Solar FlexRack Testing
The SolarFlex Rack has been thoroughly tested using the latest techniques — not only to ensure the quality of the product but also to ensure maximum performance in the field. Here is a summary of the testing performed on our product, as well as additional procedures we follow that help make the Solar FlexRack the finest solar rack mounting system on the market today.
Wind Tunnel Testing
For ground-mount Solar FlexRacks, atmospheric boundary layer wind tunnel testing has been performed in accordance with section 6.6 of ASCE 7-05, Chapter C31 of ASCE 7-10 and also applicable to the National Building Code of Canada. Accurate 1:60 scale models of the Solar FlexRack were used in the tests.
As a result of the tests, the Solar FlexRack engineering team is able to design units with the most realistic wind loads possible. The testing allows potential reduction of wind loading by as much as 32% for exterior ground-mount arrays, and as much as 50% for the interior arrays. In this way, a more cost-efficient racking system can be designed, with the most wind-resistant Solar FlexRacks reserved for exterior arrays.
The roof-mount Solar FlexRack has also benefited from wind tunnel testing. As a result of the tests, a wind deflector design was developed that makes it possible for roof ballasting weights to be reduced by a minimum of 50%.
Finite Element Analysis
Finite element analysis of the Solar FlexRack and its components allows the SFR engineering team to perform the most accurate wind and snow loading analysis, thereby meeting the design loading requirements of that area. Using this advanced computer software allows the engineering team to readily note high-stress concentrations. Adjustments then can be made to optimize the design to provide the most cost effective racking solution for each project without sacrificing strength and stability. SFR’s in-house engineering team has received professional training in the latest sophisticated analysis software.
Pull Tests
Physical load pull testing has been performed on critical individual Solar FlexRack fastened connections. The most critical connections are the tilt bracket to horizontal bolted connection and the module clip to vertical rail thread forming connection. A third-party testing laboratory performed the pull tests by loading to failure and determining the corresponding wind speed. All pull tests were performed on the basic Solar FlexRack design components. The tables below indicate the durability of even the most basic Solar FlexRack design connections.
Table 1: Slot-to-Slot connection Pull Test Results
1/2"-13 Tilt-to-Horiz. Bolted Connection |
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Sample # |
Load to Failure, lbf |
Wind Speed, mph |
1 |
2,751 |
143 |
2 |
2,010 |
122 |
3 |
2,399 |
134 |
4 |
2,984 |
149 |
5 |
2,077 |
124 |
Table 2: Module Clip Bolt Pull Test Results
1/4"-20 Module Clip Bolt |
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Sample # |
Load to Failure, lbf |
Wind Speed, mph |
1 |
2,352 |
512 |
2 |
2,414 |
519 |
3 |
2,542 |
533 |
4 |
2,447 |
523 |
5 |
2,502 |
529 |
Consultant Design Team
Solar FlexRack’s in-house engineering team routinely calls upon consultant engineers to review/concur with our design assumptions. This provides a layer of oversight that ensures compliance with all applicable codes regarding loading, design and final analysis. Also, this consultant/ design team partnership with our in-house engineering staff provides us with the ability to provide engineering-stamped permit drawings in all 50 states, the Virgin Islands, Puerto Rico and all provinces in Canada.
DSA
The Division of the State Architect (DSA) provides design and construction oversight for a wide variety of state-owned facilities based on standards used in various public buildings throughout the State of California. The SolarFlexRack engineering staff and a DSA consultant team located in California facilitates the DSA application, design and review process to ensure that all stages of review are performed in a timely and expeditious manner.