Transforge (UK)

Market leading steel fabrication company, Transforge (UK) Ltd, utilises the roof of its new purpose built factory to generate renewable energy for the manufacturing of steel components for the communication, construction, power and transport industries.

Case study summary

Following expansion and relocation to a new purpose built factory, market leading steel fabrication company Transforge (UK) Ltd, based on Eagle Business Park in Yaxley approached Worcester Renewable Energy to install a photovoltaic system to mitigate its rising energy costs as result of the company’s increased production. Managing Director, Simon Haynes, said: “Supporting the rail, tunnelling and utilities industries with the manufacture of bespoke steel components involves the use of a significant amount of machinery, the majority of which is powered by electricity. Following the addition of number of new machines to cope with increased production we decided to take advantage of the buildings large roof area by installing a photovoltaic system which now provides a significant amount renewable electricity towards the running of our machines, reducing our reliance on electricity form the grid. It also helps us reduce the amount of CO2 we produce from our business operations and we are therefore pleased to be playing our part in contributing to a more sustainable future.“ The installation maximises the roof space available on both the east and west facing roofs whilst maintaining access for any future maintenance required to the roof lights. A total of 322 REC Peak Energy panels have been installed. All of the associated electrical components, including the inverters and G59 relay have been conveniently installed adjacent to the main incoming electrics and distribution board, again allowing for ease of access and maintenance.

Customer testimonial

“We are very pleased with the installation completed by Worcester Renewable Energy, especially their willingness to accommodate our input and requests throughout the project. We were surprised at how involved the application process was to connect the system to the grid as well as the witness testing of the system by the Distribution Network Operator (DNO). We were therefore extremely appreciate that Worcester Renewable Energy acted on our behalf liaising with the DNO providing a truly turnkey installation”
Simon Haynes. Managing Director. Transforge (UK) Ltd.

Procurement & preliminary items

Following a competitive tendering process, Worcester Renewable Energy were pleased to be appointed by Transforge (UK) Ltd to design, supply, install and commission a PV system at its new purpose built factory and offices. Prior to commencing the installation, Worcester Renewable Energy obtained a connection offer from the Distribution Network Operator (DNO) to connect the system to the grid. Confirmation from the structural engineer representing the company who designed and built the steel portal frame was also sought to confirm that the roof the roof was capable of taking the static and wind loads to be imposed from the addition of the panels and mounting system.


A pre-commencement meeting was held between Worcester Renewable Energy and Transforge (UK) to agree the program of works, final panel array layout and location of electrical components. Risk assessments and methods statements were also agreed to ensure the safety of everyone on site.

Erection of scaffolding

Prior to arrival of the installation team, scaffolding was erected to permit the safe working at height. It had been agreed during the pre-commencement meeting with the customer that two loading bays would be incorporated into the scaffold design, one to service the east facing roof, and one to serve the west facing roof to reduce the amount of foot traffic on the roofs by eliminating the need for the installation team to have to travel from one roof to another. It was also agreed that the scaffold and loading bays would be erected to permit the uninterrupted use of the building so that the Transforge business activities could continue as normal whilst the installation was being carried out.

Roof inspection

On arrival to site, the installation team first carried out a full inspection of the roof area receiving the panels for any notable defects requiring prior rectification. No defects were found which was reported to the building facilities manager, allowing setting out of the roof mounting system and panel array to proceed.

Panel delivery

To keep site traffic and any resulting inconvenience to the customer to a minimum, all 322 panels were delivered to site on a single delivery. The pallets of panels were then fork lifted to the designated holding area before being lifted up onto the east and west loading bays as the panel arrays progressed using a telehandler.

Installation of DC strings

All DC cables from the panel arrays were brought through the profile sheet roof into the building adjacent to the existing soil vent pipe via second soil pipe terminal and weathering. This avoided unsightly cable drops down the sides of the building which would have been at the detriment to aesthetics of the building.

Final inspection

Prior to removal of the scaffolding the roof installation was thoroughly inspected by the Worcester Renewable Energy Installation manager to ensure the panel arrays had been installed in accordance with the design, the area was clear of all waste materials and that no damage to the roof has been caused. Once satisfied, the roof installation was signed off and the scaffolding then removed.

Completed electrical installation

The completed electrical installation comprised of four 3-phase inverters, 3-phase generation meter and a G59 relay protection panel. All of the inverters were connected to the Transofrge (UK) main server allowing the system and its performance to be monitored online both locally and remotely.

Commissioning and witness testing

As the system was over 50KW, Distribution Network Operator (DNO) witness testing of the operation of the G59 relay was required to verify and test that system would disengage should a fault condition occur on either the Grid Network or Customers installation thereby protecting both parties equipment and personnel from any resultant damage or injury. All tests were found to be satisfactory and the G59 commissioning documentation was issued by the DNO and the system brought into operation.

Completed installation

Following completion of the installation, Worcester Renewable Energy assisted Transforge (UK) Ltd in obtaining an export Meter Point Administration Number (MPAN) from the DNO so that any electricity exported to the grid can be sold under a Power Purchase Agreement (PPA).