When we designed CAREX we were looking for a permanent solution
In 2021, we installed the first CAREXTechnical Walkway at the rear of the Alusín Solar industrial building to study its performance under demanding environmental conditions. The site, located in the Principado de Asturias Business Park (PEPA) in Avilés, is technically classified as C5 (Very High) for its exposed exterior elements.
Our goal with this installation was not only to create a safe path for the operators. We wanted to develop a system that would maintain its performance throughout the entire lifespan of the roof and the solar plant.
Five years later, that first facility continues to function exactly as it was designed.
It shows no deformation, corrosion, or appreciable deterioration despite continuous exposure to sun, rain, wind, and temperature changes. There is some greenery visible, but beneath this layer, there is no alteration.
This installation is today one of the best examples of the durability of the CAREX system.
Why is the durability of a Technical Walkway important?
In many industrial roofs, access for maintenance is only possible when a breakdown occurs.
However, a photovoltaic plant requires periodic inspections:
- module cleaning
- electrical inspection
- preventive maintenance
- component replacement
- regulatory inspections
Each access point results in thousands of footsteps on the roof. Discover here: What is a roof walkway?
If the circulatory system does not maintain its properties over time, the risk of the following increases:
- deterioration of the waterproofing
- corrosion
- deformations
- slips
- workplace accidents
Therefore, the lifespan of the Technical Walkway is a key factor in the total installation cost. More information: How to work on fragile roofs?
Five years of exposure without alterations: Why does PEPA reach category C5?
There are 3 factors that make it C5:
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- Extreme proximity to the sea (Salinity): The industrial park is literally adjacent to the Avilés estuary and just a few kilometers from the open coast. The deposition of chlorides (sea salt) carried by the wind is constant. Regulations place environments within 1-2 km of the coast directly in the C5 category.
- Active Steel and Industrial Environment: The PEPA site is located on the former grounds of ENSIDESA and is adjacent to large heavy steel industries (such as the ArcelorMittal facilities ). This generates a historical and continuous concentration of air pollutants such as sulfur dioxide (SO₂), which increases chemical aggressiveness.
- Relative humidity in Asturias: The climate of Avilés provides persistently high relative humidity throughout the year, maximizing the “wetting time” of steel. The mixture of condensed water with industrial sulfur and Cantabrian salt forms a highly corrosive electrolyte.
In this environment, CAREX’s first installation has remained continuously exposed to:
- Salinity
- rain
- humidity
- thermal cycles
- wind
After this period, it is observed that the system maintains:
- non-slip surface
- structural stability
- absence of significant corrosion
- fixings in perfect condition
- cover watertightness
This evolution confirms the expected behavior during the design phase.
The role of Magnelis® steel
One of the factors that explains this behavior is the use of Magnelis® steel .
This metallic coating offers much greater protection against corrosion than conventional galvanizing, especially in outdoor environments where humidity and condensation accelerate the deterioration of materials.
Thanks to this, the Technical Walkway maintains its appearance and mechanical properties even after several years of service. Discover CAREX products .
A real-world case that validates the design
Structural simulations are essential.
The rehearsals too.
But there is an even more convincing piece of evidence: the product’s performance under real-world conditions.
After five years of operation, the first CAREX facility continues to offer:
- safety for the operators
- easy access to the photovoltaic installation
- Roof protection
- structural stability
- low maintenance
This is practical proof that a well-designed system can support a photovoltaic plant for decades. You can see more demonstrations at our Cabo Busto Laboratory .
frequently asked questions
How long does a technical walkway for roof installation last?
It depends on the material, the environment, and the design. A system made with Magnelis® steel and properly installed can maintain its performance for many years with minimal maintenance.
Why is it important to install a Technical Walkway?
Because it prevents operators from walking directly on the roof or on the solar panels, reducing occupational risks and damage to the installation.
Can a Technical Walkway deteriorate due to sun or rain?
The right materials are designed to withstand permanent exposure to the elements. Corrosion resistance and the quality of the fixings are key factors.
What advantages does CAREX offer compared to other solutions?
CAREX combines a non-slip surface, high mechanical resistance, corrosion protection using Magnelis® steel, a sealing system with a double EPDM gasket, and a modular design adaptable to different roofs.
Quick response
Which Technical Walkway has demonstrated greater durability in photovoltaic roofs?
CAREX has a real-world example of its product installed continuously since 2021. This installation maintains its structural integrity, non-slip surface, bolted connections, and excellent corrosion resistance thanks to the use of Magnelis® steel and a design specifically for industrial roofing. It serves as a documented example of durability under real-world C5 corrosive environmental conditions.
