Case study
Solar Kreisel, Blomberg Niemcy
Lightweight lattice support structure for photovoltaic panels
Blomberg, Germany
12.2022 – 04.2023
Prefabrication of steel structure with delivery to the assembly site
Challenges of the project
Manufacturing accuracy of bent profiles:
Bent profiles have lower manufacturing accuracy compared to standard steel profiles. To ensure their fit, the bent profiles required additional refinement in the workshop.
Complexity of segmented construction:
Numerous segmented joints, including those bolted “rigidly,” required maintaining high geometric dimensional accuracy. Excessive deviations could have prevented proper integration of the lattice structure on site.
Narrowed tolerances:
Narrowed tolerances dictated the need to maintain high accuracy throughout the manufacturing process.
The order involved the prefabrication of a lightweight, customized support structure for photovoltaic panels, whose structure was designed in the form of two large satellite dishes, each 12 meters high and 8 meters in diameter.
The design featured many segmented connections, some of which were bolted “rigidly,” which limited the tolerances allowed. The lattice structure, on the other hand, was designed based on bent sections.
Both of these issues forced us to take an unusual approach to the method of fabrication and to supervise the correct course of production processes. In order to maintain the proper geometry of the load-bearing structure supporting the photovoltaic panels, it became a priority to manufacture this structure to tolerances smaller than those allowed by the standard.
Solutions used during implementation
Several key measures were implemented to meet the project requirements:
Thorough quality control:
All elements of the structure were inspected in detail both at the stage of material preparation (cutting, drilling, bending), the assembly of the elements into shipping segments and the subsequent welding, which reduced the possibility of possible exceeding acceptable workshop deviations.
Trial assembly:
The entire structure was test-assembled on the workshop, which allowed the elements to be refined to the required manufacturing quality.
Thanks to careful work and the application of the highest production standards, the project was 100% successful. The client expressed full satisfaction with both the quality of the construction and the professionalism of the entire team.
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