Roll-A-Rack is a new solar-panel racking system that reduces racking and installation costs of traditional systems by 30 percent. The material costs are 50 percent less than current racking systems. Installation time and labor costs are reduced by 65 percent. 

Designed for flat roofs and ground applications, Roll-A-Rack uses roll-forming equipment to produce on-site, ballasted racking. The single-component Roll-A-Rack is significantly simpler than today’s multicomponent racking systems, which require pre-ordering, shipping, inventory and assembly. 

Roll-a-Rack is being developed by a team of scientists, engineers and solar installers with the help of a Small Business Innovation Grant from the U.S. Department of Energy Solar Energy Technologies Office. The effort harnesses a wide range of community resources and Cleveland’s rich engineering and manufacturing expertise, which is represented by the following:

• NASA’s Glenn Research Center is advising on wind uplift forces.  
• Ohio Aerospace Institute is supporting product commercialization.  
• BT Solar, a local solar installation company, will provide technical assistance and end-user feedback.  
• MAGNET, a nonprofit manufacturing consultancy, is validating the mechanical design and advising on strategic business development.  
• SDLE Research Center at Case Western Reserve University will perform accelerated weather testing.  
• The New Tech Machinery division of Mazzella Companies will build the roll-forming machines, and Sheffield Metals International, also a division of Mazzella, will provide raw materials.

Roll-A-Rack will be available by the end of 2020 .