Company Background
Blockleys Brickworks, based in the UK, has a rich history as a leading manufacturer of high-quality bricks and clay building materials. Established in the 19th century, the company has grown from a small local operation to a significant player in the construction industry, known for its expertise in producing durable and aesthetically pleasing products.
Blockleys specialises in the manufacture of extruded bricks and pavers, offering a wide range of colors, textures, and finishes that cater to both traditional and contemporary architectural styles. The company’s commitment to innovation, sustainability, and customer satisfaction has earned it a solid reputation across the UK and beyond.
Project Approach
Having successfully tendered for the project, NSI set about finalising a solar system design that maximised the generation of electricity from the roof. All of the generated electricity was expected to be used by the brickworks to displace electricity bought from the grid. To be able to develop a thorough understanding of the site and to follow industry best practice, a number of surveys and investigations were arranged. Structural, roof condition and electrical surveys all provided useful insights for the project as well as ensuring that the installed system would be safe and compliant.
The surveys indicated that there was enough residual capacity in the roof structures to take the proposed solar installation. They also provided information to enable the roof access and scaffolding design as well as highlighting the requirements to connect to the high voltage transformer on site.
Early application for the Grid Connection Agreement was vital to ensure that it didn’t hold up the project start date and so that any recommendations were incorporated into the design. The National grid granted the connection but mandated a G100 Customer Limitation Scheme to restrict export which had to be factored into the design.
With NSI Energy acting as the Principal Contractor and Project Manager, a working team consisting of NSI, sub-contractors and site management was set up to sign off and oversee the installation of the system.
NSI Energy Solution
NSI Energy provided a turnkey solar solution, meticulously engineered to meet the specific requirements of Blockleys Brickworks. With a focus on maximising on-site generation, the final design filled both the north-east and south-west facing roofs wherever possible. Care was taken to avoid installing solar panels near extracts and over the exceptionally hot kilns beneath the roof as they would reduce the performance of the panels.
Three access points were erected to get people and materials onto the roofs and the gulleys and skylights were protected to create a safe working environment for the installers. A specialist team used to dealing with high voltage transformers was brought in to complete the electrical installation and to fit additional reverse power flow relay equipment that works alongside the G100 export limitation device to ensure excess power does not reach the grid.
The strong focus on health and safety and operational imperatives meant that the work was carefully scheduled with the site team and wherever possible utilised quieter periods at the site, including a rare total power shutdown on a Sunday to make the final power connection.
This 632kW installation included 1264×500 Long solar panels, 490kW of Solis inverters and K2 systems GmbH mountings. Blockleys will save over 120 tonnes of carbon emissions each year, which is the equivalent of planting more than 5400 mature trees. The generated solar power will be utilised exclusively within the facility, contributing to operational efficiency and sustainability goals.
Key Project Facts
- 632 kWp of rooftop solar
- 584,829 kWh of annual solar power generation
- 120 Tonnes of annual carbon saving
- 1,264 solar panels
- 2,970m2 of roof space
- Investment payback of 3 years
Get Started with Saving Energy Today
Contact NSI Energy today to discuss your solar and energy needs.
NSI Energy is a trading name of Northern Storage and Interiors Ltd.
Company Number: 02812585 VAT No.: 153389353
