Fluids / Aerodynamics| Multi-Physics| Structural
Optimized Design & Stability Analysis of Solar Mounting Structures Using FEA and CFD
Executed For SolarSquare Energy Private Limited

CASE STUDY BRIEF

This case study shows how CFD and FEA were used to optimize a rooftop Solar MMS against varying wind loads. We applied an IS 875-compliant inlet velocity profile, captured aerodynamic effects around the building, and validated the structure with IS 801 for cold-formed members.

Problem Statement

Rooftop MMS required wind-load validation where code defaults missed parapet/edge effects. We generated IS 875–based inlet velocity profiles for CFD, mapped Cp/CoP by zone, and verified cold-formed members and connections per IS 801.

Target: reduce steel, control deflection, and secure joint integrity with audit-ready docs.

How we helped

We created a detailed 3D MMS model and a building-resolved external flow domain. Using a k-ω turbulence model, CFD produced Cp/CoP distributions by panel zone (edge/corner/interior). These pressures were converted to line/point loads for IS 801 checks, including non-linear bolt-pretension and frictional contacts at critical joints.

Where high stress/deflection appeared, we iterated section sizes and added local plates; the final design met IS 875 wind envelopes and IS 801 serviceability limits while reducing steel and clarifying installation details.

Challenges overcame

01.
IS 875 velocity profile for CFD—derive inlet profile by terrain category to emulate real rooftop flow.
02.
Wind-induced load variations across directions and zones (edge, corner, interior).
03.
Aerodynamic complexity around parapets—separation/reattachment causing local high pressures.
04.
Control structural deflections and global stability under extreme gusts.
05.
Connection strength—bolt pretension + frictional contact to prevent slip/bearing failure.
06.
Material optimization—reduce tonnage while maintaining FoS and serviceability.
07.
Compliance—align CFD loads with IS 875 and member checks with IS 801.
08.
Computational effort—high-fidelity meshing/solver settings without excessive runtime.

Project Approach Steps

Benefits to SolarSquare Energy Private Limited

01.
Enhanced wind-load resistance with building-aware Cp/CoP and safer margins at edge/corner panels.
02.
Even load distribution—stress hot-spots mitigated via section tuning and local plate add-ons.
03.
Verified connection integrity—bolt pretension + contact modeling reduced peak bolt stress.
04.
Code compliance—CFD aligned to IS 875; members/deflection validated to IS 801 limits.
05.
Cost-effective design—section optimization lowered steel without compromising reliability.
06.
Higher reliability & longevity—reduced deformation under dynamic winds; clearer install drawings and memos.

Testimonial

"Excellent Work"
— AB

Project Images

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