Case Study

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1.2 MW Rooftop Solar on Asbestos Sheet Roofing — Iron Castings Foundry

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01 Client

RBA Ferro Industries Ltd.

Location

West Bengal

System Size

1.2 MW rooftop solar

Facility Type

Iron and steel manufacturer

Roof Type

Asbestos (cement sheet), spanning over 1.4 kilometres

Scope

Custom structural design, corrosion-resistant hardware, installation and commissioning

Overview

Nearly eight years ago, Tech Solar Solutions delivered what was believed to be India’s largest 1.2 MW rooftop solar installation on an asbestos (cement sheet) roof, at an iron castings foundry in West Bengal. The client is one of India’s leading manufacturers of cast iron manhole covers, municipal castings and engineered iron products, supplying infrastructure projects across India and international markets. At the time, the project stood among the most technically demanding rooftop solar installations undertaken in the country.

The Challenge

A foundry environment is unforgiving on exposed hardware. Continuous emissions from the foundry’s manufacturing process accelerate the deterioration of conventional roofing and metallic components, and the plant needed to be installed across more than 1.4 kilometres of asbestos-sheet roofing, a surface that rules out standard mounting techniques, hardware and maintenance practices. There was no existing playbook to adapt. The project called for a structural methodology built specifically for this site.

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Our Approach

Our engineering team started from first principles rather than adapting a standard design. Every exposed fastening component, from the primary mounting structure down to the last nut, bolt and washer, was specified in anodized aluminium for long-term resistance to the corrosive foundry atmosphere. Structural loading, material selection, installation methodology, worker access, safety planning, corrosion protection and future maintenance were each re-evaluated against a single question: how do we engineer a solar asset that keeps operating safely and efficiently for the next 20 to 25 years under these conditions.

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The Result

Why It Matters

Engineering excellence isn’t about applying the same solution to every rooftop. It’s about understanding the environment a plant has to survive in, and designing around it rather than forcing the site to fit a standard template. This project is a working example of that approach, still shaping how Tech Solar Solutions engineers its most demanding rooftop solar projects.

Tech Solar is a solar EPC company delivering rooftop, industrial, and marine solar solutions across India. With 25+ years of experience, we engineer dependable solar systems for homes, businesses, and industry.

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