STRUCTURAL ASSESSMENT REPORT FOR THE

ROOF PHOTOVOLTAIC PANELS MOUNTING

ACCESSORIES OF THE SINGLE AND TWO-STORIED
BUILDING

Prepared By
Eng. D.M. Ravindra Dhanapala
Bsc. Eng. , C.Eng., MIE SL , MTech. WRD ,
No. 9/2, Springvelly Road,
Hindagoda, Badulla
Tele: 071-43 99 88 6
Email: ravindra.dhanapala@gmail.com

For
Alumex Group
Sapugaskanda,
Makola

31st March 2021

 
Contents

1.0  Introduction ............................................................................................................................... 1 

2.0  Objective..................................................................................................................................... 1 

3.0  Software used for the analysis ................................................................................................. 1 

3.1  Sap2000 V22 .......................................................................................................................... 1 

3.2  Ansys ...................................................................................................................................... 1 

3.3  Tekla Tedds ............................................................................................................................ 1 

4.0  Design Criteria ........................................................................................................................... 2 

4.1  The loading cases................................................................................................................... 2 

4.2  Factor of safety ...................................................................................................................... 2 

4.3  Wind load ............................................................................................................................... 2 

4.4  Single storied building .......................................................................................................... 2 

4.5  Two-storied building ............................................................................................................. 2 

4.6  The aluminium section properties ....................................................................................... 3 

4.7  Aluminium Mechanical properties ....................................................................................... 3 

4.7.1  Aluminium type - 6063-T5 Aluminium ....................................................................... 3 

4.7.2  Aluminium type - 6005-T5 Aluminium ....................................................................... 5 

4.8  Bolts Mechanical properties ................................................................................................. 5 

5.0  Calculation of the wind speed and pressure on the PV panels and analysing ...................... 5 

5.1  The maximum affordable wind speed by the solar panel mounting unit fixed on the
single-storied building. ......................................................................................................... 6 

5.2  The maximum affordable wind speed by the solar panel mounting unit fixed on the
two-storied building. ............................................................................................................ 8 

6.0  Analysis of rooftop mounting accessories. .............................................................................. 8 

6.1  Analysis of the “ALU-S66” section. ....................................................................................... 8 

6.2  Analysis of the “ALU-S25” section. ..................................................................................... 11 

6.3  Analysis of the “ALU-S26” section. ..................................................................................... 12 

6.4  Analysis of the Nut. .............................................................................................................. 12 

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 6.5  Analysis of the section “ALU-S61” ...................................................................................... 13 

6.6  Analysis of the section “ALU-S62” ...................................................................................... 13 

6.7  Roofing nut ........................................................................................................................... 13 

7.0  Recommendations ................................................................................................................... 15 

8.0  Annexure 1 ............................................................................................................................... 16 

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1.0 Introduction
This report was prepared on the request of Alumex PLC group. This report is mainly focused to
analyse the stability of the proposed aluminium roof photovoltaic PV panels mounting units on
the rooftop of the building and checking the strength of the aluminium section profiles for the
different wind speeds.

The Photovoltaic panels are expected to be installed on the rooftop of single-storied buildings and
two-storied buildings. This report includes analyses of all accessories of the solar panel mounting
unit for the maximum affordable wind speed.

The latest Finite Element analysis softwares were used to analyse the aluminium frames and other
fixing accessories.

2.0 Objective
The main objective of this report is to find out the maximum affordable wind speed by the given
solar panel mounting accessories in annexure 1.

3.0 Software used for the analysis

Most popular and powerful following structural analysis computer packages were used to analyse,
design and check the given aluminium frame.

3.1 Sap2000 V22

The SAP name has been synonymous with state-of-the-art analytical methods since its
introduction over 30 years ago. This software is used to get the maximum carrying capacity of the
given aluminium frame.

3.2 Ansys
Ansys Mechanical finite element analysis software is used to simulate computer models of
structures, electronics, or machine components for analysing strength, toughness etc. The
behaviour of connections for maximum bending moments and the clamps fixing solar panels was
analysed to the pressure at maximum wind flow, using Ansys software.

3.3 Tekla Tedds

For more than 20 years, Tekla Tedds has been the go-to document and design solution for
engineers. This powerful, easy-to-use structural analysis software reduces repetitive hand

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calculations and offers dependable multi-material element design because of its extensive, easy-
to-inspect quality assured library of calculations. Tekla Tedds software was used to calculate the
maximum wind pressure on the panels.

4.0 Design Criteria

4.1 The loading cases
Following loading cases were considered in the analysis.

 Dead load weight of panels D 0.12 kN/m2

 Wind load
 Load combinations
i. Dead load Wind load - D W
ii. Dead load-Wind load - D-W

4.2 Factor of safety

According to the table 3.4-1 of “Aluminium design manual” 2005 , 1.65 factor of safety was used
in the analysis.

4.3 Wind load

The wind load on the rooftop of both types of buildings have been calculated in accordance with
BS6399. Following design criteria also were used in the calculation of the maximum wind
pressure on the PV panels of both buildings.

 Building type factor, Kb, 4.0 Table 1

 Seasonal factor, Ss 0.95
 Direction factor, Sd 0.93
 Probability factor, Sp 1.0
 Site altitude 20 m
 Terrain category country

4.4 Single storied building

The details of the single-storied building used in the analysis, are given in the following figure 1.

4.5 Two-storied building

The details of the two-storied building used in the analysis, are given in the following figure 2.

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 Figure 1: Details of the single-storied building

4.6 The aluminium section properties

Seven types of aluminium section profiles which were given by the Alumex PLC Group, were used
in the analysis. The details are given in annexure 01.

4.7 Aluminium Mechanical properties

4.7.1 Aluminium type - 6063-T5 Aluminium
“ALU-S66” mounting rail profile is made of 6063-T5 aluminium alloy.

 Brinell Hardness - 60
 Elastic Young's, Tensile Modulus - 68 GPa

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 Figure 2: Details of the two-storied building

 Elongation at Break - 11 %
 Fatigue Strength - 70 MPa
 Poisson's Ratio - 0.33
 Shear Modulus - 26 GPa
 Shear Strength - 120 MPa
 Tensile Strength: Ultimate UTS - 180 MPa
 Tensile Strength: Yield Proof - 140 MPa

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4.7.2 Aluminium type - 6005-T5 Aluminium
Accessories items, “ALU-S60”, “ALU-S61”, “ALU-S62”, “ALU-S65”, “ALU-S25”, “ALU-S26”, are made
of 6005-T5 aluminium alloy

 Brinell Hardness - 90
 Elastic Young's, Tensile Modulus - 68 GPa
 Elongation at Break - 9.5 %
 Fatigue Strength - 95 MPa
 Poisson's Ratio - 0.33
 Shear Modulus - 26 GPa
 Shear Strength - 170 MPa
 Tensile Strength: Ultimate UTS - 290 MPa
 Tensile Strength: Yield Proof - 270 MPa

4.8 Bolts Mechanical properties

The bolts having the following mechanical properties were used in the analysis.

 Elastic Young's, Tensile Modulus - 193 GPa

 Poisson's Ratio - 0.31
 Shear Modulus - 73.6 GPa
 Tensile Strength: Ultimate UTS - 700 MPa
 Tensile Strength: Yield Proof - 450 MPa

5.0 Calculation of the wind speed and pressure on the PV panels and analysing
In this section, the calculation of the wind load on the PV panels is discussed. The Tekla Tedds
software was used to calculate the maximum wind pressure on the solar panels based on the
British Standard code of practice, BS 6399 part 1 1997 .

It is assumed that the wind pressure on the panel transfer to the four clamps on corners. Then the
fixing clamp “ALU-S62”, “ALU-S65” to the rooftop and “ALU-S66” section analysed using Sap2000
software for the different wind speed till the carrying capacity of the aluminium sections passed.

The same wind speed generates higher wind pressure on the roof of the two-storied building than
single storied building.

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5.1 The maximum affordable wind speed by the solar panel mounting unit fixed on the single-
storied building.
The maximum wind pressure generates on the side of the solar panel array. Hence the aluminium
section “ALU-S66” and other related accessories along A-A were analysed using SAP2000
software.

The optimized wind speed is 35 m/s and all accessories are capable to withstand the uplift forces
generated by the wind. The carrying capacity of all members are given in figure 4, 5 and all values
are within acceptable limits.

Angled roof 

Figure 3: The section of the panel array along A-A

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 Figure 4: Applied wind load due to the 35 m/s wind speed

Figure 5: Carrying capacity of sections on the single-storied building for the 35 m/s wind speed

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5.2 The maximum affordable wind speed by the solar panel mounting unit fixed on the two-
storied building.
Same as the previous calculation, the optimized wind speed is calculated as 33 m/s for the two-
storied building. The carrying capacity of all members are given in figure 6 and all values are
within acceptable limits.

Figure 6: Carrying capacity of sections on the two-storied building for the 33 m/s wind speed

6.0 Analysis of rooftop mounting accessories.

6.1 Analysis of the “ALU-S66” section.
The section “ALU-S66” is made of “6063 T5” aluminium alloy which is having the lowest yield
strength among all accessories of the mounting unit. Hence the section " ALU-S66" is checked for
maximum withstanding load generated by the wind pressure.

The Ansys software is used to analyse all accessories of the mounting unit. It is assumed that the
roof is stable and ridged to withstand uplift force or force in the gravity direction, generated on
the panels due to the wind speed. The model is shown in figure 7 and results are given in figure 8
to figure 10.

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 Figure 7: Model 1

The stress of the section “ALU-S66” is below the yield strength of the material for the uplift wind
load. The safety factor is between 1 to 1.65 in a small area. However, the “ALU-S66 is safe for the
wind speed of 33 m/s.

Figure 8: The stress contour at the location where “ALU-S25” is fixed, for the load generated by
33 m/s wind speed

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 Figure 9: The stress contour at the location where “ALU-S60” is fixed, for the load generated by
33 m/s wind speed

Figure 10: Factor of safety on “ALU-S66”

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6.2 Analysis of the “ALU-S25” section.
The stress of the “ALU-S25” is within the yield strength of the material. The maximum deformation
of the section is 2.1 mm and the clip will not release the solar panel at a wind speed of 33 m/s.
Therefore the section is safe.

Figure 11: Maximum Stress on the section “ALU-S25”

Figure 12: The maximum deformation of the section “ALU-S25”

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6.3 Analysis of the “ALU-S26” section.
The stress is exceeded over the ultimate strength of the material in a very small area. But the
stress of other area is on the safe.

Figure 13: Maximum Stress on the section “ALU-S26”

6.4 Analysis of the Nut.

The stress of the nut is below the yield strength of the material. Hence the nut is capable to
withstand the wind load.

Figure 14: Maximum Stress on Nut

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6.5 Analysis of the section “ALU-S61”

The section “ALU-S61 is subjected to 1418 N uplift force and the generated maximum stress is
shown in figure 15. The maximum stress is below the yield strength of the material. Hence the
section “ALU-S61” is capable to withstand a wind speed of 33 m/s.

Figure 15: Stress contour on the section “ALU-S61”

6.6 Analysis of the section “ALU-S62”

The section “ALU-S62” also stressed below the yield strength of the material for the wind speed
of 33 m/s. Hence, the section is safe. The results are shown in figure 16.

6.7 Roofing nut

The maximum stress on the roofing nut is shown in figure 17 and it is also below the yield
strength of the material.

13 
 
 Figure 16: Maximum Stress on the section “ALU-S62”

Figure 17: Maximum Stress on the roofing nut

14 
 
7.0 Recommendations
The rooftop aluminium PV panel mounting accessories were analysed for single-storied building
and two-storied building, using finite analysis software as described in section 6.0 of this report.

The rooftop solar panel mounting accessories on the single-storied building are capable to
withstand a wind speed of 35 m/s. But the same accessories on the two-storied building are
capable to withstand a wind speed of 33 m/s.

However, all provided fixing accessories of rooftop solar panel mounting could be used on the
single-storied building and two-storied building for the maximum wind speed of 33 m/s.

Prepared by

…………………………………….

Eng. D.M. Ravindra Dhanapala

BSc. Eng. , C.Eng., MIE SL , MTech. WRD ,

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8.0 Annexure 1

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