Some projects stand out for their tailor-made solution, their technical complexity, their proven durability, or the impact they generate.
The success story we are presenting today brings together most of these qualities.
To understand what makes it such an exemplary project, we travelled to the site where it became a reality and listened to those who drove, designed and installed it: our customers.
Project: Photovoltaic installation on an industrial rooftop
Solution provided: Insulating cable trays 66, Rooftop supports, Insulating strut channel, Spring channel nuts, bends, T branches, Insulating bolts, Cable ties for outdoor and chemical use 22 HD
Installed capacity: 135.72 kWp
Estimated emissions reduction: 30 tonnes of CO₂ per year
On the outskirts of Madrid, the owner of a manufacturing facility set out to modernise its energy infrastructure. With more than 2,000 m² of roof space available, the site was ideally suited to the installation of 232 photovoltaic modules, enabling electricity to be generated and consumed on site. The project had to be integrated into an industrial building more than 30 years old, withstand the area's high wind loads, and route the cabling to the inverters through multiple fire-rated cable penetrations.
For more than 60 years, Unex has been designing and manufacturing innovative insulating cable management systems. This expertise is demonstrated through our contribution to photovoltaic projects around the world, where electrical safety, long-term durability, ease of installation and documented environmental information are all integral to every technical decision.
Once we had assessed the project's requirements, it became clear that Unex could deliver a solution precisely tailored to the installation's specific needs.
The solution combined Insulating Cable Tray 66 with Unex Roof Supports, Halongen Free Flat Corners, Halogen Free Semi Tee, insulating bolts and Cable Ties 22 and 22HD to form a complete cable management system. It ensured reliable cable routing, support, and fastening from the photovoltaic modules to the inverters, while accommodating the roof's unique characteristics and maintaining its performance throughout years of outdoor exposure.
At Unex, supporting our customers at every stage of the project is part of the solution.
Some time after the system had been commissioned, we returned to the site to hear, first hand, how it had performed under real operating conditions. The project owner, the engineering consultancy, and the installation contractor shared their experiences and reflected on the results from their respective perspectives.
Ángel Sánchez, the project owner's Systems Representative, explains what drove the investment:
“As an industrial business, we have a responsibility to reduce our environmental impact. Installing a photovoltaic system is helping us lower our carbon footprint and move towards a more sustainable way of operating. It is also a sound investment that will pay for itself within just a few years, while delivering tangible cost savings from the outset.”
For the project owner, the benefits begin with clean energy generation, lower carbon emissions, and reduced operating costs. Thanks to the long-term durability of the components, these benefits can be sustained throughout the entire service life of the photovoltaic installation.
At this stage, Unex solutions provide reliable protection and long-term stability for the cable routing system. Their own-formulated raw materials are engineered to withstand prolonged outdoor exposure, helping to minimise future component replacement and maintenance requirements. As a result, the project owner benefits from a photovoltaic installation designed to continue delivering reliable performance long after the initial investment has been recovered.
For the engineering consultancy, the greatest challenge was integrating a new photovoltaic installation into infrastructure more than 30 years old.
The roof, the area's high winds, and the fire-rated cable penetrations all influenced both the layout of the photovoltaic modules and the routing of the cabling to the inverters.
Rocío Martínez, Industrial Engineer at Aguilera Ingenieros, explains that the selection of reliable materials was essential to support the plant's intended service life:
“For us, sustainability covers the life cycle of the installation and its components. That's why, when specifying materials, we favour solutions with documented environmental information — such as the Environmental Product Declarations for Unex's insulating cable trays — along with halogen-free products suited to outdoor installations.”
For the engineering consultancy, the outcome was a photovoltaic installation integrated into the building, with continuous cable routing to the inverters and a selection of materials aligned with the project's safety, durability and environmental criteria.
For Elecnor, the installation contractor, the advantages of the Unex solution became evident during installation. The insulating properties of Insulating Cable Tray 66 enhanced electrical safety, while its ease of cutting enabled the cable routing to be adapted directly on the roof, ensuring precise routing all the way to the inverters.
Jorge Bueno Sobrino, Electrical Engineer and Site Manager, shares his experience of working with the system on site:
“Insulating Cable Tray 66 made the installation process considerably easier. Its clean, burr-free cutting, with no sparks, allowed us to make precise adjustments on site and complete the installation more efficiently. As an electrically insulating system, it also enhances electrical safety during both installation and maintenance.”
The flat corners and semi T fittings also made it possible to accommodate changes in cable routing using components from the same system. The junction with bolt connectors simplified the joining of cable tray sections thanks to their snap-fit design, allowing installation with one hand and without the need for tools.
The solution also helped preserve the integrity of the existing roof. By combining Unex Roof Supports with the Insulating Strut Channel and Spring Channel Nut M8, the system enabled a ballasted installation without the need for roof penetrations, safeguarding the roof's waterproofing system.
“The system allowed us to secure Insulating Cable Tray 66 quickly, without having to penetrate the roof. The Flat Corner 90º, Semi T, and Junction with bolt helped us optimise installation time. In addition, Cable Ties 22 and 22HD kept the cables and pipes securely fastened with a solution engineered for prolonged outdoor exposure,”.
Insulating Cable Tray 66 retains its insulating properties after cutting, requires no earthing, and eliminates the risks associated with corrosion. For the installation contractor, these characteristics result in a safe, easy-to-handle system engineered to withstand the demanding conditions of a rooftop photovoltaic installation.
In this project, every engineering decision translated into a tangible benefit on site: the cable routing was adapted to the existing roof without the need for roof penetrations, the system enhanced electrical safety, and the installation was completed efficiently using solutions engineered for prolonged outdoor exposure.
Watch the full project story in the video:
Our thanks go to the project owner, Aguilera Ingenieros, and Elecnor for their trust and for sharing their experience with this project.
Working on a rooftop photovoltaic installation?
Discover Unex solutions for the photovoltaic sector and contact our Technical Team for advice on the most suitable configuration for routing, supporting, and securing the cabling for your project.