Engineering Durability Into Every System: The Structural Performance of DCE Solar Racking

EXECUTIVE SUMMARY 

Durability is not an added feature at DCE Solar. It is a foundational design principle engineered into every racking solution. From rooftops to ground mounts and trackers, DCE Solar‘s racking systems are built to withstand the most demanding environmental conditions while maintaining long term structural integrity, safety, and performance. 

Topics of Consideration for DCE’s Durability Claim:

•  Wind Tunnel Testing

•  Snow Load Engineering

•  Design Life & Warranty

•  Corrosion Protections and Epoxy Add-On

•  Material Selection and Steel Gauge 

WIND TUNNEL TESTING

Wind tunnel testing plays an important role in supporting the durability of DCE Solar’s racking systems by informing structural design decisions with a clearer understanding of how wind interacts with solar arrays in real world conditions.

Through controlled testing and analysis, DCE evaluates wind effects across different array configurations, accounting for variations in pressure, uplift, and overall system response that can change based on layout. These insights are incorporated alongside established engineering principles to ensure that dynamic wind behavior is appropriately considered during system design.

By factoring in elements such as wind direction, array height, and tilt into code compliant design methodologies, DCE is able to develop racking systems with consistent load transfer, reduced long term stress, and dependable structural performance. This approach supports durable system designs that are intended to perform reliably under demanding wind environments throughout their expected service life.

SNOW LOAD ENGINEERING

Snow load performance is engineered on a project specific basis to meet local codes and site conditions.

The Eco-Top rooftop system is designed to accommodate substantial snow accumulation typical of commercial rooftop installations. While final pounds per square foot values are determined per project, the system provides the flexibility required to meet regional snow load requirements.

For the fixed-tilt Long Span, snow load capacities can reach up to 90 PSF depending on configuration and site specific engineering. Heavy duty fixed tilt designs are routinely engineered for snow loads up to 50 PSF and beyond when required, providing confidence in cold weather and high accumulation regions.

DESIGN LIFE AND WARRANTY

DCE Solar racking systems are engineered with a design life exceeding 30 years. This reflects conservative engineering assumptions, robust material selection, and validated structural performance.

Standard product warranties are 20 years across Eco Top, Long Span, and 25 across Tracker Twin systems. This distinction between design life and warranty demonstrates DCE Solar’s engineering margin and long-term reliability expectations.

CORROSION PROTECTION

For sites with corrosive soil or environmental exposure, DCE Solar offers an epoxy add-on membrane shield solution.

For projects with corrosive soils, DCE offers an epoxy coating add-on for Driven Beam and Ground Screw foundations. The coating is applied to the portion of the foundation installed in and just above grade, typically covering a 3 to 4 foot section based on embedment depth. This epoxy barrier protects against oxidation at the air soil interface, which is often the most vulnerable corrosion zone, extending foundation life and reducing long term degradation risk.

MATERIAL SELECTION

Material thickness plays a critical role in structural performance.

Eco Top rooftop systems utilize 18-gauge steel throughout the racking assembly, delivering superior rigidity compared to many competitive rooftop systems.

Long Span ground mount systems use steel ranging from 16-gauge to 8-gauge, depending on the component and load demand. This heavier gauge construction supports higher wind speeds, increased snow loads, and longer table spans with fewer foundations.

BUILT FOR THE LONG TERM

Across all product lines, DCE Solar integrates high strength materials, weather resistant finishes, UV protection, and robust connection details. These systems are designed to perform consistently across wide temperature ranges and diverse climates while simplifying installation and reducing long term risk.

Durability at DCE Solar is proven through testing, validated through engineering, and realized in the field.

DCE Durability Document.pdf

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