AU2019200624A1

AU2019200624A1 - A structure and method

Info

Publication number: AU2019200624A1
Application number: AU2019200624A
Authority: AU
Inventors: Harvey Bennett
Original assignee: Lc Automation Pty Ltd
Current assignee: Lc Automation Pty Ltd
Priority date: 2018-01-31
Filing date: 2019-01-31
Publication date: 2019-08-15

Abstract

Embodiments of the present invention relate to a structure for mounting solar panels, such as photovoltaic panels, and a method of setting out and pouring foundations for footings of the structure. The structure may be mounted over any suitable terrain and may ideally be used in solar farms for generating electrical power.

Description

A STRUCTURE AND METHOD

FIELD OF INVENTION [0001] The present invention relates to a structure for mounting solar panels, such as photovoltaic panels, and a method of setting out and pouring foundations for footings of the structure. The structure may be mounted over any suitable terrain and may ideally be used in solar farms for generating electrical power.

BACKGROUND [0002] Solar panels for generating electrical power can be mounted in a range of situations including mounting solar panels to roofs of existing structures such domestic, industrial and semi-industrial installations. The structures used for mounting solar panels in these situations are purposely design and constructed to suit the type of roofing structure such as tiled roofs, or corrugated iron roofs, having many different pitches and slopes.

[0003] Solar farms have purpose built structures for solar panels and are constructed with the aim of generating significantly more power than most rooftop installations. Solar farms maximise power generation by optimising the exposure of solar panels to the sunlight. Typically solar farms have rows of solar panels that are arranged at the same or a similar orientation to face at an angle toward the sun and are not impacted by architecture of existing buildings to which the solar panels are installed.

[0004] One of the constrains of arranging solar panels at an angle is that they cast a shadow and when the sun is lower in the sky during days of shorter daylight hours, the panels are oriented more upright due to sun angle which casts larger shadows. To reduce this impact, rows of the panels are typically spaced apart to reduce the extent and period in which panels are in the shadow cast by another row.

SUMMARY OF THE INVENTION [0005] The present invention relates to a structure for mounting solar panels, the structure including:

a first frame that faces upwardly at an angle toward a first cardinal direction, and the first frame extends in a lengthways direction that is lateral to the first

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2019200624 31 Jan 2019 cardinal direction, such as in a north-south orientation;

a second frame that faces upwardly at an angle toward a second cardinal direction, and the second frame extends in a lengthways direction that is lateral to the second cardinal direction, such as in a north-south orientation;

wherein the first cardinal direction and the second cardinal direction are away from each other, and wherein the first and second frames are arranged side-by-side and form either a gable formation or a valley formation.

[0006] The first frame having a first plane that faces upwardly in the first cardinal direction, and the second frame having a second plane that faces upwardly in the second cardinal direction.

[0007] The first and second cardinal directions may be opposite. For example, the first cardinal direction may be in an easterly direction, the second cardinal direction may be in a westerly direction, and the lengthways direction may be in a north-south orientation. In other words, the first cardinal direction may be toward the sunrise, and the second cardinal direction may be toward the sunset.

[0008] Depending on the gradient of the terrain on which the structure is assembled, either one or both of the first and second planar faces may be curvilinear in at least the lengthways direction. It may also be possible for the first and second planar faces to be curvilinear in a width-ways direction.

[0009] The structure may be any suitable material, including wood, steel, engineered products including polymeric materials, and laminates of different materials. Ideally, the structure is coated with a corrosion inhibiting coating such as galvanised coated, or a zinc and aluminium coating such as zincalume™. In one example, any part of the structure that is positioned in the ground may have a galvanised coating, and any part of the structure above ground may be coated with a coating including zinc and aluminium.

[0010] The structure can be used for mounting solar panels having a frame made of any

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2019200624 31 Jan 2019 suitable material, including aluminium and alloys containing aluminium.

[0011] In the gable formation, the first and second planes face away from each other. In otherwords, an angle between the first and second planes is greater than 180 degrees. In one example, the planes may be arranged at an angle in the range of 200 to 240 degrees, and even more preferably, the planes may be arranged at an angle of approximately 196 to 200 degrees, and yet even more suitably, the planes may be arranged at angle of approximately 198 degrees.

[0012] In the valley formation, the first and second planes face toward each other. In other words, an angle between the first and second planes is less than 180 degrees. In one example, the planes may be arranged at an angle in the range of 170 to 120 degrees, and even more preferably, the planes may be arranged at an angle in the range of 150 to 160 degrees, and even more suitably in the range of approximately 154 degrees.

[0013] The shadow cast by solar panels mounted to either the first or second frames is dependent on number of factors, include the orbit of the sun over the sky. However, one of the benefits of the present invention is that when one of the first and second frames is directly radiated by sunlight, shadows from the first and second frame is minimised. For example, during sunrise, the first frame will receive direct sunlight, and the second frame position adjacent to the first frame will begin to be radiated directly as soon as the sun rises above the plane of the first frame. Similar, shadow from the second frame will extend over the first frame as soon as the sun falls below the plane of the second frame. One of the benefits of the present invention is that spacing between the first and second frames can be avoided all together, thereby maximising “land usage”, minimising cabling, and reducing the foot print of other associated equipment.

[0014] An upper ridge formation may be located at a junction of the first and second frames of the gable formation.

[0015] A lower trough formation may be located at a junction of the first and second frames of the valley formation.

[0016] The structure is ideally ground mounted. For example, the structure may be directed

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2019200624 31 Jan 2019 anchored to the ground, and the structure includes posts that can be attached to foundations. The posts may be attached to footings that are embedded in the foundations. The footings may, for example, be screw pile footings, or footings that are embedded in concrete.

[0017] In a preferred embodiment, the posts and footings may each be discrete bodies that are assembled together.

[0018] In another embodiment, the posts and footings may be integrally formed, and may for example have different coatings for portions that can be embedded in a foundation, and portions that are above the foundation.

[0019] In an embodiment, the footings are separable from the posts. The footings may be galvanised.

[0020] The footings may have an elongate section of substantially uniform cross-section that extends into a foundation and above the ground. The footings and the posts are configured to fit one within the other. Ideally, axes of the post and the footings are co-axial when assembled. The posts may have a uniform cross-section that inter-fits within the cross-section of the footing. For example, the posts and footings may be sections, such as roll formed sections that inter-fit.

[0021] Either one or both of the footings and the posts may have a locator, such as a locating pin, that is operable to provide a stop when the posts and footings are interfitted in an assembled position. For example, the locating pin may be attached to the post, which engages the footing when inter-fitted, or the locating pin may be attached to the footing, which engages the post when inter-fitted. The posts and footings may be in the assembled position when pre-formed openings on the footings and the posts are aligned for receiving fasteners.

[0022] Ideally, the footings are multi-end so that one end of the footings that can extend to a foundation can also be used as an upper end of the footings above the foundation and vice versa.

[0023] The footings may have apertures through which concrete, including aggregate can flow when wet, the apertures are placed along the footings.

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2019200624 31 Jan 2019 [0024] The footings may have any cross-section, including square tubular shapes, circular tubular shapes, H-shapes, L-shapes and C-shapes. The footings may have a central web. In one example, the central web may be outer wall of a rectangular or square shaped tubular section, or a wall of an L-shaped section.

[0025] In the situation in which the footings have a C-shaped cross-section, the C-shape has a central web and two side flanges extending from the web facing toward each other. The locating pin, such as a nut and bolt fastener, may extend between the flanges at a positioned above the ground, and engage a lower end of the posts to locate the posts in an operative position. Suitably, the lower end of the post engages an inside the two side flanges.

[0026] The posts and the footings may have preformed fastener openings that align when the posts are seated on the locating pin that allow fasteners, such as nut and bolt fasteners to connect the posts to the footings.

[0027] The preformed fastener openings may be provided at one end, but preferably at both ends of the footings.

[0028] Ideally, the posts can be received inside the footings.

[0029] The posts and the footings may each have first and second central webs, respectively, that are located against each other when the posts and footings are inter-fitted. The first and second central webs may be flat planar plates. The posts and footings may have at least one flange extending from the first and second central webs respectively.

[0030] The posts may also be made of any suitable section, including square tubular shapes, circular tubular shapes, H-shapes, L-shapes and preferably C-shapes. The posts may have a central web. In one example, the central web may be an outer wall of a rectangular or square shaped tubular section, or a wall of an L-shaped section.

[0031] The posts of the structure ideally extend upright and support the first and second frameworks in an operative position above the ground. The posts may be C-shaped which includes the first central web and side flanges extending from the first central web. The side

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2019200624 31 Jan 2019 flanges and first central web may form a channel along the length of the post. The channel is open along a majority of the length of the post. Suitably, the channel is open along the entire length of the post.

[0032] The first and second frames have opposite ends, such as north and south facing ends, and the structure may have end posts and a least one intermediate post between the end posts to form two lines of the posts. One line of posts support the first frame, and one of second posts supports the second frame. In addition, the first and second frames are connected.

[0033] The structure may include pairs of posts in which one of the posts (of each pair) supports either the first frame or the second frame respectively, and a pair of rafters span between the posts of each pair of posts. The pairs of post and the corresponding pairs of rafters joined to the posts spans from the first frame to the second frame to provide a standing sub-structure. Spaces between each standing sub-structure defined a bay. The structure may have any number of bays. For example, depending the particular application, the structure may have in the range of 3 to 25 bays, suitably from 5 to 15 bays, or even more suitably in the range of 6 to 12 bays.

[0034] In a preferred embodiment, the rafters that are connected to each post.

[0035] Ideally the rafters are located directly over the posts, and a haunch bracket interconnects the rafter to the respective post.

[0036] The rafters may have any suitable cross-section. The rafters may have a third central web and at least one flange extending from the third central web. In one example, the rafters may have a C-shaped cross-section in which the third central web is oriented upright, and top and bottom flanges extend from the central web.

[0037] The haunch bracket includes a main plate and at least first and second outer flanges extending outwardly from the same side of the main plate. The main plate may be located flush with the post and the rafter. Ideally, the rafter is located so that the first and third central webs of the post and the rafter are aligned, and the main plate of the haunch bracket can be

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2019200624 31 Jan 2019 located against the first central web of the post and third central web of the rafter. The first outer flanges of the haunch bracket extend about a side flanges of the post and the second outer flange extends about either one of the top or bottom flanges the rafter. Suitably, the second outer flange of the haunch plate extends about and engages the top flange of the rater. The side flanges of the post and the top and bottom flanges rafter may all extend in the same direction relative to the first and third central webs. Fasteners, such as self- drilling screws, tek screws, or nut and bolt fasteners can attach the haunch plate to the post and the rafter.

[0038] The structure may have a lengthwise beam extending between end posts of the first and second frames. The lengthwise beam may also extend between the end posts, or between the end posts and the, or each, intermediate post. The beam may also extend between multiple intermediate posts. The beam may be a fascia beam.

[0039] In a preferred embodiment, the first and second frames have parallel rafters extending widthways.

[0040] In this situation, the rafters may be parallel in plan view. The rafters may also be arranged at a first angle of inclination.

[0041] The rafters of the first frame and of the second frame may be connected at an apex of the gable formation or at the trough of the valley formation.

[0042] The structure may include a junction bracket that interconnects the rafters at the apex or at the trough.

[0043] The junction bracket may have i) a base web that can be located on the third central web of the rafters of the first and second frames and ii) a pair of flanges, in which each flange is arranged at an angle to the other and engages the top flanges of the rafters of the first and second frames. Ideally, the pairs of flanges are at an angle that corresponds to the angle between the rafters of the first and second frames. Fasteners can be used to fix the junction brackets to the rafters.

[0044] The junction bracket may also have a bottom flange that extends between the rafter of

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2019200624 31 Jan 2019 the first and second frames. Suitably, the bottom flange engages the rafters of the first and second frames.

[0045] The structure defines bays between each pair of post and each pair of rafters of the first and second frames connected to the posts.

[0046] The battens may extend over the rafters in a lengthways direction of the first and second frames. Ideally each batten comprises a plurality of purlins arranged in the line so that adjacent purlins overlap and are connected together so as to be able to pivot about longitudinal axes of the purlins. The pivot connection may be provided by a single fastener interconnecting the purlins.

[0047] The purlins may be of any suitable cross-section, but ideally have a Z-shaped section, including a fourth central web, and top and bottom flanges. The top and bottom flanges extend outward from opposite sides of the plane of the fourth central web.

[0048] The top and bottom flanges of the purlins may have a lip and electrical cabling can be accommodated under the top flange or on top of the bottom flange and secured in position using tie downs, such as cable ties, ziplock ties, fabric tie downs and so forth.

[0049] At least one of the purlins may be arranged on the haunch plate. The purlins may be attached using fasteners. The fastener attaching the purlins on top of the haunch plate, can fasten the purlin to the haunch plate and to the rafter, and indirectly to the post to which the haunch plate is connected. In other words, locating the purlin on top of the rafter in this manner provides addition rigidity to the structure.

[0050] The first and second frames may have any number of the purlins. For example, the frames may have two purlins for each solar panel.

[0051] Solar panels may be attached to the purlins without cladding extending between the purlins. Ideally, the purlins have pre-installed holes for securing solar panels to the purlins. If required, isolation members may be located between the solar panels and the purlins to minimise galvanic reaction therebetween. In addition, isolation members may also be located

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2019200624 31 Jan 2019 between the purlins and the rafters. The isolation members may be any suitable polymeric membrane, including polypropylene sheets and polyethylene sheets.

[0052] The structure may also be characterized by having solar panels mounted thereon. The solar panels may be arranged in rows and ranks. For example, each bay may have 4 rows and 4 ranks of the solar panels. Specifically, each bay of the first frame may have 2 rows and 4 ranks of the solar panels, and each bay of the second frame may have 2 rows and 4 ranks of the solar panels.

[0053] The present invention also relates to a method including the steps of:

locating a formwork template on the terrain where the structure is to be erected;

excavating foundation holes in the terrain to be erected;

attaching the footings of the structure to the formwork template at the designated locations so as to suspend the footings in the foundation holes;

adjusting the height of the formwork template to position the footings at a desired height; and pouring concrete into the foundation holes to anchor the footings in the foundation holes.

[0054] The present invention also relates to a method of assembling the structure for mounting solar panels described herein, the method including the steps of:

excavating foundation holes in the terrain to be erected;

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2019200624 31 Jan 2019 adjusting the height of the formwork template to position the footings at a desired height; and pouring concrete into the foundation holes to anchor the footings in the foundation holes.

[0055] Locating the formwork template may include manually manoeuvring the formwork template relative to setting out strings that have been installed in a preliminary step.

[0056] Excavating the foundation holes maybe are carried out manually or with the assistance of an auger. Identifying the location of the foundation holes maybe performed using the setting out strings or via the formwork template.

[0057] Ideally the footings are attached to the formwork template using fasteners to prevent pivoting movement of the footings.

[0058] Adjusting the height of the formwork may include levelling the formwork template by chocking the formwork template.

[0059] Adjusting the height of the formwork may include changing the effective length of the legs on which the formwork is supported. The effective length of the legs may be operable for locating the formwork template in a desired plane, such as a horizontal plane or in a plane substantially parallel to the slope of the terrain. In one example, the legs may be adjustable legs having a screw threaded rod that is adjusted up and down by rotating the rod. In another example, the adjustable legs may have an elongated slot and the formwork has a pin that moves along the slot to adjust the point of connection between the formwork template and the point at which the formwork is attached to the leg.

[0060] The method may also include erecting the structure for mounting solar panels described herein.

[0061] The steps of the method of the present invention may be carried out concurrently, consecutively or disjunctively with one or more pauses between each step.

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2019200624 31 Jan 2019 [0062] Once the concrete has set, the formwork template can be removed from the footings and relocated for erecting the next set of footings.

[0063] An embodiment relates to a structure for mounting solar panels, the structure including:

a first frame that faces upwardly and at an angle toward a first cardinal direction, and the first frame extends in a lengthways direction that is lateral to the first cardinal direction, and the first frame has at least two posts, in which each post supports a first rafter that extends widthways;

a second frame that faces upwardly and at an angle toward a second cardinal direction, and the second frame extends in a lengthways direction that is lateral to the second cardinal direction, and the second frame has at least two posts, in which each post supports a second rafter that extends widthways;

[0064] An embodiment of the present invention relates to a formwork template for locating footings in concrete foundations during a concrete pour, the formwork template having:

an outer perimeter frame that extends about the foot print of the structure, wherein the outer perimeter includes lengthways members, and widthways members, wherein the outer perimeter having pre-set attachment points for attaching footings to the outer perimeter;

at least one diagonal member that interconnects spaced parts of the outer perimeter frame, and the diagonal members ideally interconnected adjacent widthways members; and the outer perimeter having pre-set attachment points for attaching footings to

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2019200624 31 Jan 2019

the outer perimeter.

[0065] An embodiment relates to a structure for mounting solar panels, the structure

including:

a first framework defining a first upward planar surface, (hereafter the first plane,) in which the first planar surface is also configured to face in a first co-ordinate direction, and the first framework being arranged to extend in a north-south orientation, a second framework defining a second upward planar surface, (hereafter the second plane,) in which the second plane is also configured to face in a second co-ordinate direction, the second framework being arranged to extend in a northsouth orientation, wherein the first co-ordinate direction and the second co-ordinate direction are opposite, and wherein the first and second frameworks are arranged side-by-side and form either a gable formation or a valley formation.

[0066] The present invention relates to an installation having a plurality of the structures described herein that are arranged side-by-side, in which the first frames of one of the structures is located adjacent to the second frame of another of the structures, so that at least two of the first frames are separate by one of the second frames, and at least two of the second frames are separated by one of the first frames.

[0067] The structures may be arranged side-by-side, in which the structures are arranged adjacently in either an easterly or westerly direction relative to the other.

[0068] Suitably, solar panels are mounted to the first and second frames of the structures of the installation.

[0069] In one embodiment, a gap may be provided between the solar panels of the first and second frames of the structures arranged side-by-side. The gap may allow vehicle access or

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2019200624 31 Jan 2019 maintenance access between the structures.

[0070] In another embodiment, little or no gap may be provided between the solar panels on the first and second frames of the structures arranged side-by-side. That is to say, little or no gap is provided between the solar panels of the first and second frames of adjacent structures. For example, the gap may be less than the length of one solar panel. Suitably, the gap may be less than 50cm.

BRIEF DESCRIPTION OF THE FIGURES [0071] A preferred embodiment of the present invention will now be described with reference to the accompany figures. A summary of the figures is as follows.

[0072] Figure 1 is a perspective view of an assembled structure to which solar panels can be mounted, the structure comprising first and second frames defining first and second planes facing in easterly and westerly directions respectively, and the first and second frames extending in a north-south orientation.

[0073] Figure 2 is a side view of the assembled structure shown in figure 1.

[0074] Figure 3A is a side view of one of the footings and part of one of the posts identified in circle A in figure 2.

[0075] Figure 3B is an enlarged perspective view of part of the footings shown in figure 3A.

[0076] Figure 4A is a side view of part of the portion of the structure identified by circle B in figure 2, comprising of an upper end of a post, on which a rafter is seated and a purlin are shown in cross-section, in which the rafter is interconnected to the post via a haunch plate.

[0077] Figure 4B is a perspective view of the portion of the structure identified by circle J in figure 1.

[0078] Figure 4C is an enlarged view of the rafter and purlin identified by circle C in

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2019200624 31 Jan 2019 figure 2.

[0079] Figure 5A is a perspective view of the portion of the structure shown in circle G in figure 1, comprising rafters of the first and second frames being interconnected by a junction plate.

[0080] Figure 5B is an enlarged side view of the rafters of the first and second frames being interconnected by the junction plate as shown in circle D of figure 2.

[0081 ] Figure 6 is an enlarged view of the corner of the structure shown in circle E of figure 1, comprising a purlin supported on a rafter and a diagonal bracing member.

[0082] Figure 7 is an enlarged view of the rafter and a purlins shown in circle F of figure 1.

[0083] Figure 8 is a perspective view of a formwork template for locating and supporting the footings within foundation holes during concrete pouring, the formwork template having positioned for four pairs of footing and corresponding posts.

[0084] Figure 9 is a plan view of the formwork template shown in figure 8.

[0085] Figure 10 is a block diagram of method steps for assembling a structure, such as the structure shown and described with reference to figures 1 to 7, using the formwork template shown in figures 8 and 9.

[0086] Figure 11 is a side view of two of the structures shown in figure 1 interconnected endto-end in a lengthwise direction of the first and second frames.

[0087] Figure 12 is a plan view of the structure shown in figure 11.

[0088] Figures 13 and 14 are perspective views of posts and screw pile footings.

[0089] Figures 15 and 16 are enlarged views of the posts and screw footings identified by circles H and I in figures 13 and 14 respectively.

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2019200624 31 Jan 2019 [0090] Figure 17 is a perspective view of a formwork template for locating and supporting the footings within foundation holes during concrete pouring, the formwork template having positioned for five pairs of footing and corresponding posts.

[0091] Figures 18 and 19 are enlarged perspective and side views respectively of the portion of the formwork template shown in the circle J in Figure 17.

[0092] Figure 20 is top view of the adjustable leg shown in figures 18 and 19.

DETAILED DESCRIPTION [0093] A preferred embodiment of the present invention will now be described with reference to the accompanying figures. Specifically, the following text includes reference numerals to help identify the corresponding features in the company figures. To maintain the clarity of the figures however, not all reference numerals are included in each figure.

[0094] With reference to the figures, the structure 10 is ground mounted and has first and second frames 11,12 arranged side-by-side and interconnected in a gable formation that forms a central ridge extending in the north-south orientation lengthways of the structure 10. Although not shown in the figures, it is possible that the first and second fames 11 and 12, may be connected in a valley formation.

[0095] The first and second frames 11,12 including rafters 13 arranged widthways and battens 14 arranged lengthways. The structure 10 includes pairs of posts 15, in which one of the posts 15 (of each pair) supports either the first 11 frame or the second 12 frame respectively, and the rafters 13 span between the posts 15 and are interconnected at the ridge by a junction plate 17, best seen in figures 5A and 5B. The structure 10 includes multiple pairs of posts 15, in which each pair of posts are interconnected by the rafters 13. In particular, the structure 10 shown in Figure 1 has five pairs of posts 15, totaling ten posts 15, and the posts 15 are arranged in a line under the first and second frames 11 and 12 and define four bays between the posts 15. In addition, the rafters 13 extend outwardly beyond the posts 15 to define an eave or overhang at the side of the structure extending lengthways, see Figures 1 and 2. Figures 1,2, 11 and 12 also illustrate the battens 14 terminating flush with the sides of the rafters 13. However, it will be appreciated that the battens 14 may extend

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2019200624 31 Jan 2019 outwardly of the end rafters 13 at the gable ends if desired.

[0096] As can be seen in figures 1 and 2, the first and second frames 11 and 12 are arranged at a reflex angle in the range of 200 to 240° and ideally approximately 198° apart. The first frame 11 is arranged to face upwardly and toward a first cardinal direction, namely in an easterly direction. The second frame 12 is arranged to face upwardly and toward an opposite second cardinal direction, namely in a westerly direction.

[0097] The battens 14 are provided in the form of a line of overlapping purlins 18. Solar panels, such as photovoltaic panels housed within aluminium frames can be mounted to the purlins 18 without any cladding between the solar panels and the purlins 18. Ideally the purlins 18 and the other parts of the structure 10 above the ground are made of a carbon steel that is coated with anticorrosion zincalume™ so as to minimise galvanic reaction between the outer solar panels and the structure 10. However if desired an inert material, such as a polymeric membrane can be located between the solar panels and the purlins 18. Similarly, an inert material can also be located between the purlins 18 and the rafters 13.

[0098] One of the benefits of the structure 10 is that the solar panels on the first and second frames 11,12 can be positioned closely adjacent to each other, for instance with minimal or no spacing between the solar panels mounted to the first and second frames 11, 12. This reduces the amount of terrain required compared to other mounting systems in which the frames for mounting solar panels are arranged in one direction. In addition, arranging the first and second frames 11, 12 in a gable formation or the valley formation allows the shadow of the first frame 11 on the second frame 12 to be minimised while the sun is rising. Similarly when the sun is setting, the shadow of the second frame 12 on the first frame 11 is also avoided as much as possible.

[0099] This benefit can be further utilised when the structure 10 is duplicated in one or more of the north-south directions, as shown in figures 10 and 11, or in the east-west direction.

[0100] As can be seen in figures 3A and 3B, the posts 15 and footings 16 are C-shaped sections having first central webs 19 and second central webs 20 respectively, and two side flanges 21,23 extending outwardly and facing toward each other to form a cavity. As can be seen the cavity of the C-shape of the footings 16, can be sized to receive the posts 15.

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2019200624 31 Jan 2019 [0101] The footings 16 have a set of symmetrical openings along the length of the section so that the footings 16 are a multi-directional in the sense that the top can be used as the bottom and vice versa. Specifically, the footings 16 include fastening holes 26 in the second central web 20 and holes in the side flanges 23 that align with corresponding holes in the first central web 19 and side flanges 21 of the posts 15 that receive nut and bolt fasteners 24 that clamp the footings 16 and posts 15 together.

[0102] The second central web 20 of the footings 16 also includes larger openings 25 for allowing penetration of concrete mortar for securing the footing 16 in position. As can be seen in figure 3B, a pin 22 in the form of a nut and bolt can be located between the opposite side flanges 23 of the footings 16 which provides a stop member on which a bottom end of the posts 15 can be seated for aligning the fastening holes 26 of the footings 16 and the posts 15.

[0103] The footings 16 are coated with a galvanised coating and can be embedded in concrete foundations of an appropriate size. The structure 10 above the footings 16 are ideally coated with a zincalume™ which is galvanically compatible with the aluminium frames of the solar panels.

[0104] As can best be seen in figures 4A and 4B, the rafters 13 are in the form of C-shaped sections having an upright third central web 31 and upper and lower flanges 32, 33. The lower flange 33 of the rafter 13 is directly seated on the top end of the post 15, with the upright third central web 31 of the rafter 13 aligns with the first central web 19 of the post 15.

[0105] The posts 15 and footings 16 are arranged so that first and second webs 19 and 20 of the footings 16 and of the posts 15 in each consecutive pairing lengthways of the structure are arranged in opposite directions. For instance, if the first web 19 and the side flanges 21 of the first pair of posts 15 face in a first direction, then the first web 19 and the side flanges 21 of the second pair of posts 15 face in a second direction, which is opposite to the first direction. Similarly, as the third webs 31 of the rafters 13 align with the first webs 19 of the posts 15 on which the rafters 13 are seated, the third webs 31 of consecutive rafters in a lengthways direction also face in opposite directions. By alternating the positioning of the first and second webs 19 and 20 of the posts 15, rafters 13 and footings 16 in this way, the rigidity of the structure is improved.

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2019200624 31 Jan 2019 [0106] In addition, the posts 15 and footings 16 define an elongate open channel along the length of the posts 15 and the footing 16 that are located above the ground. The elongate channel does not require a cover to provide structural rigidity. If electrical cabling is located in the channels, a cover may be provided over the channels to protect the cabling. However, the cover is not required to provide structural rigidity. Similarly, the rafters 13 define an open channel along their length that can be accommodate electrical cabling.

[0107] A haunch plate 27 is used to securely interconnect an upper end of the post 15 and the rafter 13 on top of the posts 15. The haunch plate 27 includes a main plate 34 having a triangular section, best seen in figure 4A, and first and second locking flanges 29, 28 extending from adjacent sides of the main plate 34. The haunch plate 27 is installed so that the main plate 34 sits flush against the first central web 19 of the post 15 and the upright third web 31 of the rafter 13. The first and second locking flanges 29, 28 extend about the top flanged 32 of the rafter 13 and an outer flanged of post 15. Nut and bolt fasteners 35 can be used to secure the haunch plate 27 to the third central web 31 of the rafter 13 and to the first central web 19 of the post 15. Fasteners 35 can also be used to fix the first locking flange 29 to the top flanged 32 of the rafter 13 and fix the second locking flange 28 to an outer flanged of the post 15.

[0108] A spacing is provided between the first and second locking flanges 29, 28 which accommodates the rafter 13 as it extends outwardly of the post 15. As can best be seen in figures 1 and 2, the rafters 13 overhang outwardly of the posts 15 to form an eave.

[0109] The rafters 13 of the first and second frames 11,12 extend inwardly of the posts 15 and interconnect at a central ridge that extends in a north-south direction. The ends of the rafters 13 a square cut and are interconnected by a junction bracket 17 including a base web 36 that is located flush against the third central webs 31 of the rafters 13 and an upper angled flanged 37 having first and second portions that extend over the top flange 32 of the rafter 13. The first and second portions of the upper angled flange 37 are ideally angled to correspond to the angle of inclination of the rafters 13 to the central ridge.

[0110] Although not shown in the figures, it will be appreciated that the first and second locking flanges 29,28 could be arranged to engage either one or both of the lower flange 33

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2019200624 31 Jan 2019 of the rafter 13 and/or an inner flange 23 of the post 15 that faces the main plate 34 of the haunch plate 27.

[0111] The junction bracket 17 may also include a bottom flange 38 that extends from a lower edge of the base web 36 that engages the lower flange 33 of the rafter 13. Nut and bolt fasteners 39 can be used to clamp the base web 36 with the third central web 31 of the rafter 13 and to secure the first and second portions of the angled flange to the upper flanges 37 of the adjacent rafters 13.

[0112] As can be seen in figures 4C, 5A and 6, the purlins 18 are Z-shaped purlins having top and bottom flanges 40, 42 and an upright fourth central web 41. The lower flange 42 can be fastened to an upper flange 32 for the rafters 13 and the individual lengths of the purlins 18 can be overlapped. A single fastener 43 can be used through the upright fourth webs 41 of the purlins 18 to allow the purlins 18 to articulate, thereby accommodating difference gradients in the terrain along the length of the first and second frames 11, 12.

[0113] As can be seen in figure 4A, one of the purlins 18 is seated on the haunch plate 27, namely the haunch plate purlin. The haunch plate purlin sits on top of the upper flange 32 of the haunch plate 27 and is directly attach to the haunch plate 27 and the rafter 31 by a fastener. The haunch plate 27 therefore directly interconnects the haunch plate purlin to the respective post.

[0114] As can be seen in figures 4B and 5A, 6 and 7, the top flange 40 of the Z-shaped purlins 18 include pairs of holes 44 for fixing the solar panels to the purlins 18. The structure has pairs of spaced purlins 18 for each solar panel. Specifically, the preferred embodiment has four purlins 18 on the first frame 11 and four purlins 18 on the second frame 12. In other words, the first frame 11 has two rows of solar panels, in which each solar panel is supported on the a pair of spaced apart purlins 18. Similarly, the second frame 12 has two rows of solar panels, in which each solar panel is supported on a pair of spaced apart purlins 18.

[0115] Additional benefits of the Z-shaped purlins 18 include, the lower flange 42 of the purlins 18 can be readily access by power tools for fitting the nut and bolt fasteners, and the top flange 40 can be used to accommodate and protect electrical cabling of solar panels. For example, although not shown in the figures, cable ties can be used to fix electrical cabling

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2019200624 31 Jan 2019 beneath the top flange 40, or to the lower flange 42. The electrical cabling can be fixed to upper and lower faces of the lower flange 42.

[0116] In the event that the structure 10 is installed on uneven terrain, the length of the posts 15 can be modified and/or the length of the footings 16 above the ground can be controlled. If desired, the orientation of the first and second frames 11,12 can follow the slope of the terrain.

[0117] Figures 1,5A and 6, show the structure 10 with bracing members in the form of strip 46 or sections that have been installed diagonally between adjacent rafters 13, or adjacent posts 15 to provide triangulation stiffening.

[0118] The structure 10 according to the preferred embodiment is made up of essentially 5 main components, namely the footings 15, the posts 15, the rafters 13, the purlins 18, and connectors. The connectors include the haunch plate 27, the junction bracket 17 and bracing members 45, 46. The structure 10 has relatively few components and has a maximum height in the range of 1.5 to 2.0 metres which allows the structure 10 to be readily assembled by installers standing on the ground without scaffolding or height equipment.

[0119] Figures 8, 9 and 17 illustrate formwork templates 50 for setting out the foundations and more particularly, for supporting the footings16 in the foundations during a concrete pour. The template 50 of Figure 8 sets out four pairs of footings 16 so that the structure 10 made with this template has three bays. The template 50 of Figure 17 sets out five pairs of footings 16 so that the structure made with the template 50 has four bays. Multiple templates 50 can of course be used end-to-end to allow the length to be structure to changed.

[0120] The templates 50 of Figures 8 and 17 have an outer perimeter with two parallel side members that include two longitudinal sections 51 connected end-to-end, two end members 52 extending widthways across the template 50, and two intermediate members 53 extending across the template 50. The templates 50 also includes diagonal members 54 that stiffen the template 50 and maintain the template 50 in a square configuration.

[0121] Figure 9 is a plan view of the formwork template 50 which includes circles representing the foundations for the footings16. Extension members 55 extend outward from the perimeter

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2019200624 31 Jan 2019 of the template 50, and footings'! 6 not shown, can be temporarily connected to the extension members 55 via the faster holes (see figures 18 and 19) to suspend the footings 16 in the hole of the foundation.

[0122] The template 50 can include adjustable legs 62 that are operable to level the template 50, for example in a horizontal plane or in a plane parallel to the terrain. Figures 18 to 20 illustrate an example of an adjustable leg 62 having an elongate section 56 with a slot 61 and base plate 57, best seen in figure 20. The base plate 57 can be fixed to the ground by a ground peg passing through the hole 62. The formwork template 50 has a pin 60 that can be moved along the slot 61 and a tightening nut (not shown in the figures) to fix the elevation of the formwork template 50 on the leg 62, and hence the elevation of the formwork template 52 from the ground. The formwork template 50 also includes a stabilizing piece 58 that engages the legs 62, which helps prevent the leg 62 from pivoting about the pin 60. The stabilizing piece 58 helps to stabililize the leg 62 in an upright orientation.

[0123] Figure 10 is a block diagram illustrating the steps for setting out the foundations and pouring the foundations with footings 16. Steps include setting out string lines defining the corners and orientation of the structure on the site. The formwork template 50 can then be located in position relative to the string lines. If desired, the formwork template 50 can take the place of the string lines and surveying applied directly to the template to locate the template in position with the use of the string lines. In any event, the foundation holes can be excavated, for example using an auger under the extension members, as denoted by the circles infigure 9. The template 50 is levelled and supported in a level orientation using chocks or adjustable legs and the footings temporarily attached to the template. Concrete can then be poured into the foundations and allowed to set. Once the concrete is set the template can be disconnected from the footings and moved to the site of the next structure.

[0124] Figures 11 and 12 illustrate an installation in which the structure 10 has been repeated in an end-to-end manner in a north-south direction, thereby aligning the first frames 11 and second frames 12 in longitudinal flanks with a continuous central ridge between the flanks. The installation comprises two of the structures 10 arranged end-to-end to provide a total of eight bays.

[0125] Installation can also include the structure 10 being repeated in a side-to-side manner in

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2019200624 31 Jan 2019 an east-west direction, whereby a lowermost aspect of the first frame 11 is located adjacent to the lowermost aspect of the second frame 12 of an adjacent structure, thereby creating a wave profile of the gable formations, heading in an east-west direction. In this arrangement, the first frame of one of the structures is connected to the second frame of the same structure and is adjacent to the second frame of another adjacent structure. Similarly, the second frame of one of the structures is connected to the first frame of the same structure and is adjacent to the first frame of another adjacent structure.

[0126] Figures 11 and 12 also illustrate banks of solar panels 56 arranged in two rows and four columns on the first frames 11, and similarly two rows and four columns on the second frame 12 between consecutive posts. In other words, each bay has of the first frame has eight solar panels, and the second frame has eight solar panels.

[0127] Figures 13 and 14 illustrate an example of an alternative footing 16 in the form of a screw pile footing 62 that is rotatably driven into the ground. Figures 15 and 16 are enlarged views of the footing in circles H and I of figures 13 and 14. The screw pile footing 16 has a shaft with a screw threaded along a lower portion of the shaft, and top plate having a set of slots extending radially on the top plate. A separate bracket is used to connect the screw pile footing 16 to the post 15. The bracket has a base plate 63 and a wall including flanges 66 and 67 that are arranged at right angles to provide a corner to which a post 15 is attached. The base plate 63 has parallel slots 68 that can be align with two or more of the slots of the top plate to allow fasteners, preferably in the form of nut and bolts 65, to attach the bracket to the top plate of the screw pile 16. The flanges 66 and 67 also have holes that align with holes in the lower end of the posts 15 to allow fasteners, suitably in the form of nut and bolts 64 to attach the postsl 5 to the corner of the bracket, and in turn, anchor the posts 15 to the ground via the bracket and the footing 16.

[0128] The screw pile footings 16 do not require concrete foundations and can be used instead of, or in combination with, the footings 16 of figures 3A and 3B.

[0129] A person skilled in the art will appreciate that many variations and modifications may be made to the preferred embodiment described herein without departing from the spirit and scope of the present invention.

Claims

1. A structure for mounting solar panels, the structure including:

a first frame that faces upwardly at an angle toward a first cardinal direction, and the first frame extends in a lengthways direction that is lateral to the first cardinal direction, and the first frame has multiple first posts, in which each first post supports a first rafter that extends widthways;

a second frame that faces upwardly at an angle toward a second cardinal direction, and the second frame extends in a lengthways direction that is lateral to the second cardinal direction, and the second frame has multiple second posts, in which each second post supports a second rafter that extends widthways;

wherein the first cardinal direction and the second cardinal direction are away from each other; and wherein the first and second frames are arranged side-by-side.

2. The structure according to claim 1, wherein the first cardinal direction is in an easterly direction, the second cardinal direction is in a westerly direction, and the lengthways direction is in a north-south orientation.

3. The structure according to claim 1 or 2, in which the first rafters are connected to the second rafters and a pair of the posts support the first and second rafters.

4. The structure according to any one of the preceding claims, wherein the first rafters are supported by only one of the first posts, and the second rafters are supported by only one of the second posts, and the first and second rafters are interconnected and the respective first and second posts are paired together by the first and second rafters.

5. The structure according to any one of the preceding claims, wherein the first and second frames form a gable formation in which planes of the first and second frames face away from each other at an angle in a range of 200 to 240 degrees.

6. The structure according to any one of the preceding claims, wherein the first and second frames form a valley formation, and first and second planes for the first and

2019200624 31 Jan 2019 second frames face toward each other at an angle a range of 170 to 120 degrees.

7. The structure according to any one of the preceding claims, further including footings that are attached to the posts, in which the footings and the posts have uniform cross-sections in a longitudinal direction and slidably inter-fit into an assembled position, and either one or both of the footings and the posts have a locator that is operable to provide a stop at which the posts and footings are inter-fitted in the assembled position.

8. The structure according to claim 7, wherein the footings and the posts have preformed holes that align to receive fasteners when the footings and the posts are aligned in the assembled position.

9. The structure according to claim 7 or 8, wherein the footings consist of sections of uniform cross-sections that are multi-ended so that one end of the footings can be embedded in a concrete foundation and the other end located above the foundation and vice versa, and the sections have apertures through which concrete, including aggregate can flow when wet.

10. The structure according to any one of claims 7 to 9, wherein the posts and the footings have C-shaped cross-sections in which the post has a first central web and two side flanges extending from the first central web, and the footing has a second central web and two side flanges extending from the second central web, and the first and second central webs are located against each other in the assembled position.

11. The structure according to any one of the preceding claims, wherein the rafters sit on top of the posts, and a haunch bracket interconnects the rafters to the posts.

12. The structure according to claim 11 when appended to claim 10, wherein the haunch bracket includes a main plate and at least first and second outer flanges extending outwardly from the main plate, and the main plate is located flush with first central web of the post and the third central web of the rafter, and the first outer flanges extends about one of the side flanges of the post and the second outer flange extends about one of the side flanges of the rafter.

13. The structure according to any one of the preceding claims, wherein the rafters of the first frame and of the second frame are connected by a junction bracket that interconnects the rafters, in which the junction bracket has i) a base web that can be located flush on the

2019200624 31 Jan 2019 rafters of the first and second frames, and ii) a pair of flanges that are arranged at an angle to the other and engages top flanges of the rafters of the first and second frames.

14. The structure according to any one of the preceding claims, wherein the junction bracket also has a bottom flange that extends between the rafters of the first and second frames.

15. The structure according to any one of the preceding claims, wherein the structure has battens that are arranged over the rafters in a lengthways direction of the first and second frames, and the first and second frames each have four lines of the battens for supporting two rows of solar panels on the first frame and for supporting two rows of solar panels on the second frame.

16. The structure according to claim 15, wherein the lines of battens comprises a plurality of overlapping adjacent purlins that are connected together in a manner that allows the longitudinal axes of the adjacent purlins to be arranged at an angle.

17. The structure according to claim 15 or 16, wherein the purlins have a fourth central web and top and bottom flanges, in which the top and bottom flanges have a lip and electrical cabling can be accommodated under the top flange or on top of the bottom flange and secured in position using a tie.

18. The structure according to any one of the preceding claims, wherein solar panels are attached to the purlins.

19. The structure according to any one of the preceding claims, wherein solar panels are attached to the purlins without cladding extending between the purlins.

20. A method including the steps of:

excavating foundation holes in the terrain to be erected;

attaching footings of the structure according to any one claims 1 to 18 to the formwork template at the designated locations so as to suspend the footings in the

2019200624 31 Jan 2019 foundation holes;

21. The method according to claim 20, wherein the method includes a preliminary step of setting out string lines that mark the locate the foundation holes, and the step of locating the formwork template includes manually manoeuvring the formwork template relative to setting out string lines.

22. The method according to claim 20 or 21, wherein the step of adjusting the height of the formwork includes changing the effective length of adjustable legs on which the formwork is supported.

23. The method according to claim 22, wherein the adjustable legs have an elongated slot and the formwork has a pin that moves along the slot to adjust the point of connection between the formwork template and the point at which the formwork is attached to the leg.

24. An installation having a plurality of the structures according to any one of claims 1 to 19, in which the structure are arranged side-by-side, in which the first frames of one of the structures is located adjacent to the second frame of another of the structures, so that at least two of the first frames are separate by one of the second frames, and at least two of the second frames are separated by one of the first frames.

25. The installation according claim 24, wherein the structures have solar panels attached thereto, and a gap is provided between the solar panels of the first and second frames of the structures arranged side-by-side, in which the gap is sized to allow vehicle access or maintenance access between the structures.

26. The installation according to claim 24, wherein the structures have solar panels attached thereto, and little or no gap is provided between the solar panels on the first and second frames of the structures arranged side-by-side.