Industrial & Manufacturing
A 40,000 sq ft distribution warehouse, Midlands
This is an illustrative scenario for a single-tenant distribution warehouse. It has a large, lightly-used flat roof and steady daytime demand from conveyor, refrigeration and materials-handling equipment. Because that demand profile is where rooftop solar economics are typically strongest, it makes a useful example.
Illustrative example: this is a composite scenario built from patterns typical of industrial & manufacturing sites — it is not a specific named client, and the figures below are not a promise of what any real site would achieve. We publish it to show how we think through this kind of decision, not as a verified track record.
This is an illustrative example, built from patterns we typically see in warehousing and logistics engagements. It does not describe a specific client. However, the figures are not a guarantee of what any real site would achieve.
The scenario: a 40,000 sq ft single-tenant distribution warehouse on a standard steel-portal frame. Its shallow-pitch, built-up roof is reaching the end of its original warranty. Conveyor systems, chilled storage and materials-handling equipment drive high, steady daytime demand. Since that demand is constant, the site can use most of its solar generation directly, rather than exporting it at a lower rate.
A feasibility study typically starts with the roof. It checks sheet condition, structural loading capacity, and any wind-uplift or snow-load constraints on a span of this size. Additionally, it includes a grid-connection check with the local DNO. This confirms there is headroom for the array under consideration.
Where the roof warranty is expiring, we usually assess re-roofing and solar together. Since access and scaffolding cost money either way, doing both at once avoids paying for them twice.
We size the system to match self-consumption against the metered half-hourly load. We do not simply fill the available roof. Oversizing against a daytime-heavy but variable process load can push a meaningful share of generation to a lower export rate. As a result, it can weaken the payback.
For a site with this profile, illustrative modelling typically shows capital allowances materially improving the net cost. Payback typically lands in the region of 5–6 years. However, the real figure for any specific site depends on its tariff, roof condition and actual metered demand.
Frequently asked questions
Is this a real client result?
No — this is an illustrative, composite scenario built from patterns typical of warehousing and logistics sites, not a specific named client or a verified outcome. We use it to show the kind of assessment and reasoning involved, not to promise a specific payback.
Why does roof age matter so much for a site like this?
Large, ageing roof sheets have a defined structural loading limit, and adding an array without checking it first is the single most common reason warehouse solar projects stall late in design. We assess structural capacity before recommending a system size.
Weighing up a similar site?
This scenario is illustrative, built to show how we approach a decision like this one. Your own building or estate will differ in roof space, usage, and grid connection. A feasibility study therefore gives you the real numbers before you commit to anything.