Case Study
Next: Elmsall High Bay Over-Roof and PV System
PROJECT INFORMATION
CLIENT
Next
PROJECT START
October 2022
PROJECT DURATION
7 Weeks
Elmsall High Bay Over-Roof and PV System
Brief
Next needed to replace or upgrade the roof of the existing High Bay building (16,000 m2 in area) that had deteriorated and where water ingress was an issue. They also wanted to introduce a Solar PV system to this area. This was to be combined with introducing a further PV system to a new extension of the High Bay and constructing new inverter buildings and cable management systems.
Challenges
The projects had to be carried out on a live site working 24/7. Material deliveries and associated crane locations and lifts to transfer the materials to the roof level had to be coordinated with the Next site logistics team to prevent any impact on their activities.
The structure had to be checked to ensure sufficient capacity to accept the additional loads from the new membrane and PV system. The only available location for the new inverter building was within an area where the main underground services were positioned. The roof and PV design needed to meet Next’s insurer’s requirements.
Results
Roof Works
Lynx Building Solutions conducted a complete site survey to assess the existing structure and services to determine the frame capabilities and ensure sufficient capacity was available to carry out the works.
A new IKO membrane was installed and thoroughly tested on the entire roof area and gutters. The existing lighting protection system was lifted, replaced, and thoroughly tested.
Inverter Building
Lynx Building Solutions worked with the professional design team to coordinate the building’s design, manufacture, and installation. To overcome the underground services, steel posts (stilts) were positioned in specific locations to avoid the services, which then supported an elevated steel transfer structure which acted as the floor of the building. We supplied all components, including steelwork, cladding, gutters, access doors and staircases.
Cable Risers
To meet insurance stipulations the DC cables were kept outside the building and transferred from roof level into the Inverter buildings via purposely designed steel risers connected to the side elevations of the existing structures. Lynx Building Solutions designed and coordinated the connections to the existing structure, then manufactured and installed the steelwork and cable trays. Once cables were installed, the riser was clad in materials to match the existing walls.
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