Empowering the Future.
Innovative PV Solutions & Expertise.

About us

Econex-PV GmbH is a global provider of solar engineering solutions, PV concepts and expertise related to the implementation of solar power plants.

With our services we aim to provide and support our client’s engineering, procurement and construction Teams with all necessary know-how required for the successful, efficient, and durable implementation and operation of solar power plants.

We have a strong background in structural engineering, substructure implementation and project management which is supplemented by an extensive network of expert partners. Understanding the requirements and challenges of the modern PV market, we provide a diversified portfolio of services using own resources and involving a wide network of specialists – with only one point of contact for our clients.

Services

With our services we aim to provide and support our client’s engineering, procurement and construction Teams with all necessary know how required for the successful, efficient, and durable implementation and operation of solar power plants.

For every solar powerplant, the right preparation and taking the right steps at the right time is key. We will help you to identify the important project parameters at a very early stage of project development.

Basis of Design

Even though many legislations do not regulate the design and implementation parameters for solar power plants specifically, there are standards and normative guidelines to be followed. Looking at a potential project site, we will identify and document the structural and environmental key parameters such as applicable wind loads, snow loads as well as seismic loads and other project specific parameters that need to be considered in the further design and implementation process.

Substructure Evaluations

The goal of every solar power plant is maximisation of efficiency. Whether the target is to use an available plot to generate the maximum possible power output or to
optimally utilize a certain grid connection capacity, the efficiency of a solar power plant is affected by the plot and the used substructure technologies. We will compile the available data of the plot and investigate and compare the possible use of different substructure technologies – with the goal to recommend the suitable technologies
for your project requirements.

Yield Analysis

Efficiency means using the lowest input to achieve the highest amount of output. Applied to a solar power plant it means to get the maximum out of the available solar resource potential. Site Specific Irradiation Analysis help to identify the optimum technology for the project and to provide valuable input for the profitability analysis and business case of a solar power plant.

The design of the project is developing with the progress of the project, from a rough conceptional design in the feasibility study to the detailed design during execution. While the execution design is typically prepared by or coordinated with the specialized contractors, a reliable design basis for the tender process as well as approvals and authorization procedures is of great importance to identify project risks and provide a reliable basis for cost estimations.

Layout Development

An essential part of any project development is the preparation of a substructure and module layout, customized to the plot conditions, project requirements and substructure preference. As a basis for our client’s decision making, we prepare layout options simulating different substructure and module types, customising the spacing and table arrangements to find the best solution for every individual project.

Yield Analysis

If the decision towards a certain substructure decision has not yet been made, an important assessment criterion can be the Yield Analysis for different PV substructure types. We prepare Yield Analysis for different options and configurations to provide an adequate basis for our client’s decision-making.

Topography Survey

An important factor with a considerable impact on a project’s success is the topographic terrain conditions. Identifying the topographic terrain conditions at an early project stage helps to avoid time consuming design iterations, gives the executing companies a reliable basis for their detailed design and therefore enables a precise price calculation from the beginning. We offer detailed surveys of the project plots by using state of the art technologies such as drones or quad surveys, providing high quality data in a practical resolution.

Topography Analysis

With both layout and Topography data available, we will combine the data and generate terrain adjusted layouts that are considering different elevations and slopes. Terrain adjusted layout design helps to identify problematic areas during the design Econex-PV GmbH | service portfolio Rev_00 page 4 of 13 stage and to prevent complications during implementation on site by maintaining the specified ground clearances and making sure all substructure components are within their specified tolerances.

Cut and Fill Planning

If the terrain exceeds the available height- and slope tolerances of the designated substructure it is possible to adjust the terrain with earthworks. Areas exceeding the structural limits are either cut (soil removed to round of “peaks”) or filled (soil added to fill up “valleys”). To plan those earthworks, we prepare target topography files that allow the extraction of the relevant data for on-site implementation.

Detail Drawings

Certain legislations have specific requirements in the permitting process and some areas require detailed substructure drawings already for the permitting and approval process. We prepare substructure drawings for any substructure configuration in the required level of detail.

Structural Design

Should the permitting or design process require structural calculations, we will assist with developing verifiable structurally documentation.

Electrical Design

Besides the structural considerations, the electrical design and the dimensioning of the electrical key components is a major factor for the efficiency of a solar power plant. We prepare string layouts, single line diagrams as well as low voltage cable layouts and put your selected key components like modules, inverters, and transformers to maximum use.

The soil under a solar power plant is always afflicted with a certain degree of risk. European standards refer to this risk as an unavoidable residual risk inherent in the nature of the matter, which can lead to unforeseeable effects or complications such as building damage or construction delays if the soil is utilized. Therefore, a thorough investigation of the available soil at an early stage in the project and the consideration of the results in the further planning steps is essential to mitigate this risk.

Mechanical Soil Analysis

The buildup of the soil is decisive for the bearing capacity and the chemical properties of the soil. It is especially important to identify the soil layers, their thickness, composition, and the ground water situation. By taking core probes and analysing the soil mechanical and physical parameters in the laboratory, these parameters can be assessed in detail.

Chemical Soil Analysis

The financial model of a solar power plant is designed for a certain project lifetime, and it is crucial to make sure the structural integrity is guaranteed for this time period. The key figures related to soil are its aggressiveness towards steel according to DIN 50929-3 as well as its aggressiveness towards concrete according to DIN 4030. Their assessment at an early stage of the project gives valuable input to the following design steps and trades.

Mechanical Load Tests

Foundations of solar power plants are most commonly and efficiently planned and executed with steel profiles rammed directly into the soil. For the stability and structural integrity of the system, the resistance of the profiles in the soil to forces in all directions are decisive. To determine the minimum required ramming depth for a specific use case, there are several possible test procedures that can be used like Pull-Out-Testing or Dynamic Probing. Using our international network of Geotechnical Experts, we determine and use the technology suitable for the specific project conditions.

Corrosion is defined as the reaction of a material with the environment it is exposed to and is therefore inevitable, but there are ways and means to postpone the corrosion of any material to a degree where it does not impair the functionality and structural integrity of a system during its intended service life.

Atmospheric Corrosion Evaluations

Another factor to be considered in the corrosion analysis is the atmosphere. The atmospheric corrosion load is influenced by various factors like climatic data and humidity, maritime salt pollution and anthropogenic influences e.g. coal power plants, chemical industry plants or traffic hot spots. Determining and assessing these factors for the project location will allow the specific derivation of a corrosion class and the determination of annual zinc- and steel degradation rates.

Soil Corrosion Evaluations

Based on the parameters determined during the chemical soil analysis according to DIN 50929-3 we derive annual degradation rates of zinc and steel under the specific conditions.

Profile and Coating Recommendations

Based on the degradation rates determined for soil and atmospheric corrosion, recommendations can be made for coating, minimum zinc layer thickness and sacrificial steel thickness additions.

Lifetime Assessments

In cases where no project specific profile and coating specifications have been available during the implementation of the project, we can assess the chemical data post-implementation and predict the anticipated lifetime of the corrosion protection system.

Building solar power plants in Europe we can rely on extensive codification and regulations, as first and foremost the Eurocode and its local Annexes, however it is worthwhile to verify the codified assumptions with site specific investigations and studies.

Site Specific Wind Climate Study

Wind speed and resulting forces on PV systems depend on the natural occurrence of winds in the area of the PV system as well as on local effects like topography, type of terrain, and the arrangement of the PV system. The Eurocode in combination with the relevant local Annex, provides zoning plans with basic wind velocities for every point in its area of application that have to be taken into account in order to design a structure in accordance with these standards. Given the date of publication of the aforementioned documents as well as the rare and lengthy revision processes, it is not unlikely that there is a divergence between the basic wind velocities defined in the Eurocode and the actual wind conditions on site. Considering the dangers of under- or over dimensioning the structure, a focus in project development has to be on making the right structural assumptions. As an alternative to the codified wind zones, the Eurocode allows to develop a site-specific wind climate study, using extreme value analysis to determine the applicable assumptions with the reciprocal probability for the given design life. With our access to extensive weather data databases, we can evaluate the historical weather data for any project location and assess possible adjustments to the load assumptions according to the Eurocode.

Snow Assessments

Snow load zones are defined in the Eurocode and Local Annexes for every location in Europe. Nevertheless, in certain areas the effect of recurring weather, climate and climate change can cause unexpected exceptional loads on structures, while in other areas the probability of experiencing the snow events considered in the Eurocode has decreased. A project-related, statistical evaluation of historical snow data as part of our site-specific snow load assessment as suggested by the Eurocode, gives our customers certainty to design the structure according to the factual requirements.

Glare Assessments

In Glare assessments we evaluate the glare effects of photovoltaic systems and assess potentially resulting risks for the surroundings. Glare assessments are typically required for PV plants close to traffic routes, rads or airports and can be prepared during the design stage, but also for PV structures that were already implemented.

Technical specifications

Initiating a Tendering Procedure, the builder needs to document and communicate the requirements he has to the tendered work to achieve comparable quotations from different suppliers and therefore a sufficient foundation for the decision towards a certain product. Tendering for PV substructure this means specifically describing the substructure’s nature, technical features, and performance in a way to reflect the project requirements, customer’s quality standards, legislation as well as recognized rules of technology and engineering. By summarizing our experience and expertise in PV Substructure we help our clients to define the structure in line with all these factors and develop a project specific and customized Technical Specification and Description of the Tender Scope.

Tender Evaluation

The ideal outcome of a successful Tender procedure is to achieve several comparable quotations from different suppliers. We help our clients to assess these quotations with the goal to simplify our client’s decision making by providing the prerequisites for comparing apples to apples – making sure our clients really get what they are going for.

Technical/structural verification and advice

Having the suppliers employed on a project means entering the project execution phase. The schedules in this project phase are often a challenge, but the time pressure should not lead to compromises in quality and execution. With our technical and structural verifications, we offer our clients to review and assess the documents prepared by the suppliers in order to assure compliance with the technical specifications, codes and standards as well as local legislation and industry practice.

Acceptance inspections

After construction of the structure on site it is advisable to inspect the works and verify the implementation towards compliance with the contractor’s defined scope of works, tolerances, technical specifications, codes and standards as well as local legislation and industry practice. With our sound structural expertise we can classify non-conformances such as exceeded tolerances and recommend countermeasures. Econex-PV GmbH | service portfolio Rev_00 page 10 of 13 Our inspection and the detailed reports support our clients in their hand-over and acceptance with their contractors and smoothens the way towards practical completion and COD.

End of Warranty inspections

Besides the statutory warranty that any distributor of any component on a solar power plant must grant based on the agreed legislation, it is common for the substructure suppliers to grant an additional, voluntary guarantee. While the statutory warranty is always based on the codification of the respective legislation, the supplier’s warranty is usually specifically qualified and based on negotiated warranty conditions. Since both statutory and supplier’s warranties have expiration dates, it is important that deficiencies are noticed and reported within the respective time frame. With our End-of-Warranty-Assessments we inspect the scope before expiration of the warranty period and make sure our clients can recognize and assert claims in time and not lose their right to warranty claims.

It is a scenario that every builder or owner of a solar power plant wants to avoid but some find themselves in a situation where there is a damage on the system. In this unpopular scenario it is our priority to help our clients to get to the bottom of the situation quickly and provide all necessary support to get the systems up and running again.

On-site inspections

As a first step we consider it crucial to assess the situation on site and get our own picture of the situation. During the site visit we identify damage patterns, identify all influencing factors that might have been involved in the course of events and gather all information required for further assessments.

Technical/structural verification

In the second step we assess the gathered information and compare the execution on site with the underlying execution planning documents, codes and standards as well as recognized rules of technology and engineering. We reconstruct the circumstances that led to the damage and identify possible mismatches between the applicable basis of structural design and the as-built state.

Solution conception and engineering

Facing a damage situation, the goal of every builder or owner of a solar power plant is to rectify the defects and prevent similar events in the future. Consequently, we use the learnings from the on-site inspections, structural- and technical verifications to develop and present solutions for reconstruction and reinforcement of the structure. With our expertise related to wind and snow we can furthermore assess whether similar events are to be expected in the future and how the structure can be prepared to withstand such events.

Repowering is defined as the process of replacing old photovoltaic components with new ones. This becomes economically attractive as new components, for example modules, have decreased in price while at the same time their performance has increased significantly. Since the components have also undergone a development in format and size, the challenge is to incorporate new components with utilization of the existing substructure for maximisation of the price efficiency. Repowering can also mean the incorporation of additional capacity into existing solar system, oftentimes structurally connecting to the existing structure.

Technical/structural verification

Repowering a solar project requires as a first step to analyse and understand the structural calculations of the existing system, identify the load bearing key components, the adjustment possibilities as well as margin for modifications.

On site inspections

With the knowledge of the theoretical structural verification we conduct site visits to assess the implementation and condition of the existing structure. After a certain service life replacements and reinforcements of structural components might become necessary due to exposure to the elements and resulting corrosion, therefore we analyse and record obvious defects and corrosion patterns.

Solution conception and engineering

Based the theoretical structural possibilities of the existing structure and considering the practical condition of the structure on site, we prepare concepts and suggestions for reinforcement and alteration of the structure with the goal to efficiently fit the existing substructure to the new components’ requirements, replace components at the end of their service life or incorporate additional PV elements into the solar system.

Contact

Econex-PV GmbH
Sandelholzstraße 1
88436 Eberhardzell
Phone +49 7355 93359-0
Email info@econex-pv.com