Top tips for mounting on tile, asphalt and metal roofs

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Top Tips For Mounting On Tile, Asphalt and Metal Roofs

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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

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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

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

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Best Mounting Practices – Tile Roofs

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Tile roofing consists of 3 common elements:

Tile Roofing Overview

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

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2. Battens: Attachment points for tiles

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

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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

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Condition of the Tile:

Pests

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.

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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.

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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?

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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

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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

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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

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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

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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

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Minimizing additional weight

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

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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

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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

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Flashing Installation Best Practices

Comp Shingle Roofs

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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?

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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.

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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.

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

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Key Factors

ü Waterproofing

ü  Corrosion resistance

ü  Structural performance

ü  Ease of installation

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Waterproofing

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Seal Design Watertight & Long-lasting

•  Elevation & compression •  Shielding from elements

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Width & Elevation

Features to ensure water flows away from penetration

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Flashing Width

8” Minimum Width No Margin for Error

12” Extra-wide Flashing Protection from missed pilot holes

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Width & Elevation

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

most flashings

Highs Lows

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Width & Elevation Lows

û ü

Wind-‐‑driven Rain

Proud flashing protects low penetration points

Flat flashing can deflect and expose low penetration points

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Width & Elevation Highs

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

Wind-‐‑driven Rain

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Corrosion Resistance

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•  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).

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Material Selection

Steel flashings can rust. Aluminum will not.

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Structural Performance

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Zone 1

Zone 2

1

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

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Load Directions

SOLAR IS NOT FLAT

A@achment points experience both vertical and lateral forces.

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Engineering Certifications •  Structural Engineering Report

o  Per ASTM D 1761

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

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Installation

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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

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Use a Sealant Approved by Roofing Manufacture

Insert Sealant into pilot holes

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

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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

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

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Nailing Pattern

Shingle strips are staggered and overlapping.

Nailing Strip

Overlay area

Sawtooth Pa@ern

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Flashing Insertion

Nail locations may block flashing.

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Solving the Blockage

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

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Notch Flashing

Use tin snips to notch the flashing.

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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

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Mounting Solar on Metal Roofs

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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 -

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Many Types of Metal Roofs Barn Roof

Standing Seam

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Some would say a million types

Rolled & Corrugated Metal Roofing

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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.

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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.

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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.

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Standing Seam Mounting

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

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Many Seam Types

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Many Standing Seam Forms

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Standing Seam Clamp Choices

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Snap Seam

Seam is difficult to clamp onto.

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Special Seam Clamp

Odd seam type has special clamp style.

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Other special seam clamp

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Reverse Seam Deck

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

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Standing Seam Mount Direct

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

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Various Metal Barn Roof Profiles

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Insulated Barn Roof

Must be careful not to crush roofing.

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

New Barn Roof

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Retrofit of Barn Roof

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

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Self-drilling Screw Options

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

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

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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

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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.

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Barn Roof mounted PV using EZ Metal Roof Mounts

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

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Alternate to Standing Seam Mounting

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

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EZ Corrugated Roof Mount

Penetration on top of ridges to avoid water ingress

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Alternative corrugated roof mount.

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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.

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

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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

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Steven Bushong Solar Power World Moderator [email protected]


Questions?

Cliff Shrock Senior Engineer SunModo [email protected]

Brandon Gwinner Account Executive SunModo [email protected]

Brian Stearns President/Founder EcoFasten Solar [email protected]

Dan Felix IronRidge IR Training Manager [email protected]

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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

Date post:	06-Aug-2015
Category:	Engineering
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