The Evolution of Roof Equipment Support Structures

According to a recent industry report, the global market for roof equipment support structures is projected to grow at a CAGR of 4.1% till 2033. However, the industry wasn’t always this popular, or thriving like today. While there has always been a demand for a “roof over one’s head,” the level of protection it got wasn’t always a primary concern.

Roofs have been an integral part of human survival. As the commercial sector also moved to large buildings from small shops, the equipment used in these buildings has also become more and more sophisticated.

Today, large chillers, ductwork, electrical components, and more make up the equipment system placed on commercial roofs, among other things. These need to be supported properly to ensure that the structure is safe and sound, and doesn’t harm the commercial rooftop it is placed on.

In this article, we will take a closer look at the evolution of these roof equipment support structures, discussing its evolution over time.

Early Necessity and Innovations

Roof equipment support structures became necessary as buildings grew taller and more complex. In the early 20th century, the demand for rooftop installations such as water tanks, ventilation systems, and antennas increased. These installations needed reliable support systems to prevent structural damage and ensure safety.

In the 1920s, engineers began experimenting with various materials and designs to create stable rooftop support structures. Early supports were often makeshift, using wooden beams and metal brackets. These rudimentary supports were prone to failure, leading to several accidents and inefficiencies.

The Incident that Changed Everything

One notable incident in 1937 highlighted the dire need for reliable roof equipment support structures. In New York City, a rooftop water tank installation failed due to inadequate support, causing the tank to collapse and flood the building. This incident resulted in significant property damage and highlighted the dangers of inadequate rooftop support systems.

Impact of the 1937 Incident:

• Increased Awareness: The incident drew attention to the importance of proper rooftop support.
• Regulatory Changes: Building codes and regulations began to include specific requirements for rooftop support structures. OSHA also became actively involved in rooftop structures and started working on rooftop safety codes for roof workers.
• Technological Advancements: Engineers and architects started to innovate more robust and reliable support systems.

Despite the safety progress made since the 1937 incident, there have been several collapses reported from 2020 onwards. As a result, the need for reliable roof equipment support structures, especially in commercial settings, is becoming even more and more pressing.

Evolution in Materials and Design

The mid-20th century saw significant advancements in the materials and design of roof equipment support structures. The introduction of galvanized steel and aluminum revolutionized the industry, offering stronger and more durable options compared to wood and basic metal brackets.

These materials provided better load distribution and resistance to environmental factors, ensuring the longevity and safety of rooftop installations.

Technological Advancements in the Late 20th Century

The late 20th century brought further innovations with the advent of computer-aided design (CAD) and finite element analysis (FEA). These technologies allowed engineers to design more precise and efficient support structures, taking into account various loads and stresses.

This technological evolution led to several developments in the industry, including:

1. CAD Software: Enabled detailed and accurate design of support structures, reducing errors and improving efficiency.
2. FEA: Allowed for stress testing and optimization of designs, ensuring that support structures could withstand various loads and environmental conditions.
3. Modular Designs: Prefabricated, modular support systems emerged, offering quick and easy installation with consistent quality.

Modern Roof Equipment Support Structures

Today, roof equipment support structures are integral to construction projects, ensuring the safety and stability of rooftop installations. Modern support systems are designed to accommodate various equipment types and withstand different environmental conditions, including wind, seismic activity, and temperature fluctuations.

Common trends in the industry include:

• Sustainability: The use of eco-friendly materials and energy-efficient manufacturing processes.
• Customization: Tailored solutions to meet specific project requirements, including adjustable and modular designs.
• Enhanced Safety: Improved safety features, such as non-slip surfaces and enhanced load-bearing capabilities.

Case Study: The Burj Khalifa

The construction of the Burj Khalifa, the world’s tallest building, showcased the importance of advanced roof equipment support structures. The building’s rooftop hosts numerous installations, including communication antennas, HVAC units, and maintenance equipment.

Engineers used a wide range of different materials and design techniques to ensure that these supports could handle the extreme conditions at such heights. While at higher altitudes, the exposure of equipment is limited, there are still openings that allow for large commercial equipment to be housed. These openings are exposed to a number of different elements, especially considering the erratic weather systems the city has been seeing recently.

As a result, appropriate roof equipment support structures are a basic necessity for the building. Key features that make the system stand out include:

• High-Strength Steel: Used for its superior load-bearing capacity and durability.
• Seismic Bracing: Ensured stability during potential earthquakes.
• Weatherproofing: Protected supports from harsh desert climate conditions.

Based on the improvements in roof equipment support structures across the globe, the future of roof equipment support structures looks promising, with ongoing research and development aimed at further improving efficiency, sustainability, and safety. Emerging technologies, such as smart materials and IoT-enabled monitoring systems, are expected to revolutionize the industry.

PHP Systems/Designs has been the leading manufacturer of commercial roof equipment support structures, including:

• Pipe supports,
• Duct supports,
• Cable tray supports,
• Equipment supports,
• Walkways, crossovers, stairs, and ramps,
• Platform systems,
• System components,
• Solar panel mounts, and more.

As the future introduces new materials and technologies into the industry, we, too, intend to evolve with it. This includes adopting new materials that can acclimate to environmental changes, providing enhanced performance and longevity.

Furthermore, PHP Systems/Designs is integrating IoT monitoring systems into new rooftop equipment support structures, depending on customer preference. This allows for real-time monitoring of the structures as well as the equipment on top of it. These systems detect and help address issues long before they become critical, all while ensuring worker safety and OSHA compliance.

If you’d like to learn more about the innovative solutions we can offer you, get in touch with us today. Call us at 800.797.6585 to request a pricing and get started with your project right away!