4 Roof

construction /build & slope

3 Limitingfactors,e.g. shading

2 Orientation

As each site has individual requirements, Kingspan will develop a bespoke package, taking into account:

1 Location /insolation level

SolarRadiation Map

Orientation, Pitch and ShadingFor optimal performance, the photovoltaic array should face

between south-east and south-west at an elevation of about

30-40°. However, in the UK, even flat roofs receive 90% of the

energy of an optimum pitched system – see AC output table below).

It is important to ensure that the PV modules are not shaded during

the day. Avoid placing the array where there will be significant

shading from surrounding buildings or trees, since this decreases

the output from the system.

Although generally installed on a roof, the PV modules can be

installed on any south facing elevation. It can also be used for solar

shading or as a rainscreen on a building wall – this is particularly

suitable for prestige buildings.

AC outputs in kWh (kilowatt hour) / kWp (kilowatt peak)

Effect of orientation and pitch on array performance (% of Ideal).

Vert 80 70 60 50 40 30 20 10 Horiz

East 58 65 70 76 80 84 86 88 90 90SE 69 77 84 89 93 96 96 96 94 90South 71 80 87 93 97 100 100 98 96 90SW 67 75 82 87 92 95 96 96 94 90West 56 63 69 74 78 82 86 87 89 90

Location kWh790 kWh / Year830 kWh / Year850 kWh / Year900 kWh / Year

PlanningThe majority of buildings do not require planning permission for the

installation of PV modules. If the building is in a conservation area

or is a listed building you may need to apply for full planning

permission. Kingspan recommends checking with your local

council to ascertain the planning requirement for your specific

project / building.

Solar IrradianceAverage annual solar radiation (kWh/m²/day) for Great Britain

and Ireland.

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Project Kingspan Ltd

Location Holywell, Flintshire, North Wales

Product Roof Mounted PV System, Safetraxx®

Output 350,000kWh per annum

Build Refurbishment

Kingspan has completed the next phase of its ongoing drive

towards sustainable manufacturing with the installation of one of its

latest product developments at the state of the art manufacturing

facility at Holywell. 2,900m2 of Kingspan photovoltaic modules have

now been installed and fully commissioned on the roof of one of

the south facing manufacturing buildings. The addition of the

photovoltaic array on the Kingspan roof panels makes the facility a

prime example of the effectiveness of the ‘insulate and generate’

principle.

The 406.08kWp system comprising one thousand seven hundred

and twenty eight 235Wp crystalline PV modules, is expected to

generate circa 350,000kWh per annum, making a significant

contribution to powering the plant’s electricity needs.

It took just 5 weeks to complete the

project, and the maintenance of the

Kingspan Roof Mounted PV System

has been made both safer and easier

with the installation of Kingspan

Safetraxx®, an off-ridge fall protection

system.

The Safetraxx® system complies

with BS EN 795 and, when installed in conjunction with Kingspan

Insulated Panels, is available with the Kingspan Total Guarantee.

An important aspect in maintaining the energy efficiency of the

building envelope was that the fixings do not penetrate the

insulation layer, so there are no thermal bridging problems.

Output has been recorded since the system was installed and the

energy saving is significantly better than predicted – up by 7.21%.

CaseStudy Manufacturing

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Retail /Distribution

CaseStudy

Project Morrisons Distribution Centre

Location Bridgwater, Somerset

Products Insulated Roof & Wall Panels, Roof Mounted PV System,Insulated Cold Store Panels, Structural Products

Output 197,279kWh per annum

Build New Build

Morrisons’ South West Regional Distribution Centre, a 59 acre

goods facility at Bridgwater in Somerset, is an exemplar scheme

that uses Kingspan Roof Mounted PV System to create one of

Europe’s most energy efficient logistics facilities.

Using 1,548 modules, this system will provide a single-source,

insulated, roof and solar PV power source delivering a total

peak output of over 220kWp and an estimated 197,279kWh

of energy per annum.

Paul Kettlewell, Senior Construction Project Manager at Morrisons,

said: “Our ambition for Bridgwater was to achieve the best in

sustainable design in accordance with our stated aims for

environmental corporate responsibility.”

“We believe that minimising carbon

emissions is an important issue and

that refrigeration, transport and

waste are areas where significant

reductions can be achieved. We are

very pleased with the work that

Kingspan has done and the fact that

the solar power generated at the

distribution centre will provide more than 6 per cent of the

facility’s needs.”

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CaseStudy Agriculture

Project Lavenham Fen Farm

Location Cambridgeshire

Products Roof Mounted PV System, Safetraxx®

Output 352.7kWp

Build Refurbishment

Massive rises in energy bills over recent years have made the

refrigeration and storage of produce an increasingly costly part of

modern farming.

The owners of Lavenham Fen Farm in Cambridgeshire, however,

are proving that this need not be the case, using Kingspan Roof

Mounted PV System to slash bills from the farm’s two potato storage

buildings.

The buildings, separately housing standard and organic potatoes,

require large amounts of energy to power internal cooling systems,

keeping harvested potatoes at a constant low temperature. With

electricity usage metered at half-hourly rates, this previously

resulted in massive energy bills for the farm owners.

To tackle these costs, the farm owners used investment from

Regenerco to help fund the purchase and installation of the

Kingspan Roof Mounted PV System and Safetraxx® system.

Installed on the roofs of the storage buildings, the PV system

comprises a little over one thousand five hundred, 235Wp crystalline

PV modules and can produce an overall output of 352.7kWp,

making it one of the largest roof mounted PV arrays in the UK.

Robert Pickard, Estates Manager for

co-owners Abbots Ripton Farming

Company, comments: “We have found

it difficult to produce electricity by

wind or hydroelectric power, so PV is

an excellent solution. The buildings

are tall and the visual impact of the

panels is minimal. There is also a

secondary benefit of fitting the panels to the roofs, as in the

summer, they trap the solar energy which reduces the

temperature on the roof sheets below the panels.”

“The production of electricity during expensive peak periods is of

great benefit to ourselves and to the consumer as all energy

generated onsite is channelled directly into powering the potato

storage facility.”

Kingspan Roof Mounted PV System at Lavenham Fen Farm has

been registered and accredited under the FiT scheme.

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IndustrialCaseStudy

Project Stennack House Headquarters

Location St. Austell, Cornwall

Products Insulated Roof Panels, Roof Mounted PV System

Output 57.33kWp

Build Refurbishment

Stennack House is the corporate headquarters of Ocean Housing

Group Ltd. Following the initial phase of the project, where the old

asbestos roof was replaced with over 1,200m2 of energy efficient

Kingspan KS1000 RW Insulated Panels, the next step was to

provide a source of energy generation with the addition of the latest

PV technology.

In this case Kingspan Roof Mounted PV System was combined

with the BREEAM A+ rated Kingspan Insulated Panels, allowing the

building owners to take full advantage of not only a significant

building fabric improvement, but also carbon reduction, energy

generation and a dramatic reduction in energy costs.

Two hundred and seventy three Sharp 210W polycrystalline PV

modules with a 57.33kWp capacity were installed to the south

facing elevations of the roof, in what is believed to be the seventh

largest array of photovoltaics in the country and the largest in the

South West.

“We are in a win-win situation,” explains David Renwick, Chief

Executive of the Ocean Group. “All the ‘green’ electricity we

generate on site is free for us to use.”

Kingspan’s PV team of engineers were

involved throughout the project, from

assessing the structural capability of

the existing building to support the new

roof with the additional weight of the

Kingspan Roof Mounted PV System,

to optimising the system design and

successfully project managing the

complete installation of the PV system.

It is estimated that the electricity produced will save over £20,000

annually, with a predicted lifespan in excess of 25 years. Stennack

House provides a clear example of how effective the combination

of insulated panels with the power of PV can be, and that putting

your roof to work is truly the way forward to achieve zero carbon.

“The programme went really well, and we were very impressed

with Kingspan who pulled out all the stops ensuring the project

was delivered on time.”

Matthew Goddard, Commercial Manager, MITIE Tilley Roofing.

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Kingspan’s Journey toCarbon Neutrality

Buildings that are carbon neutral / net-zero energy are designed in a way that reduces the demand oncentralised electricity generation, saving energy, CO2 and fossil fuels. This is done by harvesting energyon-site, usually through a combination of energy producing technologies such as solar and wind, withimproved energy efficiency and work practices.

It is a real challenge for manufacturers to move to net-zero energy

but one that is well worth pursuing, both in terms of cutting costs,

reducing reliance on power from the grid and exceeding customer

expectations in managing environmental impacts on the planets

climate and ecological balance.

It is important to lead by example, and by 2020,Kingspan Insulated Panels plan to achievecarbon neutrality through a number of initiatives,which will be rolled out across all operations.

The Holywell site has already taken a number of steps to achieve

this goal, including

� The installation of solar panels which are expected to produce

317,000kWh per annum.

� The proposed installation of two, 2.5MW wind turbines,

predicted to deliver 12,264,000kWh electricity per annum.

� The further development of the already existing landfill scheme.

Kingspan Insulated Panels is now looking at the next phase to

move all of our manufacturing sites towards carbon neutrality /

net-zero energy.

Kingspan Group’s own Head Office in Kingscourt, Ireland has been

able to take a major step along the road to net-zero energy with the

installation of Kingspan Roof Mounted PV System.

Kingspan has installed 1000m2 of photovoltaic modules which

more than offsets the total annual electricity usage of the Group

offices in what is thought to be one of the largest PV installations in

Ireland. The 130kWp system, which comprises of five hundred and

fifty three 235Wp crystalline PV modules, is expected to generate

circa 100,000 kWh per annum.

Commissioned and approved by ESB on the 10th October 2011,

the Kingscourt system took just 2 weeks to complete, and

was predicted to save around 52,500Kg/CO2 per annum.

The installation makes a significant contribution to reducing carbon

as well as generating energy.

This system comes in addition to the systems at Kingspan

Insulation’s manufacturing facility in Pembridge and Kingspan

Insulated Panels plant in Holywell. At 800kW and 406kW

respectively they are currently two of the largest roof-top PV arrays

in the UK. At both plants the PV systems were designed to supply

a significant proportion of the site’s lighting and manufacturing

electricity needs.

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Kingspan LimitedGreenfield Business Park No. 2, Greenfield, Holywell, Flintshire, North Wales CH8 7GJt: +44 (0) 1352 717232 f: +44 (0) 1352 710161 www.kingspanpanels.co.uk

For the product offering in other markets please contact your local sales representative or visit www.kingspanpanels.com

Care has been taken to ensure that the contents of this publication are accurate, but Kingspan Limited and its subsidiary companies do not accept responsibility for errors or forinformation that is found to be misleading. Suggestions for, or description of, the end use or application of products or methods of working are for information only andKingspan Limited and its subsidiaries accept no liability in respect thereof.

07/2013