Top tips for mounting on tile, asphalt and metal roofs

transcript

#SolarWebinar

Top Tips For Mounting On Tile, Asphalt and Metal Roofs

#SolarWebinar

q  This webinar will be available afterwards at solarpowerworldonline.com & email

q  Q&A at the end of the presentation q  Hashtag for this webinar: #SolarWebinar

Before We Start

#SolarWebinar

Steven Bushong Solar Power World Moderator

Meet your presenters…

Headshot 216x200

Cliff Shrock Senior Engineer SunModo

Brandon Gwinner Account Executive SunModo

Brian Stearns President/Founder EcoFasten Solar

Dan Felix IronRidge IR Training Manager

#SolarWebinar

C o m m i t t e d t o t h e c o n n e c t i o n

#SolarWebinar

Best Mounting Practices – Tile Roofs

#SolarWebinar

Tile roofing consists of 3 common elements:

Tile Roofing Overview

1. Tiles: Various profiles – Flat, W, S, Mission

#SolarWebinar

2. Battens: Attachment points for tiles

#SolarWebinar

3.  Underlayment on sheathing (post-1986, per code)

#SolarWebinar

What to look for before you install?

What type of Tile?

Your mounting/flashing solution will be specific to Tile type.

Flat W profile S profile

#SolarWebinar

Condition of the Tile:

Gnawing and added moisture can degrade materials rapidly, causing structural or waterproofing failure

Tile roofs present an ideal home for bats, squirrels, rats, wasps, etc….

Damage from Past Work Dropped tools or standing the wrong way can break and crack tiles.

Damaged tiles should be replaced before installing a PV system. Solar mounting solutions that replace a tile with flashing are a great source for replacement tiles.

#SolarWebinar

What to look for before you install? Condition of the Underlayment

15# / 30# / 40# asphalt-impregnated felt, modified bitumen, or plastic/synthetic fabrication

Capillary action and saturated tile can cause moisture at underside of tile

Wind-driven rain can also find its way up and under tile

Look for mold, curling of the underlayment and cracking. These would be signs of a leak or the need to reroof.

#SolarWebinar

Roof Construction:

Does the underlayment/sheathing or battens require repairs? What is the spacing between battens? – important if using a metal

flashing at roof deck on a retrofit. What is the rafter spacing?

#SolarWebinar

PV on Tile Installation

Mounting Options for Tile:

Flashing Systems

that Replace a Tile Tile Hooks Hanger Bolt

Assemblies Standoffs that

Require Drilling or Cutting Tile

#SolarWebinar

Mounting Option Considerations

In the past:

Cutting or boring tiles to flash a standoff

Tile hooks- Weak attachments (lever arm) can deflect and break tile under loads, providing a direct path to solar attachment for moisture, pests, etc….

Both methods usually involve “bibbing” or mastic & metal flashing at the roof underlayment, with metal boot flashing at tile surface

New Innovations: New products that are less labor intensive, with less tooling and no messy mastic

#SolarWebinar

PV on Tile Installation- Considerations

Follow the Determined Array Layout •  Will be determined by structural

engineer and approved by Authority Having Jurisdiction (AHJ).

•  Always install mounts into Rafters. Predrill holes into center of rafter for Lag bolts.

Rafter

#SolarWebinar

The Tile Roofing Institute (TRI) recommends flashing/seal at the roof deck and at the tile level

Flashings should be tested to: •  UL 441 Section 25-Flashing

Standard for Gas Vents (closest standard for PV attachments)

•  ICC-ES AC 286 § 4.1

#SolarWebinar

Mission (clay) or lightweight tile

Fragile, not ideal to install over due to due breakage of tile

Strip & go method: Removal of tiles – replace with asphalt shingles under array location

#SolarWebinar

Minimizing additional weight

Tile is heavy – minimizing additional weight on the roof, and gaining approval from a structural engineer will ensure structural integrity

#SolarWebinar

Time on the roof

Even the strongest types of tile can be brittle

Spend as little time on the roof as possible to minimize chance of dropping tools or standing the wrong way

#SolarWebinar

EcoFasten Solar designs, engineers, and manufactures patented, watertight solar roof mounts designed with the installer in mind.

About EcoFasten Solar

Solutions for all roof types, including: •  Tile Flashing System

GreenFasten •  QuikFoot •  Simple Seal •  CorruSlide

Tile Roofing

Composition Shingle

Metal Roofing Corrugated Metal Roofing

#SolarWebinar

Flashing Installation Best Practices

Comp Shingle Roofs

#SolarWebinar

The First Question:

“How do I attach solar to the roof?”

…so that it doesn’t damage the home, …doesn’t fly off during a storm,

…and doesn’t cost an arm & a leg?

#SolarWebinar

In the Pioneers Days of Solar…

“Goop & A Prayer”

•  Did not meet code •  Voided roof warranty •  High risk of leaks & liability

Tens of penetra,ons on each install add up to thousands of poten-al leaks within warranty.

#SolarWebinar

As We Grow, We Learn

•  IBC 1503.2 o  Flashing shall be installed in such a manner so as

to prevent moisture entering […] penetrations through the roof plane.

•  IBC 1507.2.9 o  Flashing shall be applied in accordance with this section

and the asphalt shingle manufacturer's printed instructions.

#SolarWebinar

Lot of Flashing Options Definition: Flashing – a strip of metal used to stop water from penetrating the junction of a roof with another surface.

#SolarWebinar

Key Factors

ü Waterproofing

ü  Corrosion resistance

ü  Structural performance

ü  Ease of installation

#SolarWebinar

Waterproofing

#SolarWebinar

Seal Design Watertight & Long-lasting

•  Elevation & compression •  Shielding from elements

#SolarWebinar

Width & Elevation

Features to ensure water flows away from penetration

#SolarWebinar

Flashing Width

8” Minimum Width No Margin for Error

12” Extra-wide Flashing Protection from missed pilot holes

#SolarWebinar

Width & Elevation

•  Thick asphalt shingles are pa@erned •  Creates “highs & lows” that are problematic for

most flashings

Highs Lows

#SolarWebinar

Width & Elevation Lows

Wind-‐‑driven Rain

Proud flashing protects low penetration points

Flat flashing can deflect and expose low penetration points

#SolarWebinar

Width & Elevation Highs

ü Wide flashing traps water within low areas û Narrow flashing can expose high penetration points

Wind-‐‑driven Rain

#SolarWebinar

Corrosion Resistance

#SolarWebinar

•  IBC 1503.2.1

Where flashing is of metal, the metal shall be corrosion resistant with a thickness of not less than 0.019 inch (0.483 mm) (No. 26 galvanized sheet).

#SolarWebinar

Material Selection

Steel flashings can rust. Aluminum will not.

#SolarWebinar

Structural Performance

#SolarWebinar

Zone 1

Zone 2

Design Loads

Wind Speed Zone 1 Zone 285 140 28790 159 325100 203 408110 251 500120 305 600130 362 710140 425 828150 492 955

Uplift (lbs.)

Manufacturer #3 Manufacture #2

Manufacture #1

Design Factors: •  Code version: ASCE 7-‐‑05 or 7-‐‑10 •  Location Info (wind/snow, exposure, etc.) •  Building info (height, slope, etc.) •  AMachment Spacing & placement

#SolarWebinar

Load Directions

SOLAR IS NOT FLAT

A@achment points experience both vertical and lateral forces.

#SolarWebinar

Engineering Certifications •  Structural Engineering Report

o  Per ASTM D 1761

•  IAPMO-ES Evaluation Report o  Per IBC & IRC (2006 & 2009)

#SolarWebinar

Installation

#SolarWebinar

Layout Attachment Locations •  Mark rafters and a@achment Locations •  Drill ¼” Pilot Holes, 3.5” deep. Verify being Centered on the Rafters

Min 3” to 3.25”

Pilot drill hole locations

Rafter Locations

#SolarWebinar

Use a Sealant Approved by Roofing Manufacture

Insert Sealant into pilot holes

EverGuard® Caulk FillGard M Pourable Sealer TAM-‐‑Seal Roof Patch

#SolarWebinar

Proper Placement

Incorrect with flashing hanging over

the shingle edge line

Correct With flashing 1/8”

above the shingle edge line

Acceptable With flashing

trimmed into the next course

Trim shingle Not under 3rd

Course of shingles

#SolarWebinar

•  IBC 1507.2.7 Asphalt shingles shall have the minimum number of fasteners required by the manufacturer.

#SolarWebinar

Nailing Pattern

Shingle strips are staggered and overlapping.

Nailing Strip

Overlay area

Sawtooth Pa@ern

#SolarWebinar

Flashing Insertion

Nail locations may block flashing.

#SolarWebinar

Solving the Blockage

1.  Mark depth of blockage 2.  Pivot to determine horizontal location

#SolarWebinar

Notch Flashing

Use tin snips to notch the flashing.

#SolarWebinar

IronRidge FlashFoot 1. Insert & Align Install guides on flashing make it easy to line-‐‑up with pilot hole

2. Install L-‐‑foot & lag bolt L-‐‑foot, lag bolt and flashing come together all at once

3. AMach and Level Rail is simply dropped into open-‐‑top L-‐‑feet

#SolarWebinar

Mounting Solar on Metal Roofs

#SolarWebinar

Mounting Solar on Metal Roofs

OVERVIEW: Mounting methods for mounting solar electric systems on various types of metal roofs. AGENDA:

1.  Metal roof type variety: metal barn type roof sheeting, standing seam roofs, and Q deck steel roofs encountered in commercial buildings. (Cliff)

2.  Underlying structures: wood trusses, wood skip sheeting, steel trusses. (Cliff) 3.  Options and limitations of mounting to the afore mentioned types of roof. 4.  Techniques for fastening to such roofs. (Cliff) 5.  Role of a Structural Engineer in designing such systems and selecting the fasteners for metal

roofs. (Cliff) 6.  Samples of PV mounts and fasteners that might be used for various roofs. (Brandon)

- Best Practices -

#SolarWebinar

Many Types of Metal Roofs Barn Roof

Standing Seam

#SolarWebinar

Some would say a million types

Rolled & Corrugated Metal Roofing

#SolarWebinar

Under roof uses E-W wood purlins

Roof build up with steel or wood rafters and E-W wood purlins for barn roof, standing seam, or corrugated roof.

#SolarWebinar

Standing Seam Mount only as strong as the connection to the roof

•  Cut-away of standing seam roof showing clips used to connect to roof sheathing.

•  On new construction, clips every 24 inches or less.

#SolarWebinar

Seam Clamps used on Standing Seam Roof

Seams are top flange and seam clamps are mounted at 90 deg. angle to seam. Rails mounted to clamps using L feet.

#SolarWebinar

Standing Seam Mounting

Completed project showing the use of a standing seam clamp and E-W rails for PV Panel mounting.

#SolarWebinar

Many Seam Types

#SolarWebinar

Many Standing Seam Forms

#SolarWebinar

Standing Seam Clamp Choices

#SolarWebinar

Snap Seam

Seam is difficult to clamp onto.

#SolarWebinar

Special Seam Clamp

Odd seam type has special clamp style.

#SolarWebinar

Other special seam clamp

#SolarWebinar

Reverse Seam Deck

#SolarWebinar

Loading panels onto SS Roof Mounting of panels on Standing Seam Roof using seam clamps and E-W rails.

#SolarWebinar

Standing Seam Mount Direct

Horse arena PV using direct mount S-5 seam clamps.

#SolarWebinar

Various Metal Barn Roof Profiles

#SolarWebinar

Insulated Barn Roof

Must be careful not to crush roofing.

#SolarWebinar

New metal barn roofing on cabin structure with E-W purlins over wood rafters.

New Barn Roof

#SolarWebinar

Retrofit of Barn Roof

Metal barn roof retrofit on house using E-W 2 by 4 wood purlins attached to old shingle roof.

#SolarWebinar

Self-drilling Screw Options

#SolarWebinar

SunModo EZ Metal Roof Mounts with integral water sealing washer in base.

#SolarWebinar

EZ Metal Roof Mount Water seal washer built into base of unit

#SolarWebinar

Initial installation of EZ Roof Mounts with L foot thru roof to E-W wood purlins, then N-S rails.

Barn Roof mounted PV using EZ Metal Roof Mounts

#SolarWebinar

Close up of Barn Roof Mtg.

Close up view during panel mounting showing the roof mount, L foot and wire dressing prior to mounting the PV panel.

#SolarWebinar

Barn Roof mounted PV using EZ Metal Roof Mounts

Completed installation on Barn Roof using EZ Metal Roof Mounts and N-S rails.

#SolarWebinar

Alternate to Standing Seam Mounting

Standing seam roof but using EZ Metal roof mounts with stanchion and L foot, E-W rails.

#SolarWebinar

EZ Corrugated Roof Mount

Penetration on top of ridges to avoid water ingress

#SolarWebinar

Alternative corrugated roof mount.

#SolarWebinar

Example of Corrugated Roof using Strut and Rail

Strut is fastened N-S on ridges of corrugation, then rails are mounted using L feet on E-W orientation.

#SolarWebinar

Beautiful example of PV on barn roof using EZ Metal roof mounts.

#SolarWebinar

Short Summary •  Many metal roof types

o  Standing Seam o  Barn Roof (Roll Roof) o  Corrugated Roof o  Other; metal shingles, custom metal

•  Many Under-roof systems o  Wood Purlin o  Steel Z and C purlin o  Steel frame and Q deck

#SolarWebinar

Steven Bushong Solar Power World Moderator sbushong@wtwhmedia.com

Questions?

Cliff Shrock Senior Engineer SunModo cliffs@sunmodo.com

Brandon Gwinner Account Executive SunModo brandong@sunmodo.com

Brian Stearns President/Founder EcoFasten Solar brian@ecofastensolar.com

Dan Felix IronRidge IR Training Manager Dfelix@ironridge.com

#SolarWebinar

Thank You q  This webinar will be available at

solarpowerworldonline.com & email

q  Tweet with hashtag #SolarWebinar

q  Connect with Solar Power World

q  Discuss this on EngineeringExchange.com