As global energy demands increase and urban rooftops become the new frontier for clean energy production, the design and performance of solar panel mounting systems are more critical than ever. Among the industry leaders in this space is Aerocompact, a specialist manufacturer of aerodynamic flat-roof and pitched-roof PV racking systems engineered for maximum safety, flexibility, and ease of installation.
This article explores the performance, design, and safety considerations of Aerocompact solar mounting systems, including how they align with the latest international standards in wind resistance, electrical safety, structural integrity, and fire prevention, while offering tangible advantages for installers, building owners, and insurers alike.
Why Mounting Systems Matter More Than You Think
It’s easy to focus on photovoltaic modules and inverters when designing a solar energy system. However, the mounting structure is what determines whether the panels will remain operational and secure over their intended 25–30 year lifespan. Poor mounting decisions can lead to damage from wind uplift, hail impact, electrical faults, or water infiltration—jeopardising safety and financial returns.
Aerocompact addresses these challenges with a precision-engineered lineup of mounting systems that are tested, certified, and performance-validated for structural, mechanical, and environmental resilience.
Aerocompact: A Quick Overview
Founded in Austria, Aerocompact has expanded globally, offering solutions tailored to local climate and regulatory conditions. Their product lines—such as COMPACTFLAT, COMPACTPITCH, and COMPACTGROUND—cater to flat roofs, pitched roofs, and ground-mount applications respectively. The COMPACTFLAT series, in particular, is well-suited for commercial and industrial buildings, where ballast-free or low-ballast designs are needed to preserve roof integrity.
Aerocompact systems are built from corrosion-resistant aluminium and stainless steel, designed with wind tunnel testing in mind, and comply with standards such as IEC 61215, IEC 61730, and FM Global DS 1-15, which governs rooftop solar PV installations from a property loss prevention standpoint.
Wind Engineering and Ballast Optimisation
One of Aerocompact’s standout features is their aerodynamic optimisation based on extensive Boundary Layer Wind Tunnel (BLWT) testing. Unlike standard models that rely on static wind load assumptions, Aerocompact evaluates real-world wind effects—including vortex shedding, cornering wind uplift, and turbulence caused by rooftop obstructions.
Key highlights include:
- Wind load resistance up to 2400 Pa without requiring roof penetration
- Optimised ballast layout using proprietary simulation software (COMPACTTOOL) to minimise concrete weight while meeting safety thresholds
- Closed and open array designs to accommodate variable wind exposure zones
- FM Approved clamp systems for standing seam roofs, ensuring precise load transfer without compromising roof membranes
In compliance with DS 1-15, Aerocompact systems provide secure anchoring through clamps or ballast for all mechanical components—critical in areas exposed to cyclonic wind events or urban turbulence.
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Fire Safety and Electrical Protection
The risk of rooftop fires from photovoltaic systems—particularly due to undetected DC ground faults—has become a central concern for insurers and authorities alike. Aerocompact integrates fire safety measures by promoting:
- Use of non-combustible mounting components, including aluminium rails and stainless steel hardware
- Minimum spacing between arrays, typically ≥1.2 m (4 ft), to allow firefighter access and reduce flame propagation
- Compatibility with residual current monitoring (RCM) and remote-operated DC disconnect switches, in line with recommendations from NFPA 70 and FM DS 1-15
Aerocompact structures avoid enclosing wiring within ribbed decking or inaccessible voids. This design choice reduces ignition risk and ensures accessibility for annual thermographic inspections and ground fault detection testing—both of which are key maintenance practices for operational PV systems.
Structural Load and Drainage Considerations
Flat-roof PV systems introduce dead weight and alter snow/rain load patterns. Aerocompact mitigates these risks by ensuring:
- Panel tilt angles ≤10° to prevent excessive snow drifting
- Uniform load distribution via support feet with integrated pressure plates
- Compatibility with roofs designed with a slope of at least 1° (1/4 inch per foot) for efficient drainage
- Drainage spacing incorporated in mounting rails to prevent ponding around curbed areas or parapets
Installers and consultants can simulate the static and dynamic loads using the COMPACTTOOL platform, which calculates combined ballast + panel + hardware weights against regional roof load allowances. This helps prevent structural failure, particularly on lightweight membrane or trapezoidal roofs.
Materials and Environmental Durability
Aerocompact systems are engineered for high resistance to UV, temperature cycling, freeze-thaw exposure, and chemical corrosion. Their systems incorporate:
- Aluminium EN AW-6063 T66 profiles, which retain mechanical properties after decades of exposure
- Stainless steel A2 or A4 fasteners, suitable for coastal or chemical plant environments
- Resistance to hail impact, compliant with FM 4473 (2-inch hailstones) and FM 4478 for fire spread and impact testing
This level of durability not only supports long-term system uptime but also contributes to maintaining warranty integrity and insurance coverage.
Supporting Standards and Certifications
Aerocompact’s engineering practices are closely aligned with major international and insurance-backed standards, including:
- FM Global DS 1-15 – Roof Mounted Solar PV Panels
- IEC 61215 – Design qualification for crystalline silicon PV modules
- IEC 61730 – Safety testing for PV modules
- ASTM C1491/C1262 – Concrete paver specifications for ballasted systems
- SEAOC PV2-2012 – Wind design guidance for flat-roof PV
These certifications serve as a reassurance for building owners, developers, and financiers concerned with long-term asset protection, structural integrity, and fire risk mitigation.
Installer-Friendly Design with High ROI Potential
Aerocompact mounting systems are engineered not just for structural performance, but also for rapid deployment and low labour cost. For commercial rooftop installations, time and complexity directly impact return on investment. Aerocompact’s tool-free, modular designs reduce installation time by up to 40% compared to traditional racking systems.
Key advantages include:
- Click-in rails and pre-assembled components, which reduce the need for drilling or cutting on-site
- Integrated cable management channels to secure DC wiring without external conduit trays
- Ballast-free options for sensitive roofs or projects seeking to minimise structural load
- Universal clamps and adaptive hardware that fit most module sizes and thicknesses
For installers, this translates to fewer components, lower inventory requirements, and smoother logistics. For building owners, it means reduced downtime, faster commissioning, and quicker access to solar energy savings.
Maintenance Efficiency and Lifecycle Durability
Rooftop solar systems are exposed to constant environmental stress—from thermal cycling to moisture ingress. Over time, this can degrade not just the modules but the mechanical framework as well. Aerocompact’s focus on long-term operational reliability supports better energy yields, reduced maintenance, and fewer insurance claims.
Recommended maintenance procedures include:
- Annual thermographic inspections of wiring, connectors, and inverters to detect hotspots and degraded insulation
- Mechanical checks for loosened fasteners, corrosion at clamp points, and signs of wear on slip sheets or pads
- Insulation resistance testing every three years in accordance with IEC 62446 to detect early-stage faults
- Visual inspections of roof penetrations and drainage pathways to prevent leaks and structural damage
All Aerocompact hardware is compatible with these inspection regimes. Systems are designed with accessible aisles for technicians and removable panels for ease of servicing.
Case Study: Commercial Flat Roof, 500 kWp System
In a recent project on a logistics warehouse in Southeast Asia, Aerocompact’s COMPACTFLAT S system was selected for a 500 kWp rooftop PV installation. The client required:
- No roof penetrations due to membrane waterproofing
- Wind load compliance for gusts up to 45 m/s
- Minimal ballast due to roof load constraints
Using Aerocompact’s simulation software, engineers customised the array layout with additional ballast at the roof edges and around HVAC units. The system achieved compliance with ASCE 7-16 wind standards, while keeping the total load below 15 kg/m².
The result: full installation in 12 working days, seamless integration with the waterproofing warranty, and successful post-installation wind inspection.
Fire Services and Insurance Considerations
Modern fire codes increasingly require rooftop PV arrays to be installed with clearances for firefighter access, proper shutdown procedures, and flame spread containment. Aerocompact’s systems are designed with:
- Minimum 1.2 m aisle spacing for fire access, as recommended in FM DS 1-15
- Non-combustible mounting hardware and absence of foam or plastic insulation
- Compatibility with residual current monitoring (RCM) for early detection of electrical faults
- Support for remote DC disconnect switches placed near combiner boxes
Many insurers, especially those following FM Global guidelines, prefer or require systems to be compliant with FM 4478 fire and wind standards. Aerocompact systems are either pre-certified or readily certifiable under these conditions, which can translate into lower premiums or simplified claims processes.
Singapore Context: Regulations, Climate, and Suitability
Singapore’s dense urban infrastructure, frequent rainfall, and proximity to the coast introduce several unique considerations for rooftop PV systems:
- High humidity and salt corrosion risks necessitate corrosion-resistant hardware like stainless steel A4 and anodised aluminium—all included in Aerocompact systems.
- Tropical storm winds can exceed 100 km/h. Aerocompact’s BLWT-tested systems are verified for uplift and lateral wind pressures specific to low-slope commercial roofs.
- Limited roof access on HDB or strata-title buildings means fast, clean installation is essential. Aerocompact’s tool-free rail systems and lightweight materials minimise on-site work and disruption.
- SCDF and BCA regulations require fire-safe PV layouts with proper array spacing. Aerocompact’s standard layout tools include built-in compliance with these spacing recommendations.
With the Singapore Green Plan 2030 driving renewable energy adoption, developers and property managers are seeking systems that are both cost-efficient and future-proof—criteria where Aerocompact performs strongly.
Final Thoughts: Why Aerocompact Is More Than Just a Mounting System
Aerocompact’s engineering philosophy goes beyond structural support—it’s about creating a foundation for safe, efficient, and durable solar energy systems. From certified wind tunnel testing to fire-resistant layouts, from installer convenience to regulatory compliance, Aerocompact sets a benchmark in mounting technology.
Whether you’re a facility owner seeking long-term energy resilience or a solar EPC firm looking to streamline installation workflows, the choice of mounting system plays a critical role in project success. Aerocompact provides that assurance—backed by data, certifications, and global deployment experience.