Project Challenges

The Fisher & Paykel Healthcare 5.3MW rooftop solar project is one of the largest rooftop PV projects in New Zealand. Installed across approximately70,000 square metresof rooftop space, the project placed high demands on system safety, structural reliability, installation efficiency and long-term rooftop protection.

As the project is located on a medical manufacturing campus, production continuity was a key consideration. The mounting system needed to support fast installation while minimising disruption to daily operations.

The large rooftop scale also created challenges around roof load capacity, cable routing, drainage and long-term maintenance. The solution had to ensure stable structural performance while reducing additional load on the building and protecting the roof from water accumulation, leakage risks and cable-related safety issues.

Solution Highlights

Clenergy supplied itsSolarRoof rooftop mounting solutionandRUNNUR cable management systemfor the project.

SolarRoof is made from high-strength aluminium alloy, providing strong structural support while keeping the overall system weight low. This helped reduce load pressure on the large-scale rooftop while maintaining long-term system stability.

The system also supports fast and efficient installation. Its patented Z-module can be inserted from either the side or the top of the rail, reducing the need for on-site cutting or welding. The ezClick accessories feature a guided, no-hole-alignment design, allowing rails and module frames to slide into position and be fixed quickly.

RUNNUR provided a safer and more organised cable management solution for the large rooftop installation. Its flexible design supports horizontal connections, directional bending and vertical radius transitions, helping simplify cable routing across complex rooftop areas. Its drainage-friendly structure also helps guide rainwater away, reducing the risk of water accumulation, leakage and module shading.

Project Value

The project is expected to generate more than6.6 million kWh of clean electricity annuallyand reduce carbon emissions by approximately486 tonnes per year.

By combining SolarRoof and RUNNUR, Clenergy delivered a reliable rooftop PV solution that supports structural safety, fast installation, rooftop protection and long-term operation. The project sets a strong example for large-scale commercial and industrial rooftop solar applications in New Zealand.