Solar panel installation above existing rooftop equipment

Kymos Laboratory in Sant Cugat, Spain, required the installation of 219 solar panels across its 1,585 m² rooftop. Walraven provided a tailored support solution that maximised the available space while allowing the building’s existing rooftop equipment to remain fully operational.

Installing solar panels on a complex roof

The project involved installing solar modules on a roof already occupied by climate control equipment and air handling units.

The solution needed to:

Install 219 solar panels without moving or interfering with the existing equipment.
Avoid penetration of the roof membrane.
Maximise the available rooftop space.
Maintain normal building operations during installation.

Tailored solar support solution

Walraven engineers developed a bespoke support structure specifically for the project, providing detailed drawings and calculations to ensure efficient assembly on site.

The solar panel support system incorporated:

Walraven Maxx Heavy Rail Profiles.
Walraven RapidStrut® channels with Walraven BIS UltraProtect® 1000 surface protection.
Walraven Maxx Linear Connectors.
Walraven Maxx Base Plates and 90° Profile Connectors.
Walraven Solar Panel Clamps.

The structure was designed to position the solar panels 2.5 metres above the roof, allowing them to be installed above the existing rooftop equipment. Ballast blocks provided the required stability without perforating the roof membrane.

To support performance and drainage, the panels were installed with a 2% slope, helping to minimise shading effects while allowing rainwater to drain effectively.

Maximising rooftop performance

By utilising the space above the existing equipment, the project team was able to optimise the roof area available for solar energy generation without affecting the operation of the building.

The solution delivered several benefits:

Efficient use of rooftop space.
Improved solar yield through optimised panel positioning.
Reduced heat impact on both the HVAC equipment and the roof surface.
Installation without interrupting building operations.
No welding required during installation.

Delivering sustainable energy generation

Through careful engineering and a bespoke support design, Walraven enabled the installation of 219 solar panels on a complex rooftop environment. The result is a non-penetrating, future-proof solar mounting solution that maximises energy generation while preserving the functionality of the existing rooftop infrastructure.