Conger Solar Systems – Patented Technology

Conger Technology

Solar Tensile Structures

PATENTED ALL TERRAIN SOLAR TECHNOLOGY

Conger Solar Systems’ patented PV panel suspension systems utilize tensioned steel cable technology to reduce cost and create entirely new solar applications. Conger Solar Systems’ incorporate the same tensile structure principles used in thousands of suspension bridges around the world to suspend solar panels over land already used for other purposes such as irrigation and water conveyance canals and parking lots. Conger solar systems also have application over agricultural fields and pastures, aquaculture (fish) farms, road and railways and unusable tough terrain and landfills. Our patented technology allows unparalleled versatility, enabling PV arrays to be supported at virtually any height over spans of up to 410 feet/125 meters. Conger Solar Systems are ultralight compared to traditional rigid structures which rely on significantly more steel to support the system, yet are structurally engineered to withstand hurricane force winds, seismic forces and winter snow loads.

Underlying tensioned cable support structure

Rendering of completed structure over 100’ canal

Structurally engineered shop drawing of patented Conger long-span system

Conger structures are engineered using Computer Fluid Dynamics modeling to withstand asymmetrical, multi-directional, exponential wind forces

Helical Piers & Earth Anchors

SAVE TIME, SAVE MATERIAL, SAVE MONEY

Conger’s tensioned steel cable structures are anchored via helical piers which install quickly and easily with standard drilling attachments affixed to modern excavation equipment. Helical piers save on material and installation cost as compared to common cement foundations. The helical piers are engineered to support great tension and compression loads by transferring the structure’s load to the soil, leveraging the earth’s holding capacity. Helical piers are further tied into the earth with stingray type Earth anchors. Driven into the earth with hydraulic tools, tensioned, then twisted, the earth anchors further distribute the load from the entire structure and leverage the earth to bear the static, seismic, wind, and or snow load.

Space Frames

Conger long-span systems greater than 50 feet utilize lightweight, rigid space frame sub-structures attached to tensioned cables to support pods of solar panels. The space frame structures are a network of assembled linear components arranged so forces are transferred in a three-dimensional manner which significantly increases load bearing capability vs. continuous surface systems of equal or more weight. The inherent rigidity and great stiffness of space frames provides exceptional ability to resist asymmetrical or heavy concentrated load.

Standard space frame with pod and panels mounted

Angled space frame with pod and panels

Angled space frame with pod and panels (end view)

Pods

LIGHT, STRONG, FLEXIBLE

Pods with panels installed on a tough terrain ground mount Conger system

The final, patented sub-assembly of all Conger systems is our proprietary pods that attach arrays of PV panels to the supporting structure. Assembled from structurally engineered lightweight but strong, galvanized, cold-rolled C-channel steel, with lips for extra rigidity, solar panels are attached to the pods with universal clips that are compatible with all panels, including next generation thin film panels. The pods are either attached to the space frames for long-span systems or attached directly to the tensioned wire cables using proprietary, patented cable clamps.

Panel Support Pod Assembly

Panel Support Pod Structure with Panels Attached

Cable Mounting Systems

Space frames with pods and solar panels being installed on a Conger structure over a canal

Space frames with pods and panels or stand-alone pods with panels (short-span systems) are attached to the tensioned wire cable with proprietary mounting hardware. The multi-component clamps are specifically designed to make installation of large, heavy assembled arrays of solar panels fast and safe. With the top portion of the clamping system attached to the pods or space frames on the ground prior to affixing panels, the completed arrays are quickly and easily hoisted onto the supporting tensioned wire cable. With the arrays resting on the cables, the crane steadies the arrays in place while Conger structure mechanics quickly and easily attach the lower portion of the clamping system using basic hand tools, as if they were members of a race car pit crew.

Panel Support Pod Side Elevation with Pod/Wire Cable Connectors Attached

Pod-to-Wire Cable Connectors With Bottom Plate Attached

Pod-to-Wire Cable Connector initially rests on the wire cable. This connection allows for the pod to rest stably once the pod is lifted into place. The u-bolt and the top plate are attached to the pod before it is lifted into place.

After the pod has been lifted into place and is resting on the wire cables, the bottom plate is installed from below to complete the connection. It is secured in place with galvanized nuts using an electric torque wrench. Removing the solar array for maintenance is just as easy by reversing the process, similar to changing a tire on a car.

Universal Panel-to-Pod Connectors

Conger systems are naturally designed to support all types of solar panels, from the largest to the thinnest next generation panels under development. Using universal mounting clips, panels of any size can be installed on Conger systems; adjusting the mounting height of the universal clip with common spacers accommodates thicker panels. A universal thin mount clip is easily substituted to affix the thinnest panels. The extensibility of the clips extends the useful life of Conger systems indefinitely.

Single Axis Tracker

Conger systems can include optional single axis trackers incorporated into the space frame and pod sub-assemblies to properly tilt solar arrays towards the sun to maximize electricity generation.

The Conger Advantage

Conger Solar Systems designs, engineers, builds and manages solar support structures that use 40% less steel and are installed in half the time of traditional, rigid support structures.

Low Cost Solution

The use of tensioned cables allows more weight to be supported using less material, creating inherently light, efficient, and cost-effective structures. The nature of the design also requires significantly fewer foundations (typically cement), reducing the environmental footprint and foundation cost. Cables are self-aligning and can be tensioned quickly with modern hydraulic tools, resulting in a fast and efficient construction process with significantly reduced labor costs.

Multiple Benefits Beyond Electricity Generation

Conger’s structures reduce solar system costs and do more than simply generate electricity. In addition to generating electricity to power the grid and pump and aerate water, Conger’s systems installed over land used for other purposes multiply infrastructure and land value by creating shade which saves water and increases crop yields and cools the planet. Conger Solar System’s unique technology can address multiple sustainability challenges with a single, cost-efficient technology capable of being applied at very large scale.

A research study recently conducted by several University of California professors concluded California could save 63,000,000,000 (billion) gallons of water if the state covered its canals with solar. The solar facilities over canals will generate approximately 14 GW of clean, renewable energy!