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ColorCote® Case Study 10 - Sun power creates green energy for the Dumpling Hut in the Milford Track, Fiordland.

At first glance, the Department of Conservation’s Dumpling Hut on the Milford Track looks like any other visitor facility on the world famous Fiordland tramping trail…..until you look more closely at the roof.

What seems like a standard metal roof turns out to be a cleverly designed and manufactured solar power system that has been made to blend in with its surroundings.

The first of its kind in New Zealand, the new Solar Rib® system supplies power for visitors to the hut, whilst maintaining a minimal environmental footprint.

Solar Rib® roofing has been developed by Calder Stewart Roofing, using ColorCote® ZRX™ pre-painted roof panels as the substrate. Solar Rib® is the first self-contained, power-generating steel roofing profile in New Zealand, which does away with unsightly older technology solar panels by incorporating the cells into the structure of the roofing metal.

The ‘photo-voltaics’ used in Solar Rib® come in the form of a laminate that is light and flexible, enabling it to be installed onto the roofing metal without the need of additional support from underneath, other than the standard roof purlins. The unique solar power system allows the ColorCote® roof to retain its crisp and clean appearance, without visually detracting from the pristine environment.

The ColorCote® ZRX™ panels are ideal for the harsh weather conditions experienced in Fiordland, with its high rainfall and cold winters. The hot-dipped aluminium/zinc alloy-coated steel substrate has a thicker coating of polyester primer for improved corrosion resistance and a 70% PVF2 top coat. This system gives outstanding gloss, colour retention and durability in severe environments.

Solar Rib® has been used on houses in Southland, with one roof producing nearly 15kilowatt hours of electricity per day and Calder Stewart was keen to see how it would perform in the harsher climate of Fiordland, where the rainfall can exceed 7000mm in a year. Solar Rib® works off solar radiation, which is still collected by the panels even on cloudy days and will continue to receive energy from the sun should snow or ice build up on the roof. 50Watt peak power per square metre of Solar-Rib® is produced per metre of roofing and some installations can produce most of the building’s electricity and even return power to the national grid.

In addition to extreme weather, the Dumpling Hut roof has another natural hazard to ward off – the inquisitive Kea alpine parrot. Prior to the roof being installed at Dumpling Hut, a test panel was placed at Mintaro Hut to test its Kea-proof properties. Kea have been responsible for short circuiting and even destroying power supplies in remote locations, but the Solar Rib® design and robust ColorCote® roof foiled all attempts by the parrots to undermine it.

Dumpling Hut, Milford Track Photo Gallery

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