In order to generate solar power at one of its new production sites in Iggensbach (Bavaria), Fenecon planned to install a large facade solar panel system. The planners and contractors opted for a facade system by fischer BWM Fassadensysteme to securely fasten the photovoltaic modules. The system was developed in cooperation with the module manufacturer Solarwatt to meet the project’s requirements.

Fenecon is a leading manufacturer of energy storage solutions and offers systems for private households, commercial use, industrial purposes, energy providers, and vehicle manufacturers. The company’s solutions use the OpenEMS-based in-house energy management system FEMS. Based in Deggendorf, Lower Bavaria, Fenecon has been producing large container storage systems from electric vehicle batteries since 2017. The success of this concept soon required production to expand. At the start of the year, the company launched operations at the new CarBatteryReFactory site in Iggensbach, located approx. 30 kilometres northwest of Passau. Storage systems will be produced from zero, first and second-life vehicle batteries at the factory. In addition to the production site, the complex furthermore comprises storage facilities, development laboratories and offices. The CarBatteryReFactory represents an important step in the industrialisation and large series production of large container storage systems from electric vehicle batteries.

Fenecon planned to generate a large proportion of the energy for its new plant from renewable sources and therefore envisioned suitable roof and facade surfaces for the purpose of generating solar power through photovoltaic modules integrated into the rear-ventilated curtain-wall facade. “The advantage compared to roof and rooftop systems is that the winter yield of solar facades is higher while the electricity generation is also significantly improved in the otherwise less favourable months”, explains Benjamin Orths, who was involved in the project as International Product Manager of facade systems at the fischer Group of Companies.

Gaass Florian GmbH from Grainet, Lower Bavaria, was awarded the contract to carry out the work on the facade using solar modules by our partner Solarwatt from Dresden, Germany. In total, 552 Solarwatt vision GM 3.0 style glass-glass solar modules were installed on a surface of approx. 1,050 square metres, generating a peak output of 204.24 kilowatt peak (kWp). The solar modules have a general technical approval that allows them to be used for solar car park monitoring and facades without requiring additional securing. fischer BWM Fassadensysteme supported the project managers with planning the facade and developed a project-specific fixing solution compatible with other projects in partnership with Solarwatt. “This resulted in a completely secure system suitable in any area such as residential, office and commercial construction, as long as there is an anchor substrate”, Benjamin Orths states. “With our substructure for PV systems, pre-sealed surfaces can be used and existing facades can be utilised to generate renewable energy”. What makes this innovative design so special is that there is no need for any visually unappealing elements such as insertion tracks and brackets, as high-quality architectural facades can be fastened with clasps. This system further enables a distinguished facade while keeping joints to a minimum. At the same time, it constitutes a permanent and restraint-free construction that securely fastens the modules in the facade. The system is easy and convenient to install and disassemble as needed.

Fenecon’s new plant has been designed as a steel structure. While the parts of the facade not used for solar energy feature an insulated cassette facade, the PV modules are anchored into the supporting structure by a substructure. Vertical carrier profiles serve as a base structure for the horizontal ATK 103 PV clasp profiles, which were fastened to the vertical profiles with drilling screws. The PV modules were then hooked into the open C-profile of these horizontal elements with the pre-mounted clasps attached to the back. Benjamin Orths emphasises, “We made quick progress thanks to pre-mounting the clasps with special screws that precisely fit the horizontal profile”. The size (1780 x 1052 x 40 millimetres) and weight (25.5 kilogrammes) of the PV modules required comprehensive calculations taking into account the weight and wind loads as well as any necessary current regulations and standards.

With the substructure for PV modules, fischer BWM Fassadensysteme facilitates the construction of an aesthetically appealing and safe structure with a sustainable energy source. Thanks to the lasting safety and functionality of the firmly fastened solar facades, solar energy can be converted into electricity for decades without releasing emissions or using resources. This has resulted in a structure that guarantees future-proof, renewable and environmentally friendly energy generation for generations to come.