South aisle roof solar panels project

The Church of England has committed to an ambitious 2030 net-zero carbon target. St Bene’t’s has committed to working towards becoming an Eco Church, implementing sustainable practices wherever possible and reducing our carbon footprint significantly. As part of this, we are currently installing solar panels on the south aisle roof. The existing lead on the south aisle roof was nearing the end of its useful life, and would have needed to be replaced in the next 5 years or so. It therefore made sense to replace the lead at the same time as we install solar panels (new lead will last for approximately 60 years; solar panels have an expected lifespan of at least 25 years).

 

Current electricity usage at St Bene’t’s is 4.1 MWh pa (11.2 kWh per day). This is predominantly used for lighting (a new LED system installed in 2019, which has reduced consumption by about a third), with small amounts used for computers, cleaning appliances and heating water for hot drinks. The heating system is powered by gas, consuming about 40.1 MWh pa . We are using all the available roof space (~60m2) by mounting 24 x 415 W solar panels (each 2m2) directly onto a new lead roof. This will give a 10 kW solar array, generating approximately 8.7 MWh pa (23.8 kWh per day), assuming a typical annual weather cycle.  This will result in a reduction of almost 2te CO2 per annum in our carbon footprint.

 

Because solar energy production, and our electricity use, are both uneven, both on a daily basis and throughout the year, we are installing a 10kWh battery in the existing oak cupboard on the north wall of the tower, in order to maximise efficiency by storing excess energy until we need it.  A 8kW hybrid inverter is also being installed in the cupboard. The space around these units will be well ventilated to provide adequate natural air cooling and an alarm installed as a precaution to detect any (unlikely) overheating.  Any generated power which exceeds our needs (both direct use and to keep the battery charged) will for the time being be exported to the grid.  However, our ambition is eventually to use the additional 4.6 MWh pa to provide some of the power for our heating, by converting from gas to an electricity powered heat pump system. 

 

On this page we are posting photos of the project in progress.  The first stage has involved removing the old lead roof, strengthening the underlying roof structure to take the load of the solar panels, using a new steel ridge girder and the modification of the support beams to take the wooden base for the lead roof.  This stage is almost complete and will be followed by the laying and sealing of the new lead on top of the supporting platform.  Then towards the end of August the solar panel array will be mounted on fixing stands attached to the roof and connected to our power system and the storage battery mounted in the Tower.  We will continue to post photos over the next few weeks; the project is due to be completed by the end of September.

 

25 July 2024

Roof strengthening girder and new beams - tower end of roof

Close up of roof strengthening girder

Roof strengthening girder and new beams - vestry (east) end of roof, showing how south end of church is joined to Corpus Christi College at far end

Close-up of east end of roof with architect Jerry Lander and Valiant contractor Les

West edge parapet at tower end

Corrugated steel roof covering the whole scaffolding structure to keep the roof dry during the installation

Tower wall above roof over Ramsey Room, showing weathering of lower portion where water has run off nave roof

Corner section of parapet at tower end, where the west and south edge parapets meet

8 August 2024

Central section of roof with boarding now in place with lambs wool insulation underneath between beams. Brown pipes are temporary drains; when lead is in place the black cast iron drains take water from nave roof to south aisle roof, with the water draining further to gulleys below the south edge parapet

The object on the trestle is one of 48 metal posts that the solar panels will be fixed to. The post is fixed to the wooden roof and will protrude through the lead covering when this is laid on top. The square ‘top hat’ on the post is then folded down and sealed to the roof lead to provide a water-tight seal round the post.

16 August 2024

Valiant contractor Mark demonstrating how the lead ‘top hat’ folds down ready to be sealed to the roof lead sheeting

Rolls of lead sheet waiting to be installed

Rolls of lead ready to be laid on the completed wooden roof boarding at west (tower) end of roof

Close-up of solar panel fixing post showing central fixing disc and the lead ‘top hat’ which is folded down and sealed to the lead sheeting through which the post protrudes

Close up of lead sheet roll showing grainy finish, the imprint of the packed bed of sand on which the molten lead is poured to form the sheet

Close-up of section of tiled Corpus roof which joins St Bene’t’s roof at right angles; aligning the wood platforms, lead and the edge of the tiled roof to give a watertight seal and good drainage from both roofs is a complex exercise!

Close-up of how the St Bene’t’s and Corpus Christi roofs join

Gulley area adjacent to south roof parapet into which water drains

One of several drain holes (enlarged for this project compared with the originals) which lead the roof water into downspouts and the drains at ground level

The boarded south aisle roof awaiting laying of the lead sheet

7 September 2024

Completed leadwork with solar panel posts - full view of south aisle roof

Completed leadwork with solar panel posts - east end of roof

Completed leadwork with solar panel posts - junction with Corpus Cosyn building

Completed leadwork with solar panel posts - full view, east to west

Completed leadwork with solar panel posts - full view, west to east

13 September 2024

Junction of roof with Corpus Cosyn Building, showing bricked up window

Junction of roof with Corpus Cosyn Building, detail of bricked up window

Solar panel mounting posts, covered in lead and sealed into roof lead covering

Close up of solar mounting post, sealed into roof lead covering

Downspout from main church roof, discharging onto south aisle roof from which water passes down to ground drain

East end downspout; water will drain down the roof slope, under the solar panels

View of St Bene’t’s Saxon Tower from south aisle roof

View of St Bene’t’s Saxon Tower and South Aisle windows from south aisle roof; also showing water drainage hoppers and downspouts from main roof

17 September 2024

Solar panels installed on south aisle roof, in beautiful sunshine, awaiting connection to our battery and power supply

20 September 2024

Solar panel installation – west to east

Solar panel installation showing wire grill to exclude birds

Close up of wire grill to exclude birds

Solar panels, middle section with church reflections

Bottom section of new tower drainage downspout, taking rainwater from upper roof to new south aisle roof, from which it drains to ground

Scaffolding to replace damaged tower downspout showing some new and some missing sections

16 October 2024

Full scaffolding to top of tower showing extent of downspout repair/replacement and construction of pipe sections from lead sheet

Worn and damaged sections of old tower downspout which were replaced by new lead pipe

Lead plaque on roof showing the date of the current lead roof replacement alongside that of the previous lead recasting (1969)