Fitting Solar Panels: 2025 Comprehensive Guide
Fitting solar panels to commercial roof spaces is a smart and strategic investment that brings long-term benefits, such as reducing energy costs, enhancing sustainability efforts, and boosting property value.
However, to maximise these advantages, a proper and thorough installation is paramount. This guide walks you through every crucial aspect of the process, from choosing high-quality materials and using safe scaffolding techniques to ensuring health and safety compliance.
We also cover effective fixing methods and the importance of planning for recycling after installation, ensuring a sustainable, efficient, and long-lasting commercial solar energy system.
1. Materials Used in PV System Installation
The quality of materials used in a solar PV system installation directly impacts the system’s efficiency, durability, and long-term performance. Each component plays a crucial role in ensuring the panels generate maximum energy while withstanding environmental factors such as wind, rain, and temperature fluctuations. Below are the key materials used to fitting solar panels:
Key Components:
Solar Panel Mounting Systems
Typically constructed from marine-grade anodised aluminium or hot-dipped galvanised steel, these racking structures securely attach panels to the roof while withstanding external weather conditions.
Solar PV Panels
Tire one products made from high-grade silicon cells, encased in tempered glass and aluminium frames, ensuring durability and high energy conversion efficiency.
Cabling & Connectors
BS7671: Regs 712 and compliant solar panel systems.Weather-resistant and UV PV1-F rated electrical cabling and components that ensure safe and efficient energy transfer between the panels and the inverter.
Fasteners & Fixings
Stainless steel bolts, clamps, and brackets that securely attach solar panels to the mounting system, preventing movement or damage over time.
Correct torque tightness setting is key to the effectiveness of the fixing.
Inverters
Essential for converting solar energy into usable electricity. Options include:
✅ ENA, Energy Networks Association G98, G99, G100 compliant
✅ String inverters - Cost-effective and widely used.
✅ Micro-inverters - DC/AC conversion on the roof for optimised PV performance.
✅ Power optimisers - Optimum efficiency, mitigate shading effects and provides instant DC safe shutdown.
Flashing & Sealants
An EPDM seal applied on mounting points to prevent leaks and protect the roof from water damage, ensuring a long-lasting and weatherproof installation.
Epdm is rated from -40°C to +120°C to hanlde adverse weather.
Using high-quality materials in solar PV system installations not only enhances system performance but also minimises maintenance costs and extends the lifespan of the commercial solar panel array.
2. Scaffolding & Site Preparation for PV System Installation
Proper scaffolding and site preparation are essential for the safe and efficient installation of solar PV systems. Scaffolding, meeting BSEN 12811-1 regulations, provides a secure platform for commercial solar installers working at heights, ensuring full compliance with safety standards and supporting the handling of heavy materials. Additionally, site preparation identifies structural concerns, optimises workflow, and ensures a smooth installation process. With work-at-height and full arrest certifications, these measures guarantee a durable, effective solar energy system that maximises long-term renewable energy benefits.
Why Scaffolding is Necessary:
Supports heavy materials such as solar panels, mounting systems, and tools.
Provides safe access for solar installers working at heights.
Ensures compliance with health and safety regulations, reducing the risk of accidents.
Site Preparation:
Structural Assessment and Roof Condition Check
Engineers assess the roof's load-bearing capacity, identifying and addressing any necessary repairs or reinforcements before installing the solar panels.
Planning & Layout
Using AutoCAD PVsol determines optimal panel positioning to maximise sunlight exposure and efficiency.
Repair and Prepare for Installation
Engineers identify and implement repairs or reinforcements, such as strengthening the roof, replacing damaged sections, and adding support beams, to ensure it can safely support the solar system.
By ensuring proper scaffolding and site preparation, businesses can achieve a safe, efficient, and long-lasting solar panel installation.
3. How Are Solar Panels Fixed to the Roof?
The method used to fix commercial solar panels to the roof depends on the type of roof structure. Proper panel mounting brackets ensures stability, durability, and maximum energy production while minimising damage to the roof. Different roof types require specific installation techniques to optimise performance and structural integrity. Below are the most common mounting methods used for various commercial roofs.
Flat Roof PV system Installations:
Fixed Tilt Systems
Adjustable frames allow panels to be positioned at an optimal angle for sunlight absorption, improving energy generation.
Ballasted Roof Systems
Uses weighted mounting structures to hold panels in place without roof penetration, ideal for flat roofs and protecting waterproofing membranes.
Pitched Roof Solar PV Installations:
Direct Mount Inroof Systems
Panels are fixed directly to roof beams using specialised hooks or clamps, ensuring stability and durability. Various options are available like Solfit, Viridian and GSE Inroof systems.
Rail-Based Retrofit Systems
Various fixing methods using aluminium rails are securely attached to the roof structure using bracketary and bolts, providing strong and adjustable mounting solutions.
Green Roof or Membrane Roof Installations:
Lightweight Racking Systems
Protects delicate roof surfaces while ensuring secure panel installation.
Systems like Bauder roofing system is ideal for new builds and retrofits, featuring a secure mounting system welded membrane-to-membrane for a risk-free, zero-penetration installation.
Non-Penetrative Mounting Systems
Designed to protect waterproof membranes by avoiding drilling or bolting into the structures by weighed down sytems like Park Tegra ballast and Van Der Valk weigh down mounting systems.
Selecting the right solar panel mounting system is crucial for efficiency, longevity, and minimal roof impact in commercial solar installations.
4. Health & Safety Considerations in Solar Panel Installations
Ensuring the safety of workers during solar panel installations is crucial. Proper planning and adherence to health and safety regulations can prevent accidents and ensure smooth operations. Below are some key safety measures to follow:
Protective Equipment
Five point of PPE is mandatory, helmets, steel toe caps boots, HI Viz, glasses and gloves.
RAM's task specific PPE are also mandatory for installers.
Risk Assessments & Site Surveys
Identifying potential hazards before work begins.
All risk to be recorded in the RAM's Document, a specific assessment is to be carried out to alleviate risks to minimal level.
Electrical Safety (Qualified Personnel Only)
Proper designs and Bs7671 Regs compliant electrical systems.
Electrical commissioning testing and certification to be issued and building control and notification to be filed.
Weather Conditions
Solar panel installations should be designed and built to withstand adverse weather conditions, including strong winds. The solar modules must be durable enough to endure hailstones, heavy snow, and high winds, ensuring long-term reliability and performance.
By implementing these measures, the risk of injury can be minimised, and a safe working environment is maintained.
5. Recycling & Sustainability After Solar Panel Installation
Solar PV panels are designed to last 25-30 years, but when they reach the end of their lifecycle, recycling plays a critical role in reducing environmental impact. Proper recycling processes ensure that valuable materials are recovered, and the waste generated is minimised, contributing to a sustainable future. Below is an overview of how the recycling process works and the sustainability benefits it offers:
Component Separation
Electronic parts are dismantled and processed safely.
Material Recovery
Glass, aluminium, and silicon are extracted and reused.
Reintegration into Production
Recycled materials are repurposed for new solar PV panels or other industrial applications.
Sustainability Benefits:
✅ Reduces landfill waste.
✅ Minimises raw material consumption.
✅Supports a circular economy in renewable energy.
Recycling replaced solar PV panels not only conserves resources but also helps in lowering the carbon footprint of the renewable energy industry, promoting a more sustainable and environmentally friendly energy solution.
Secure, Sustainable Commercial Solar PV System Installation
At Excel Energy, installing commercial solar panels is a detailed process that demands careful planning, precision, and strict adherence to health and safety standards. From selecting top quality premium materials to implementing secure scaffolding techniques, every step is designed for efficiency and reliability. Future recycling considerations also ensure a sustainable, long-lasting solar energy system.
Is your business ready to harness the power of solar? Don’t miss out on a clean, cost-effective energy solution. Contact Excel Energy today to explore the best solar installation options for your commercial property!
