The challenge
Irvin-GQ is a defence and aerospace manufacturer supplying parachute and aerial-delivery systems into Ministry of Defence and NATO programmes. The facility runs a continuous daytime production load with precision sewing, testing rigs and compressed-air plant across two shifts — total annual site consumption of 1,076,078 kWh. Two constraints shaped the brief. First, the buildings carry two large roof elevations of differing construction, which meant the ballast and panel layout had to be engineered per elevation rather than applied as a single blanket design. Second, the customer had a board-level deadline aligned to financial year-end and a Scope 3 reporting commitment cascading from their MoD customer base, so the project could not slip.
Our solution
FLD ran a full structural feasibility survey on both roof elevations before finalising the layout. A Valk flat-roof ballast mounting system was specified so panels sit securely without roof penetrations, preserving the existing waterproofing. The full 637 kW array was distributed across the two elevations to maximise yield without overloading either roof. Five Solis 110 kW Pro commercial three-phase inverters were installed in a dedicated plant room with 415V distribution, fault protection and remote monitoring. A G99 application was coordinated with NGED in parallel with procurement, compressing the overall lead time. Installation was phased so production was never stopped. A single NICEIC Approved Contractor sign-off covered the complete installation.
The result
At peak generation the building runs fully off-grid against a premises consumption of 1,076,017 kWh per year. Annual CO2 saving of 441.632 tonnes — 14,800 trees-equivalent. Payback 3 years, lifetime ROI £3 million. The client has since commissioned FLD to scope battery storage addition to capture afternoon surplus against overnight site load, and is progressing with Scope 3 reporting integration into their MoD supply-chain disclosures.
Factory, warehouse and commercial rooftop solar from 30 kWp to 1 MW across Swansea, Cardiff, Newport, Pembrokeshire and the wider South Wales region.
Discuss a scheme like 637 kW Rooftop Solar: Irvin-GQ, South Wales | FLD
Send us the outline of your site and we will come back within one working day with a feasibility view and an honest lead time.
