Butler News

FedEx Ground is installing the largest U.S. rooftop solar-electric system at its distribution hub in Woodbridge, New Jersey. It’s the fifth solar project for a FedEx operating unit, but the first that will involve FedEx Ground and BlueScope Construction (BSC.) BP Solar will be the solar system provider and installer.

BlueScope Construction provided structural design, building shell materials and erection on the original Woodbridge facility and its subsequent expansions. BSC was asked to join the rooftop solar project by FedEx Ground to help ensure that all roof warranties remained intact with the addition of the solar panels.

Because reinforcement of the roof structure was impractical in an operating facility, BSC evaluated unused MEP (mechanical, electrical, plumbing) dead load capacity by surveying the completed systems in place to determine the extent of roof area capable of sustaining the weight of the photovoltaic modules and the required cable and raceway. Exclusion zones were identified to allow the solar power engineers to arrange the optimum array. The total roof size of the facility is 538,000 square feet with 50% of the roof area to be used for photovoltaic modules or raceway. BSC helped the project team work out a material staging and installation plan that minimizes rooftop traffic and protects the integrity of the roof. Inverters and cable marshalling cabinets will be located on the ground adjacent to existing electrical equipment.

BP Solar and BSC coordinated the direct attachment of the photovoltaic modules to the Butler MR-24 standing seam roof system without any roof penetrations! This coordinated engineering effort will not compromise the superior 25-year weathertightness warranty offered with the roof and allows the roof to continue to provide excellent performance for FedEx Ground.

Approximately 12,400 solar panels will be placed on the roof. When operational, the system will have a generating capacity of 2.42 megawatts of electricity, which could provide up to 30% of the hub’s annual energy needs.

BlueScope Construction will remain as a consultant throughout the project to protect FedEx Ground’s weathertightness roof warranty. The project is expected to begin installation in August 2009 and be completed by November.