Solar-field AL310 Technical manual for aluminium support structure for photovoltaic free-fields/ flat roofs
1
1. Aluminium system for free-fields 1.1 GENERAL The aluminium support system for free-fields is made entirely from aluminium alloy EN AW 6060. All of the steel accessories (bolts, nuts, etc...) are made from stainless steel A2. The system is available in 2 versions, 2 portrait & 3 landscape with angles of 25°,30°,35°. The system offers a choice of heavy and light constructions, with the difference being the span between the girders (3,1m & 2,5m accordingly). The mounting of the system requires a reinforced concrete foundation.
Typology
Aluminium 25°
Aluminium 30°
Aluminium 35°
Purlin
PV panel layout
P80
Portrait
Code A80P-25
P80
Landscape
A80L-25
P105
Portrait
A105P-25
P105
Landscape
A105L-25
P80
Portrait
A80P-30
P80
Landscape
A80L-30
P105
Portrait
A105P-30
P105
Landscape
A105L-30
P80
Portrait
A80P-35
P80
Landscape
A80L-35
P105
Portrait
A105P-35
P105
Landscape
A105L-35
2
2. Assembly for trianlges (free-fields) The individual parts for assembling the trianlges are provided with the necessary machining for easier and faster installation.
2.1 FIXING TO THE FOUNDATION Anchor Bolts
The floor bracket is fastened to the concrete with concrete anchor bolts (FBN II M12).
Floor Bracket
Attention: Isolating material must be placed between the floor bracket and the concrete foundation in order to protect the floor bracket and fasteners from corrosion.
Isolating Material Concrete Foundation
Rear floor bracket
The rear floor bracket is placed 2 meters from the front floor bracket on center.
The oval holes in the floor bracket provide the necessary adjustments (left and right) in order to bring the front and rear floor brackets in correct alignment.
2,0 m
Front floor bracket
3
2.2 INSTALLING THE FRONT AND REAR LEGS The legs are placed in the floor brackets and are fastened with a hexagon head bolt M12x80 and a safety nut M12. The washer with ribs is used to adjust the height of the leg and then the hexagon head bolt is tightened.
Rear leg Front leg
Safety nut Μ 12 Hexagon head bolt Μ 12x80 Washer with ribs for adjusting the hieght
2.3 INSTALLING THE DIAGONAL BRACING The diagonal bracing is placed between the two legs in order to stabilize the construction The brace is fastened to the legs with a hexagon head bolt M12x60 and a safety nut M12.
Diagonal bracing
Hexagon head bolt Μ 12x60
Safety nut Μ 12
4
2.4 INSTALLING THE GIRDER CONNECTOR First the girder connector is fastened to the girder at a specific position according to the typology and construction documentation provided for the specific project. Hammer head screws are placed inside the groove under the girder and are fastened to the girder connector with safety nuts. Hammer head screw Μ 8x20
Girder connector
Safety nut Μ 8
Girder
5
2.5 INSTALLING THE GIRDER The girder with the girder connector fastened in the correct position is placed over the front and back legs and fastened with a hexagon head bolt M12x80 and a safety nut M12. The girder connector can be adjusted to insure that the correct height of the girder after tightening the hexagon head bolts. Afterwards the end covers are placed on both ends of the girder.
Girder connector
Washer with ribs for adjusting the Safety nut
Hexagon head bolt Μ 12x80
Girder
End cover for girder
6
3. Installing and aligning the triangles (free-fields).
After repeating the previous steps, the triangles are placed in rows according the the project specifications. The largest span that can be used between girders is 3,1m If needed the triangles can be adjusted in order to insure the correct alignment.
2,0
3.1 ADJUSTMENTS
m
) 05 1 (P 80) m (P 3,1 5m 2,
) 05 ) 1 0 (P m (P8 1 , 3 ,5m 2
The legs can be adjusted in height by using the adjustability of the floor bracket.
The girder can be adjusted in length by loosening the hammer head bolts, which will free the girder to move both left and right. Also the girder connector can be used to adjust the height of the girder up and down.
Hammer head bolt Μ 8x20
7
3.2 INSTALLING DIAGONAL BRACING Diagonal bracing is placed at the beginning and the end of a set of triangles and every third span.
Diagonal bracing
3.3 TABLE FOR FASTENER TORQUE
Drawing
Description
Torque
Anchor bolt
According to specifications
Bolt Μ 12x80
56 Nm
Bolt Μ 12x60
32 Nm
Hammer head bolt Μ 8x20
32 Nm
8
4. Aluminium systems for flat roofs 4.1 GENERAL The aluminium support system for flat roofs is made entirely from aluminium alloy EN AW 6060. All of the fasteners and accessories (bolts, nuts, etc...) are made from stainless steel A2. The system is available in 2 basic versions, 2 portrait & 3 landscape with angles 25°και30°. The fixation to the flat roof is made with the appropriate chemical anchor bolts (FIS EM & FIS HB) that are tested and certified for weather sealing.
Typology
Purlin
PV panel layout
Code
Aluminium flat roof 25°
P80
Portrait
AL80P-25
P80
Landscape
AL80L-25
Aluminium flat roof 30°
P80
Portrait
AL80P-30
P80
Landscape
AL80L-30
9
5. Assembly for trianlges (Flat roofs). The individual parts for assembling the trianlges are provided with the necessary machining for easier and faster installation.
5.1 FIXING TO THE FLAT ROOF Anchor Bolt
The floor bracket is fastened to the concrete with chemical anchor bolts. The appropriate types of chemical anchors are the FIS HB (when the support is fastened directly to the concrete slab or with a thin insulating pad) and the FIS EM (for fastening over thick plates of insulation). The insulation can be asphalt, cement, polystyrene plates, etc. The rods M12 are recommended to be at least A2 quality and the nominal depth of the anchor is provided in the technical manuals of fischer.
Floor Bracket Isolation Material Flat roof
Rear Floor Bracket
Attention: Isolating material must be placed between the floor bracket and the concrete foundation in order to protect the floor bracket and fasteners from corrosion.
The rear floor bracket is placed 2,62 meters from the front floor bracket on center.
The oval holes in the floor bracket provide the necessary adjustments (left and right) in order to bring the front and rear floor brackets in correct alignment.
Front Floor Bracket
2,6
2m
10
5.2 INSTALLING THE FRONT AND REAR LEGS The legs are placed in the floor brackets and are fastened with a hexagon head bolt M12x80 and a safety nut M12. The washer with ribs is used to adjust the height of the leg and then the hexagon head bolt is tightened.
Rear Leg
Rear Floor Bracket
Safety Nut Μ 12 Washer with ribs for adjusting the hieght
Washer with ribs for adjusting the hieght Hexagon Head Bolt Μ 12x80
5.3 INSTALLING THE GIRDER CONNECTOR First the girder connector is fastened to the girder at a specific position according to the typology and construction documentation provided for the specific project. Hammer head screws are placed inside the groove under the girder and are fastened to the girder connector with safety nuts. Afterwards the end covers are placed on both ends of the girder.
Hammer Head Bolt Μ 8x20
Girder Connector
Girder Safety Nut Μ8 End Cover for Girder
11
5.4 INSTALLING THE GIRDER The girder with the girder connector fastened in the correct position is placed over the back leg and fastened with a hexagon head bolt M12x80 and a safety nut M12. The girder connector can be adjusted to insure that the correct height of the girder after tightening the hexagon head bolts.
Girder
Girder
Girder Connector Washer with ribs for adjusting the hieght
Washer with ribs for adjusting the hieght Bolt Μ 12x80
Safety Nut Safety Nut
Floor Bracket Bolt Μ 12x80
2.3 INSTALLING DIAGONAL BRACING The diagonal bracing is placed between the back leg and the girder in order to stabilize the construction The brace is fastened to the legs with a hexagon head bolt M12x60 and a safety nut M12.
Safety Nut Μ 12
Diagonal Brace
Girder Hexagon head bolt Μ 12x60
12
6. Installing and aligning the triangles (Flat roofs).
After repeating the previous steps, the triangles are placed in rows according the the project specifications. The largest span that can be used between girders is 2,5m If needed the triangles can be adjusted in order to insure the correct alignment.
m 2,5 2,6
2m
6.1 ADJUSTMENTS
The legs can be adjusted in height by using the adjustability of the floor brackets.
Also the girder connector can be used to adjust the height of the girder up and down.
m 2,5
13
6.2 INSTALLING DIAGONAL BRACING Diagonal bracing is placed at the beginning and the end of a set of triangles and every third span.
Diagonal Bracing
6.3 TABLE FOR FASTENER TORQUE
Drawing
Description
Torque
Anchor Bolt
According to specifications
Bolt Μ 12x80
56 Nm
Bolt Μ 12x60
32 Nm
Hammer head bolt Μ 8x20
32 Nm
14
7. Installing purlins The purlins are installed over the girders with a special corner clamp connector. The hammer head nut is inserted into the channel of the girder and is locked into posistion with a clock-wise turning motion. The corner clamp is inserted into the side channel of the purlin and is fastened to the hammer head nut with an allen screw M8.
Hammer head nut
Allen screw
Corner clamp connector
7.1 PURLIN CONNECTOR When the purlin is used continuously to span over several girders, then a special purlin connector is used to fasten the two purlins together. The purlin connector is inserted into the chamber of the purlin and fastened with self-tapping stainless steel screws. Screw St4,2x13 Purlin Purlin Connector
15
8. Installing the panels The panels are fixed to the purlins with special clamps. There are end clamps that are used to fix the panels at the beginning and the end of a series, and there are middle clamps that are used between two panels. The clamps are available pre-assembled (with allen screw, spring, plastic grip, hammerhead nut) and are availble for every panel thickness.
Allen screw
The hammer head nut is inserted into the channel of the purlin and turned to lock into the desired position. Then the clamp is fastened into place with the allen screw.
Clamp
Hammer head nut
16
9. Technical data sheets 1- point load F
SolarFine 150
L/2
Height
150 mm
Width
41 mm
Perimeter
522,34 mm
Ix
229,10 cm4
Iy
4 25,71 cm
Wx
29,68 cm3
Wy
12,54 cm3
Radii(x)
5,06 cm
Radii(y)
1,70 cm
L
Area
2 894,02 mm
3 supports - Uniformly load
Weight
2413,85 gr/m
F (N) 20000
L 2- point load F L/3
F L/3 L
2 supports - Uniformly load q
qL
qL
L
L
SolarFine 150
19000 18000 17000 16000 15000 14000 13000 12000
3-supports
11000
2-supports
10000 1 point load
9000 8000
2 point load
7000 6000 5000 4000 3000 2000 1000 0 0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6 L (m)
17
1- point load F
SolarFine 100 L/2
Height
100 mm
Width
41 mm
Perimeter
422,34 mm
L 2- point load F
F
cm4
Ix
78,53
Iy
18,79 cm4
L/3
L/3 L
Wx
14,87
cm3
Wy
9,17 cm3
Radii(x)
3,32 cm
Radii(y)
1,62 cm
Area
714,02 mm2
Weight
1927,85 gr/m
2 supports - Uniformly load q
L 3 supports - Uniformly load qL
qL
L
L
SolarFine 100
F (N) 15000 14000 13000 12000 11000 10000
3-supports 9000
2-supports
8000
1 point load
7000
2 point load
6000 5000 4000 3000 2000 1000 0 0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6
L (m)
18
SolarPrime 105
1- point load
F L/3
L/2
105 mm
Width
77,8 mm
Perimeter
490,32 mm
Ix
107,81 cm4
Iy
39,11 cm4
Wx
18,24 cm3
Wy
10,05 cm3
Radii(x)
3,75 cm
Radii(y)
2,26 cm
Area
768,05 mm2
Weight
2073,72 gr/m
2 supports Uniformly load q
2- point load
F
Height
F L/3
L
L
L
3 supports Uniformly load qL qL
F (N)
L
SolarPrime 105
15000 14000 13000 12000 11000 10000
3-supports
9000
2-supports 8000 1 point load 7000 2 point load 6000 5000 4000 3000 2000 1000 0 0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6 L (m)
L
19
SolarPrime 80
1- point load
F
80 mm
Width
77,8 mm
Perimeter
440,32 mm
Ix
53,90 cm4
Iy
34,43 cm4
Wx
12,00 cm3
Wy
8,85 cm3
Radii(x)
2,80 cm
Radii(y)
2,24 cm
Area
688,05 mm2
Weight
1857,72 gr/m
2 supports Uniformly load q
2- point load
F
Height
F
3 supports Uniformly load qL qL
L/3 L/3
L/2
L
L
L
L
SolarPrime 80
F (N) 15000 14000 13000 12000 11000 10000
2-supports 9000 3-supports 8000
1 point load
7000
2 point load
6000 5000 4000 3000 2000 1000 0 0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
5,5
6 L (m)
L
20
10. Structural design loads of brackets Load 1: Vertical compression (15kN) Load 2: Horizontal forces
(6,5kN)
15kN 6,5kN
Load 1: Vertical compression (10kN) Load 2: Horizontal forces
(10kN)
Load 3: Vertical tensile forces (10kN)
10kN
10kN
10kN
Founded in 1958, the fischer brand is synonymous for safe, innovative and sophisticated technical solutions which set new standards in fixing engineering. The products and applications are unique fixing systems that are invented and produced by fischer. That is the reason that there exist unlimited solutions and a large range of applications, and today is recognised as the leader in the market of fixing systems.
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E.W.I. / ETICS
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www.fischer.gr
The contents of this manual are subject to change without prior notice. Fischer Hellas Emporiki EPE is not responsible for typographical errors. PLS012 05/2012
1958, the beginning. 2012, world-wide.