Some tips and tricks directly from solar mounting and racking manufacturers, including proper waterproofing, residential location, full-package systems and installation plans.

Fixing leaks from residential PV installations costs more than you think.
Jeff Spies, vice president of business development for Quick Mount PV

Waterproofing penetrations for solar mounting is a serious issue. Unfortunately, many underestimate the long term cost impacts of this critical decision.

A solar array on a new roof can last 30 years, but long-term waterproofing is a challenge as mounts flex daily due to wind loads and the difference in expansion/contraction of wood roofing versus the metal PV racking.

Solar waterproofing is a statistical challenge. Solar installations require dozens of penetrations, meaning even a small leak rate can still be a big problem. A “small” 1 percent leak rate after 10 years equates to 30 to 50 percent of your PV installation leaking.

For a 5-kW system, quality flashed solar mounts cost $500 to $1,000 (10 to 20 cents/watt), however, removing/reinstalling the PV system costs $2,500 to $7,500 (50 cents to $1.50/watt) which equates to 25 to 50 percent of the cost of a brand new system, and wood rot or mold damage further increase costs. Fixing leaks will cost most PV owners more than replacing their inverter.

Most customers assume their warranties protect against this risk, but in reality, waterproofing warranties usually last no more than 10 years.

Saving money by economizing on waterproofing could be a costly mistake. In the end, quality solar flashed mounts are cheap insurance.

Most important residential installation concern? Location, location, location.
Russell Eisenman, marketing and social media for Quickscrews International Corp.

The most important consideration for using solar panels is installing them in the proper location and at the correct angle to the sun. Sunlight is important for solar, but even cloudy areas are great for solar energy. What matters more is one’s roof. As long as the roof is free of shade and faces south (east and west are good too, but south is optimal), there will be plenty of sunshine for the panels.

If you live in a place where direct sunlight for continuous periods of time is a challenge, then one may want to consider triple junction laminated panels. This category of panels contains photovoltaic cells which respond to more than one wavelength of light, picking up low-range or indirect light and converting them into electrical energy.

If one’s roof isn’t optimal for solar (faces the wrong direction, made of the wrong materials, etc.), a ground-mounted solar system is a good alternative. People commonly choose ground mounted if there is a lot of space on the property.
As often as possible, go for tabbed solar cells because this will make wiring easier for the installer. It may be a little more expensive, but the convenience is well worth it.

Make sure your racking system for large-scale installations is the full package.
Harman Kaur, marketing manager for RBI Solar

A good solar racking system for large-scale installations should have the following features:

• Fewer Posts — Reduced number of posts leads to faster installation.
• Self-grounded — Utility-scale racking should be ETL classified to UL 2703.
• Built-in Wire Management — This reduces the cost of wire management devices.
• Pre-assembled — Fast on-site installation happens with pre-assembled components.
• String Sizes — A good racking system should accommodate various string sizes.
• Individual Design — Projects should be individually designed to meet local building code requirements.
• Foundation Options — Different foundation options should be available to install the racking.
• Total Cost — Racking cost should include all components including cost of design/complete engineering, posts, racks, mounting hardware, freight to the jobsite and installation of posts/racks.
• Options — Often installation options offered by the racking manufacturer are economical, as they have highly skilled construction crews that install nothing but solar racking.

Figure out a game plan before beginning a job to ensure everything runs smoothly.
Kate Bayard, director of marketing for SolarDock

Visiting the site and developing an installation plan in advance helps the job run smoothly, resulting in less downtime and increased production. Three important things to consider in advance:

1. Do the build plans match actual roof conditions? Compare mechanical build plans to as-built roof conditions. Check layout specs to confirm dimensions, location of obstructions, shading or quirky roof features. If anything looks amiss, let the designer know so a solution can be developed before you get on the roof.
2. How will equipment be handled and staged? Identify where delivery trucks should unload, how equipment and materials will be lifted to the roof and where they will be staged for maximum efficiency during installation. This avoids confusion on delivery day, helping you get to work sooner.
3. Who will do what? Give workers clearly defined jobs that allow them to specialize on a single task. By having only one job, the worker is able to be more efficient and proficient at what they are doing. It also helps the foreman troubleshoot problems because he knows who was responsible for what.

-- Solar Builder magazine

Choosing the right mounting and racking system might seem like your biggest task, but don’t forget about cable management, too.

By William Feldman

Most any solar panel installation worth its salt, whether on the roof or on the ground, should feature secure mounting for the panels and a secure and protective raceway system to manage the dozens, hundreds or even thousands of cables. The issue heard, probably around the globe, is “What do we do with all these wires?”

When Snake Tray, a manufacturer of cable management systems, wanted to install solar panels on the roof of its headquarters in Bay Shore, N.Y., to reduce its electric bill, right off the bat it ruled out using conduit to route the cable because it is expensive and labor-intensive to install and often requires de-rating cables to compensate for the excessive heat buildup inside the conduit.

Instead, capitalizing on its engineering know-how, the company created an innovative system of cable management devices designed specifically for solar installations to streamline wiring for the 535 solar panels that were slated to go up on the roof. The new system, which also facilitates easy access to the cable and provides continuous support for them and the panels, was based on the company’s signature product, Snake Tray, a metal cable management system of open-web trays. The entire system is lightweight and does not substantially add to the weight load of the solar panel installation on the roof.

Solar Snake Tray is a weatherproof hand-bendable cable conveyance that easily, quickly and securely carries the DC circuitry from solar panels to their terminations. Installers change directions simply by bending the tray to accommodate the route of the run, which is a lot faster for installers in comparison to working with alternative methods.

The Solar Snake Trays feature an open, patented “lobster trap” design that permits easy drop-in of cables and lets air flow freely around the cables, allowing for heat dissipation and enabling copper conductors to carry their full capacity. This open web design precludes the need to increase the size of the cable and conduit, saving on the cost of copper cable. Also, the bendability of the tray simplifies installation compared to installation of other methods.

The trays connect with a single connector for a speedy bonded attachment, tray to tray, maintaining NEC compliance. The system is weatherproof and keeps cables in place even in hurricane force winds of up to 120 mph. Solar Snake Tray is available in hot-dipped galvanized or stainless steel to protect against weather and other environmental conditions.

Snake Tray also manufactures other solar accessories, including the UL-classified Solar Mega Snake, a pole-mounted management system capable of spanning distances in excess of 30 ft, and the Solar Messenger Snake Tray, which clips easily onto messenger wire rope without the need for tools or hardware.

Snake Tray, which itself generates about 75 percent of its electrical energy off its own roof, has supplied more than 1 million ft of Solar Snake Trays in installations in the United States and around the world in the last three years, in projects ranging from schools and sewage treatment plants, drugstores, meatpacking plants and railway station carports, all the way up to utility grade solar arrays producing hundreds of megawatts of energy.

-- Solar Builder magazine

As evident on this lengthy page, there are many, many players in the solar industry. It can seem overwhelming to narrow down the choices for the best mounting and racking system for a new solar project. Some companies focus on specific applications — like metal rooftops or landfill caps — while others focus on different materials — like fiberglass or HDPE.

Solar Builder reached out to the vast and diverse mounting and racking community, and the following are submissions from companies spanning all corners of the North American market, from residential rooftops to large ground-mounts and everything in between. It’s interesting to see how companies are working to reduce installation risks and system costs. Here are the newest and most unique mounting and racking systems out there now for your reviewing pleasure.

Advanced Racking Solutions VICERACK
VICERACK by Advanced Racking Solutions offers a low-weight, tilted mounting solution for all low-pitch, standing seam roof profiles. The weight of a VICERACK system (including solar modules) is less than 2 psf and is designed for inclinations of 5 to 30°.
The versatility of VICERACK means the system, connected with S-5! clamps, can be installed either square or skewed to the roof on both the north and south facing pitches.
Analyzed by several pre-engineered building supply companies, VICERACK systems are configured to avoid additional snow accumulation. The rear vented design and open side profile result in lower operating temperatures and improved solar yield. Access is available to all modules for maintenance. advancedracking.com

Applied Energy Technologies RAYPORT-B
AET claims to have the only stainless steel roof ballast system on the market with its RAYPORT-B solar rack that is designed to minimize installation time and cost. The RAYPORT-B is designed with the end-user in mind. Ease of ordering (only four part numbers to order), top-down assembly of PV modules, integrated fasteners (allowing one common bolt to be used for all joints), integrated panel grounding and industry-leading installation time make the RAYPORT-B a favorite with installers.
AET’s racks are the quickest to assemble on the market and fit all major solar modules. A full layout and loading analysis is provided for every project. With manufacturing located in Ohio, AET has the shortest lead-time in the industry. Most racking systems are available for immediate shipment. aetenergy.com

Creotecc Mounting Systems
Creotecc mounting systems provide superior module retention without the use of clamps, thereby accelerating installation times, minimizing stress on modules and improving aesthetics. With no clamps to fasten, modules are placed quickly and easily into insertion rails for faster panelization. Resting securely in place without clamps, modules are able to contract and expand naturally, minimizing the risk of micro-cracks and early degradation. Finally, straight rows are automatically produced by the insertion rail, creating a continuous, even plane surface and a beautiful, gap-free appearance. With more than 1 GW installed globally, Creotecc mounting systems for residential, commercial and utility applications are made in the United States, are P.E. certified and UL 2703 recognized. creotecc.us

DynoRaxx Evolution
The DynoRaxx Evolution flat roof system features rugged fiberglass components and DynoRaxx’s innovative tool-less clamping mechanism. The compact ballasted design requires no roof penetrations and has a smaller footprint than competitive systems.
The DynoRaxx Evolution fiberglass components cost less than traditional metal systems. The baskets are stacked like cups for huge savings in shipping. Installers assemble the system quicker with the tool-less pivot clamp design. This means a lower installed cost per watt and more profitable PV installations.
After an initial measurement and chalk line to place the first row, the precision components require no further field measuring. From module to module and row to row, installers work quickly assembling racking and clamping solar panels. dynoraxx.com

EcoFasten
Information from EcoFasten for mounting on low slope roofs and steep slope roofs.

Ecolibrium Solar ballasted systems
Ecolibrium Solar designs ballasted, flat-roof racking hardware, with a goal of reducing the cost and duration required to install solar arrays by focusing on polymer-based solutions, weatherability and roof-membrane material compatibility.
Ecolibrium’s original product, Ecofoot, offers simple installation — one foot and one bolt provides 15 modules/man-hours install time, with the ability to accommodate any framed module. Ecofoot2 offers integrated grounding and built-in wire management. The low part-count and simple, top-down clamping system makes installing the largest projects fast and easy. The system only requires a drill to install all the components including wind deflectors which reduce the ballast requirements lightening the load placed upon the roof. ecolibriumsolar.com

HatiCon Solar Pitched Roof System
HatiCon Solar’s pitched roof system is optimized for simple and fast on-site installation with no fabrication. Solar PV panels can be easily installed in portrait and landscape orientations. HatiCon Solar’s adjustable universal clamps click or slide on to the rail and only require one Allen wrench to tighten. This means less clamp inventory for the distributor or installer. Integrated grounding technology is available. Angle brackets connect standard industry stanchions to the HatiCon Solar rail. Angle brackets allow up to 1 1/2 in. of vertical and 3/4 in. of back-to-front adjustability in the field with no fabrication. The pitched roof system is available in mill and black anodized finishes. All hardware is stainless steel. Rails can span up to 16 ft and the system can work on a pitch of up to 70°. haticonsolar.com

MAGE SYSTEMTEC
MAGE SYSTEMTEC is a universally adaptable, easy-to-use mounting system that reduces installation time over conventional systems. It is designed to provide customized solutions with strong results on a wide array of ground and pitched roofing applications. Its innovative click-lock technology requires only a few tools which drastically reduces the installation time. This, in turn, increases the overall yield of the PV system for the end-customer due to lower costs for the investment and accelerated pay off time.
Covered by MAGE SOLAR’s 10-year material warranty, the rails are made of high-tier 6063-T6 extruded aluminum with fasteners and other hardware parts from stainless steel. M5 and M8 bolt sizes, a drill and clamps are sufficient for installation. magesolar.com

OMG Roofing Products PowerGrip
OMG PowerGrip is a roof mount system for securing solar racks to thermoplastic (TPO and PVC) roofing membranes. PowerGrip provides a secure connection directly to the roof deck or structural members. Once secured and heat-welded in place, properly installed PowerGrips limit rack movement and remain watertight.
Factory fabricated OMG PowerGrip assemblies are easy-to-install and compatible with most solar racking systems on the market. No field fabrication or assembly is required. Since they eliminate the need to cut open the roof down to the deck, the system saves time and labor. PowerGrips feature a 9-in. wide diameter welding flange and a 1/2-in. tall weather resistant aluminum perch. An exposed 1-in. tall by 3/8-in. diameter stainless steel bolt provides a secure connection point for solar racks. olyfast.com

PanelClaw Sun Bear
Sun Bear is a penetrating ground-mount racking system from PanelClaw designed for large-scale installation of PV power plants for almost any terrain, foundation and environment. With its distinct truss design structure Sun Bear streamlines PV construction with just four major components and zero loose fasteners to reduce construction risk, integrated turnbuckles to safely perform in-field adjustments, telescoping frame that maximizes shipping capacity and interchangeable foundations to reduce project risk.
Sun Bear takes an innovative approach to large ground-mount applications to reduce project risk and decrease total project lifecycle costs. Its four-component design includes a pre-assembled frame and in-field adjustability, for an unmatched combination of simplicity and flexibility. panelclaw.com

Patriot Solar 375 Series Ballasted Ground Mount
With only four major components — block, post, truss and rail — Patriot Solar’s ballasted ground-mount system is ideal for large commercial and utility-scale installations. The mounting structure is 100 percent hot-dipped galvanized steel. Five panels can fit per section. Tilt angles range from 10 to 40°. It’s rugged and weather resistant, and the ballasted ground mount comes with a 10-year guaranteed against mechanical failure (breakage) of the frame construction. patriotsolargroup.com

PV Racking
Find information on PV Racking for roof and ground-mounted racking here.

Quick Mount PV roof mounts
Quick Mount PV uses its patented QBlock Elevated Water Seal technology for superior waterproofing in the Classic Composition Mount and the Classic Shake Mount mounts on wood shake roofs. The QBase Composition Mount is a base-and-post style mount ideal for new roof construction. The QBase, the strongest mechanical roof attachment available, is also used for the QBase Low Slope, QBase Shake & Slate and QBase Universal Tile Mounts. The Classic Conduit Mount lifts conduit off the roof to prevent wiring from overheating, and the Conduit Penetration Flashing waterproofs roof penetrations for conduit passing through the roof.
Quick Hook USA is the industry’s first flashed tile hook mount, available for curved and flat tile roofs. The Quick Groove offers Quick Mount PV’s patented waterproofing technology for Zep-compatible installations. quickmountpv.com
Check out installation instructional videos from Quick Mount PV here.

SolarDock mounting system
Invented in 2003, SolarDock was designed to meet the needs of commercial property owners and tenants for racking that would protect their building while providing a strong ROI. SolarDock is made from durable mill-grade aluminum and stainless steel, has been rigorously tested in the wind-tunnel and has TUV Rheinland’s certification.
SolarDock is engineered to protect the roof with no penetrations and has no metal parts touching the roof, eliminating the chance of roof leaks and damage. SolarDock’s full-frame support protects the panel from micro-fractures created by wind uplift forces. Enclosed sides and back protect the wiring from damage caused by weather, animals and birds. SolarDock saves money throughout the life of the system, with reduced installation costs, little or no operations costs and increased power generation. solardock.com

Solar FlexRack Utility Ground Mount
The SFR Utility Ground Mount incorporates advanced design engineering for optimal use of materials. Its all-steel rack dramatically reduces the price per watt. The entire system comes pre-assembled in two pieces, allowing for easy installation by a three-person crew in less than 10 minutes. The SFR Utility Ground Mount also has an integrated wire management system built into every rack by using z-purlin horizontal rails.
The SFR Utility Ground Mount utilizes a direct bolt connection for mounting modules to the rack. This method also bonds the module to the rack eliminating the need for an extra step to ground the modules to the racking system. Every rack is custom designed and project specific using structural analysis software to analyze the structure and ensure compliance with all applicable local building codes. solarflexrack.com

Sollega FastRack
Sollega Inc. debuts the new FastRack (FR5) 5° low-pitch solar roof-mounting system. The FR5 complements Sollega’s existing InstaRack (IR10 and IR15) product line and is the first truly universal one-piece modular mounting system engineered to mount all 60- and 72-cell modules. The lightweight stackable design is efficient to ship and quick to stage and install. The FR5 arrives assembled and ready to install with all hardware pre-attached. To install, position the FR5, add ballast and attach the module with four pre-installed top-mount bolts. Grounding is performed using a UL-certified mid-clamp. As with all Sollega mounting systems, all attachments utilize one tool, a standard 1/2-in. socket. Manufactured in California utilizing recycled HDPE plastic enhanced with ultra-violet (UV) inhibitor, the FR5 is guaranteed for 25 years. sollega.com

SunLink Precision RMS
SunLink’s Precision RMS boasts design innovations that enable installation on rooftops with limited deck capacity and advanced features that allow for faster installation making it possible for more building owners to install solar, even in locations where it wasn’t previously possible.
These features include roof-friendly rubber feet that can be adjusted to align loads with structural elements of the roof, and a roof following capacity of 7°/12 percent. Plus, with a linked rail structure and stiff aluminum frame, Precision RMS can withstand conditions in the highest wind, seismic and corrosion zones — opening up a wider range of environmental sites to solar, as well. sunlink.com

Sunmodo Ez Roof Mount
Not only is the Sunmodo’s Ez Roof Mount easy to install, but it is water tight and durable when used with any composite shingled roof. Ez Roof Mount has been certified under IAPMO ES for 100 percent compliance with International Building Code (IBC), International Residential Code (IRC) as well as watertight compliance UL 441 criteria.
In addition, Sunmodo offers Ez Metal Roof Mount, specially designed for metal roofs. With few components and single penetration, Ez Metal Roof Mount has a fast installation.
Recently, Sunmodo introduced another product line for metal roofs. The universal seam clamp is specially designed to distribute load evenly against metal standing seam roofs and allow for continuous pressure contact against the attachment surface with no permanent damage to the roof. sunmodo.com
Check out an installation video from Sunmodo here.

Zilla racking and mounting systems
Zilla designs and manufactures innovative solar racking, flashings, mounting systems and products that make solar power more practical and affordable than ever before. Zilla accomplishes this through thoughtful design that facilitates intuitive use and cost-saving efficiencies throughout the manufacturing, delivery and installation processes.
The Zilla product line applies best-in-class technology to provide outstanding racking and mounting solutions. Zilla leads the industry with systems that are on the cutting edge of technology and is redefining solar mounting solutions in ways that make solar installations safer, easier and more affordable. The company offers flat roof, flush mount, ground mount and custom systems to meet customer needs while focusing on strength, performance and value. zillarac.com

-- Solar Builder magazine

Low-pitched metal roofs can successfully support solar modules when they’re angled just right. Advanced Racking Solutions manufactures tilted systems that happen to work perfectly on metal rooftops.

Metal rooftops are found atop a wide range of buildings — family homes, storage warehouses, large industrial shops, sports arenas, you name it. All metal rooftops must be pitched, and large metal rooftops are considered “low-pitch” because they’re at angles less than 10°. The process of installing solar on these large metal rooftops is not so much of an issue as the fact that low-slope rooftops need modules tilted to get the most production. Advanced Racking Solutions focuses exclusively on manufacturing solar mounting solutions for low-pitched metal rooftops to solve the tilt problem.

“Because there’s a pitch to the roof, the traditional way of putting solar on a metal rooftop is to put it flush-mount on the south side, meaning parallel with the roof surface, and put nothing on the north side,” says Eric Stephenson, director of engineering and technology. “For low-pitched metal roofs, we developed a tilted solution, which would allow you to put solar on both the south and the north. It opens up the other half of the roof to rooftop solar.”

Flush-mount systems are not ideal for low-pitched metal roofs because their low tilt angles subject modules to snow cover and general poor yield since they’re almost horizontal. Heat buildup is also a big problem underneath the modules.

“With our titled solution, it’s vented and allows the heat to escape,” Stephenson says. “And because it’s tilted, you have a small aisle between each row. There’s no more climbing over top of the modules to get access to modules in the middle of the array.”

The two common types of metal roofs include an exposed fastener roof and a standing-seam roof. Exposed fastener roofs or corrugated steel roofs screw sheet metal into the structure, so fasteners are exposed. Advanced Racking manufactures the VICERAIL system for exposed fastener roofs and uses an EJOT fastener to penetrate the roof. The fastener is then sealed to make it water-tight.

Most of Advanced Racking’s work is on standing-seam rooftops. A standing-seam roof has a rib or seam that stands up generally every 2 ft. Roof panels meet together and roll into a weather-tight seam without using any fasteners.

“That seam presents a continuous knob that you can grab onto,” Stephenson says. “We use the S-5! clamp to connect the racking system to the roof. We took a version of our ballasted racking system and adapted it to use the S-5! clamp to clamp onto the seams.”

Advanced Racking’s VICERACK system’s ability to clamp onto the seams allows the system to be installed without ballast. As with any flat-rooftop solar project, the biggest obstacle is often ensuring the building can support an additional load. Not needing ballast with the Advanced Racking system is helpful for design.

“What was critical for us is that we have a system that would be benign as far as the wind loading was concerned,” Stephenson says. “The additional wind load on the building would make the project undoable. We spent a lot of time in the wind tunnel to make sure that we had a system that would not add any additional wind loads to the structure. We were able to achieve that.”

The type of material you place on top of a metal rooftop requires attention, too.

“All of [Advanced Racking’s] racking members are aluminum and the fasteners are stainless steel,” Stephenson says. “The aluminum is primarily for corrosion resistance. It’s also compatible with the types of coatings on rooftops. Standing seam rooftops are often finished with galvalume, a combination of galvanizing and aluminum coating. Having an aluminum racking system avoids some of the problems that come with dissimilar metals.”

Advanced Racking’s systems are almost entirely shop-assembled, so work on top of the roof is minimal. Very few tools are needed to install the S-5! clamps in the case of a standing-seam rooftop installation.

Metal rooftop mounting and racking systems from Advanced Racking Solutions are easy enough to install, but Stephenson says the real obstacle in gaining larger acceptance is changing people’s views on how solar works on metal roofs.

“One of the challenges that people have with low-pitched metal roofs is that a flush-mount system is not a great solution,” he says. “When people see that there is a better solution for a low-pitched metal roof, they will start to look differently at rooftops that are out there. Roofs that were previously overlooked or not looked at very favorably will become a lot more appealing.”

-- Solar Builder magazine

Ballasted ground-mounts work just as well as penetrating ones, especially when it comes to difficult land conditions.

Visions of large ground-mounted solar projects consist of large posts drilled into the earth, with dirt and small rocks being hauled away. But not all ground conditions are ideal for a penetrating system. Ballasted mounting systems can work just as well on the ground as they do on rooftops. Patriot Solar Group has a ballasted ground-mount that has seen success at landfills, brownfields and among rocky soil conditions.

“Landfill caps cannot be penetrated at all so you cannot use a post-driven solution,” says Adam Parr, account manager for Patriot Solar. “Brownfields cannot have any major soil disturbance. For rocky soils, you can drive posts but you then run into possibly hitting rock and throwing off your array.”

These difficult ground conditions are usually the cheaper alternative for solar power compared to lush, green landscapes.

“When you look at the cost of the land of [difficult ground areas] compared to a pristine farm field or other ‘building suited’ land, it makes sense to go with inexpensive or otherwise unusable land,” Parr says.

Parr describes Patriot Solar’s ballasted ground-mount as “simple, with minimal parts and ease of use, all while providing the most functionality.” The system consists of: a cement block with adjusting plates that come pre-poured to site; a post that can be adjusted up and down for height differences and 10 to 30° to accommodate slopes; a truss which can be adjusted to the desired module tilt from 10 to 40°; and rails that hold five panels before sliding onto the next rail.

Patriot’s standard ballast block meets a 100 mph wind-load. For large projects, the company provides civil engineering assistance to ensure the ballast system meets desired criteria.

“We have built-in fork pockets for ease of use and can add a jagged edge that cuts into the dirt to prevent erosion or slippage,” Parr says. “Duck bills or earth anchors can be used as well if you have a slope to prevent sliding. You can also size the block smaller and add duck bills to use less cement and still meet the desired wind loads.”

Ballasted ground-mounts are more expensive than post-driven systems, mostly from the additional costs in concrete. But considering the costs associated with site prep and excavation (for rocky conditions) in addition to the added labor, the costs are pretty comparable for the two systems.

Patriot Solar Group began first as a manufacturer of fixed and tracking ground-mounts but soon saw a market demand for ballasted systems, so they were added to the product line-up.

“More and more landfills are being developed because it is land that is otherwise unusable,” Parr says. “Poor soils and unusable land make the cost of the land much less expensive. [And] there are no other options. They have to be ballasted.”

Patriot’s unique telescoping post has a multiple-angle adjustment plate that allows for height alteration with 10 to 30° of tilt variance. This allows the block to follow the contour of the land and keep in line with both post-driven sections and other ballasted sections of the array. Instead of laboring over removing large rocks, using ballasted ground mounts next to penetrating mounts saved crews time and money.

“With our ability to adjust the post height and tilt, we minimize the amount of site prep and can combat variations in slope,” Parr says. “Our design allows installation of racking and panels to take place on the ground without any heavy machinery or scaffolding.”

The next time developers run into rough terrain, a ballasted ground-mount could be the simple solution to a complicated installation problem.

-- Solar Builder magazine

Single-axis trackers are fast to install, easy to maintain and generate the most solar energy at the lowest lifetime cost.

By Tim Cain

The goal of solar power is to lower costs, generate savings and provide a hedge against rising energy rates. Solar developers, financiers, utilities and businesses are all looking for a viable economic model to maximize a solar project’s return on investment (ROI). Driving down the cost of solar hardware and increasing productivity are the sure ways to maximize the ROI of a solar power system.

“I’ve seen a lot of changes in the industry,” says project superintendent Kevin Rosales, a 12-year veteran with SPG Solar, a provider of solar technologies and services for commercial and utility-scale solar projects. “The fierce competition, low cost of solar panels and dwindling energy rebates have made us look for ways to streamline our processes while maintaining high quality. Single-axis trackers were the natural answer.”

INCREASE PRODUCTION
In an effort to increase solar output, single-axis trackers have become the “go-to” racking solution since they increase production by up to 30 percent. Traditionally open fields used a fixed-tilt system, with the introduction of single-axis trackers and the lower levelized cost of energy (LCOE), trackers have become the mainstream ground-mount solution.

The decision to choose between a fixed-tilt and a single-axis tracker depends on geography, land, soil type, foundations and module stringing. Historically, there were reservations about a single-axis tracker and the increased maintenance and ground cover ratio (GCR). However, the technology has improved and most single-axis trackers require less than 16 man-hours of maintenance annually per megawatt and use a backtracking algorithm. So even with GCRs higher than 40 percent, the economics for a single-axis tracker still make sense in the Southwest compared to a fixed-tilt.

“The best tracker is one that’s been designed to shorten the overall installation timeline,” Rosales says. “Take the latest SunSeeker tracker, for instance; we ensured that it has a smaller footprint, one-third of the piers per megawatt and requires fewer materials and less labor. This all adds up to one thing: faster installation, which translates into lower costs that we can pass on to our customers in the form of lower project pricing.”

INSTALLATION-FRIENDLY
Single-axis trackers, like any other solar power system, are only as successful as their installation. Tracker installation can be divided into four important areas: foundation installation, racking installation, commissioning and operations and maintenance (O&M).

Foundation Installation
Vibro-piling wide flange beams is the preferred method of tracker installation for those who want to reduce costs, mitigate land impact and shorten construction timelines. Laying out the foundation with survey points versus string lines or other methods will increase efficiency and accuracy, thereby reducing labor costs. It is absolutely critical to have the proper machinery and skilled installation crew for this — a typical crew consists of one operator on the vibro-pile machine, one on the skid steer and one laborer verifying accurate placement and elevation of the pile. Maintaining pier tolerances in x, y, z directions eases installation of the tracker’s racking components and improves the overall quality of the installation.

Racking Installation
Staging materials during the installation of the piers increases the efficiency of the installation and cuts down on the time required to install the racking. This process can be separated into four segments — motor and controller installation, driveline installation, array wing installation and module installation. The most efficient way to tackle these segments is to deploy crews on each of these tasks. And, as with any racking product, quality control of the installation crews is critical to the success of the installation. Because welding has been eliminated with most single-axis trackers, the need for special on-site inspections is reduced, thereby decreasing the build cycletime.

Commissioning
It’s important to understand the system’s configurations and input variables prior to starting commissioning. This ensures that proper safety protocols are in place and removes the risk of improper configuration. Documentation of the system configurations and settings is important for O&M crews to troubleshoot the system in the future if required. Most systems have minor adjustment points to accommodate any aesthetic concerns, which may be small but are critical to the overall look of the system.

O&M
A well-established training manual or program — including installation and commissioning records — should be in place for any installation. Service technicians should be certified, trained and knowledgeable of the systems they are maintaining. While O&M requirements for systems vary, proper maintenance of the system is key to its uptime. If trackers are properly maintained, an uptime of up to 99 percent can be expected for most systems.

As the cost of solar continues to dramatically decline, with the price of solar panels falling 41 percent from 2011 to 2012 and the installed price of solar dropping 27 percent, prices are expected to continue to drop, but they will eventually bottom out. Improving production, therefore, becomes even more imperative. The simple installation of a single-axis tracking system increases a system’s output and maximizes a project’s ROI.

-- Solar Builder magazine

HatiCon Solar repurposed a ground-mount to fit on the roof of a new green building in Seattle.

At its grand opening on Earth Day (April 22) this year, the Bullitt Center introduced itself to Seattle and the world. The six-story, 50,000-sq-ft office building is the first urban commercial building in the United States to meet the goals of the Living Building Challenge. The international certificate program, created in 2006, promotes the most advanced measurement of sustainability in building. Influenced in seven performance areas — beauty, energy, equity, health, materials, site and water — projects that achieve the Living Building Challenge are the greenest in the world.

The Bullitt Center, here still being finished, has a 242-kW solar system on its roof, manufactured by HatiCon Solar. Photos courtesy of John Stamets.

In the case of the Bullitt Center, in addition to its wooden frame (which should extend the structure’s lifespan to 250 years), automatically programed windows (for temperature regulation), oversized windows and high ceilings (to provide 82 percent of the center’s lighting naturally) and composting toilets (all water and waste is treated on site), the $30 million building is completely off-grid, using geothermal energy and a 242-kW solar power system.

The large rooftop system is unique in that it’s actually a ground-mount refurbished to fit on top of the building. HatiCon Solar, an Ontario, Calif.-based mounting and racking manufacturer, produces systems for pitched roofs, flat roofs and ground, but found its all-aluminum, ground-mount the most ideal for the Bullitt Center. Additional testing and certification was needed — the city had to approve the solar panels to extend out over the sidewalk — but HatiCon Solar’s involvement in the ground-breaking project was fairly uncomplicated.

HatiCon Solar founded in 2009 and has more than 100 MW of product in the ground in the United States thus far. Each system uses pre-assembled components and few parts to provide a quick installation, including universal module clamps that slide and click onto structural rails. HatiCon Solar systems are all-aluminum (except for stainless steel hardware and ground posts), which provides an even greener product for customers.

“At the end of the project’s life, [the mounting/racking system] is 98 percent recyclable,” says Eduardo Lainez, sales and marketing coordinator. “If you’re doing a large ground-mount installation and you’re looking at an ROI of a few years, at the end of life of the whole project, instead of getting 10 cents on the dollar for a steel-structure system, you’re getting closer to 70 to 90 cents on the dollar for an aluminum system. You’re actually generating some money on the backend, which is nice.”

HatiCon Solar’s mounting systems are very flexible, and Lainez says the company has found itself doing a lot of odd projects — the Bullitt Center being maybe the oddest. The HatiCon Solar ground-mount product was reconfigured to be placed on the roof of the six-story building.

HatiCon Solar installed a ground-mount system on the roof of the six-story Bullitt Center in Seattle.
Photos courtesy of John Stamets.

“The roof in particular could take a really strong point load, so you could do large spans,” Lainez says of the Bullitt project. “It’s more like BIPV than a stand-alone system on top. They needed a specific flush look. They were looking for an aesthetic look, so we modified our system.”

Assembly of the system was done on the roof, as it was easier to move the parts piece by piece. HatiCon modified and tested its existing ground-mount system with new aluminum connections to meet all requirements and building codes.
“We did do additional tests, both for installation and rain to make sure the rain would run off correctly, that the installation would work,” Lainez says. “The rails are extremely light and extremely strong, and the point load on the roof isn’t extremely heavy. There’s that wind strength, and it can take the snow load.”

The 242-kW system should produce more than enough energy for the Bullitt Center year-round. With super-insulated walls, a highly efficient heating and cooling system and the large windows, less electricity is needed to heat and cool the building and keep it lit up. Large electricity suckers, like computers, servers and other office equipment, are put on an energy limit. Tenants of the building can swap unused portions of their energy budget to other tenants, thus sharing the center’s full range of benefits.

Solar power makes up a small portion of the Bullitt Center, but it’s making a huge presence in producing a net-zero building, thanks to HatiCon Solar’s innovative mounting solution.

-- Solar Builder magazine

Solar Builder  wanted to offer our readers a look into those mounting companies separating themselves from the crowd. With more than 50 mounting-specific manufacturers in the industry, it can be easy to get lost in the shuffle. Embracing social media and designing for a mobile era only ensures a company’s longevity. Check out our picks for the best mounting manufacturers on YouTube, Twitter and those inventing apps.

YOUTUBE STARS

Search for an installation video or product review of any common solar mounting company and you’ll be flooded with amateur videos from average citizens and installers not affiliated with mounting companies. Sometimes these informal and pure reviews are the best way to know if a system works, but there are many good YouTube channels from the manufacturers themselves. Most feature installation videos either in animation or real-life applications. If you really have questions about a system, videos straight from the experts might be more beneficial than Jim Bob working in his backyard. Here are our picks of some of the elite solar mounting YouTubers active in the last year. (Views and video totals accurate as of April 21, 2014.)

IronRidge

17,743 views | 8 total videos | 4 new videos since Jan. 2013
IronRidge has a good mix of animated overviews and actual step-by-step installation videos. Have questions about how to install the roof-mount system on tilt legs? That’s covered in a video that gives exclusive tips like how to torque rails and keep track of loose bolts. IronRidge released the FlashFoot in early 2014, and a YouTube video explanation was a perfect way to introduce the new product to the solar community.

Quick Mount PV

18,542 views | 43 total videos | 25 new videos since Jan. 2013
It’s safe to say that installing solar on shingled or tiled roofs is a little more complicated than a basic flat-roof project. Quick Mount PV makes the installation process a no-brainer with its YouTube channel (and all videos are also nicely organized on the Quick Mount PV website). From quick tips showing how to cut tile to in-house demonstrations on how to find rafters, these videos really are helpful to the novice solar installer or those double-checking their work.

Solar FlexRack

10,719 views | 16 total videos | 8 new videos since Jan. 2013
Solar FlexRack has a unique pre-assembled, unfolding design to its ground-mount system, but that means nothing until you see it in action. The company has a number of videos showing installations in a variety of conditions, and most are in real-time, proving how quickly mounts can be installed. Step-by-step videos provide a little extra help to installers who may have questions about how that unfolding contraption actually works.

GameChange Racking

811 views | 13 total videos | 13 new videos since Jan. 2013
Seeing a real-time installation of a ground-mount is occasionally beneficial, but who really wants to spend 20 minutes watching a guy secure bolts? GameChange Racking knows our attention spans are dwindling, so the company speeds up its install videos to fit in less than four minutes. GameChange also shows transparency, letting viewers see its systems go through wind-load testing. We could watch videos of huge 120-mph fans all day.

EXPERT TWEETERS

Besides the best breaking solar construction news from Solar Builder (@solar_builder), Twitter is full of solar companies tackling issues and relaying the latest industry information. Solar companies have really embraced social media, and it makes a big difference as customers get younger and more tech-savvy. Whether installers or manufacturers actively participate in online conversations could sway decisions about project and product selection. Here are some of Solar Builder’s favorite fellow conversationalists.

Applied Energy Technologies (AET) @AETenergy
A great mix of industry news and actual product installations. Join in with the company’s hashtag challenge: #LayMoreRackThanAET.

Ecolibrium Solar @EcolibriumSolar
Very conversational account, asking questions while promoting unknown elements of its products.

SolarDock @solardock
Promotes necessary tips, like remembering about fire safety on rooftops and gives suggestions on how to better design arrays.

AllEarth Renewables @allearthrenew
Spreads the good news about solar outside of just its own Northeast home. Want to know the latest local and state bills concerning solar? This account has the info.

UNIQUE APPS

A new age is upon us, one run by smart gadgets and advanced technology. Most of these devices and their applications can make our lives better and easier, as long as we keep the Candy Crushing and Snapchatting to a minimum. It seems like every company or product has a mobile app these days, but surprisingly only a few solar mounting companies have developed tools to make solar installations easier. Here are the ones that do more than just list systems and ways to purchase.

Unirac Toolbelt
Available on iOS and Android devices
The Unirac Toolbelt is like a full set of tools any solar installer would benefit from having on hand. Users have many cool functions right in one device, like a True South Compass, a U-clinometer (which helps determine the pitch and angle of any surface) and the Theodolite (which uses your device’s camera to determine roof angle, height, altitude, latitude, longitude and azimuth, all at ground-level). The Toolbelt app also makes working with Unirac products even easier, with direct access to technical support and configurators to map out a new project, module-by-module.

 
RBI Solar Shading Calculator
Available on iOS devices
RBI Solar’s shading calculator helps installers calculate row spacing in the field so they have a better idea how far apart rows need to be in different areas. Users pick their location on a map so approximate sun angles can be considered. Then after submitting the array’s tilt angle and module length, the app calculates the post-to-post distance, the inter-row spacing and the distance from the front of the first panel to the front of the second. RBI Solar’s shading calculator takes a lot of the guesswork out of project planning.

Solar Builder
Available on iOS devices
We wouldn’t be a good magazine without a shameless plug of our own app in this category. The Solar Builder  app is an extension of this fantastic print publication and our website. Bonus videos and expanded graphics are peppered throughout our interactive pages, and archived copies stay on your device for easy viewing at a later date. Now instead of carrying your favorite article in your wallet for years to come (you do that, right?), you can pull it up whenever you want, without the crease marks or coffee stains.

-- Solar Builder magazine

Frameless modules are becoming more than just an aesthetics-pleaser on residential roofs. There are many benefits to them — better fire protection, better moisture barrier, no grounding needed — but there are also many installation aspects that take some getting used to. How are they mounted? What about wire management? What are the extra costs? Solar Builder  hopes this crash course helps answer some of the basics.

Jing Tian, product manager at Trina Solar
Trina Solar manufactures the PDG5, a 60-cell dual glass module. It comes in at around 255 W, has a 15.2% module efficiency and is UL certified. Trina offers a 30-year warranty on the product.

Trina Solar’s PDG5 frameless module

SB: What is a dual glass/frameless module?
JT: A traditional module is a silicon sandwich. There’s glass with a silicon cell in middle, and the backsheet is typically polymeric with a frame around to ensure the mechanical integrity of the product.
With a dual glass module, we replaced the backsheet with another sheet of glass, so it’s a glass sandwich without a frame. The cells are encapsulated in glass.

SB: What are the advantages of a frameless module?
JT: Glass is much less flammable than polymeric materials. From a fire safety perspective, that’s why we passed as a Class A fire-rated module. One of the common concerns with a silicon module is a microcrack. Having a glass panel, front and back, gives better mechanical protection during transportation and installation. There’s also no grounding for the frame because there is no metal for the modules.

SB: What type of customer wants a frameless module?
JT: These modules target any customer. There’s an industry adoption curve for people to get used to dealing with a dual glass panel [like] handling of the module, the installation process. What really appeals right now to early adopters is aesthetics, fire safety and high wind load. Because there’s better mechanical integrity, it provides better resistance to wind loads.

SB: Are special parts needed to install frameless modules?
JT: Trina developed our own clamps that mate with most commercial rails. For ground-mounting, [we’re] continuing with a C-clamp-type of solution. But we have been working with mechanical BOS companies, from ground-mount to roof-mount, to work with their existing solutions to work with our modules. We’re working with partners to make it easier for installation.

John Williamson, engineering manager for Array Technologies Inc.
Array Technologies Inc. (ATI) manufactures fixed-mounting and tracking systems. The company recently developed a new design for both its DuraTrack HZ tracker and DuraRack fixed rack to accommodate frameless modules.

SB: Did Array need to redesign its systems for frameless modules?
JW: Array designed a custom tracker structure, including a brand-new racking system designed especially for frameless modules. The racking system was extremely rigid to prevent module damage. However, it included a well-thought out assembly system that allowed rapid deployment and installation on-site and minimized materials as much as possible using custom-designed rails and clips to keep structural costs down, and assembly tools to reduce installation time on-site.

Frameless modules show installed on an Array Technologies tracking system

SB: How does securing frameless modules differ from traditional modules?
JW: Though the backbone of the tracker structure remains the same, ATI uses a completely different system for racking both kinds of modules. Framed modules don’t require special supports and custom designed clips for attachment to a structure. Frameless modules require special clips to support them at specific locations. To install these at the lowest possible price point, custom racks must be designed for the individual frameless module to support them properly.

SB: Can installers adapt to installing frameless modules pretty quickly?
JW: Workers can be trained in less than a day on how to properly install frameless modules. There are different instructions and tools needed. We have full documentation that we provide our customers for install, as well as an excellent project management team who will train customers on best practices and installation techniques.

SB: Why incorporate frameless modules into your systems?
JW: We incorporated frameless modules due to the demand of our customers. As a leading ground-mount solutions provider, it is our policy to work with customers to find the most effective configuration of our tracker to bring lowest LCOE, fastest installation and the most reliable product possible. If that requires designing new racking systems or other subcomponents for large projects, we will happily take on the engineering challenge.

SB: What is your outlook on frameless modules in the industry?
JW: Frameless modules are becoming somewhat popular because they are cheaper than framed modules by themselves. However, removing the frames requires the racking company to support the frames in special ways with more expense, often requiring special clips that are expensive to manufacture and install. I think in certain cases projects can be less expensive than framed modules, but it often requires a development partnership between the module company and racking company to get there. If cost simply shifts from the modules to the racking, it doesn’t save the customer any money and can slow down a typical project.

-- Solar Builder magazine

Tracking systems are simpler and more efficient than ever.

The utility-scale solar market is one of the largest areas of opportunity in North America, underscored by the fact that it more than doubled in size between 2012 and 2013 alone. With analysts projecting this growth trajectory to continue through at least 2016, the sector continues to draw the attention of investors. At the same time, the costs and capabilities of balance of system (BOS) components continue to improve, providing developers and installers with an expanded arsenal to help stakeholders get immediate and long-lasting returns from their solar assets.

One structural BOS component growing in popularity is solar trackers, which are motorized structures that orient photovoltaic (PV) panels toward the sun throughout the day to maximize the capture of sunlight. When properly utilized, trackers have been shown to significantly boost the production of utility-scale PV plants and accelerate ROI for system owners.

Let’s take a look at the potential benefits of horizontal, single-axis solar trackers (the most commonly implemented tracker design) and examine the considerations installers face throughout the tracker selection and construction processes.

Figure 1 — Energy yields during average June day in comparison to TOU prices.

Why solar trackers?
Solar trackers enable large-scale PV installations to better capture solar irradiance as the sun moves across the sky. Output gains will vary, depending on both project site and tracker technology, with higher-performing models achieving as much as a 25-percent performance increase.

Furthermore, utilities across the United States are increasingly implementing time-of-use (TOU) rate structures, where electricity prices rise during periods of peak demand — typically in the late afternoon hours. As we can see from Figure 1 (a case study from a PV system located in Chowchilla, Calif.), the tracker-equipped project will capture increased sunlight during peak use hours, corresponding to stronger rates of return. Additionally, as electricity rates increase and TOU rates land in project financing contracts, the monetary benefits of trackers are only getting stronger.

When irradiance is important and/or in combination with a power purchase agreement (PPA), trackers are usually a no-brainer solution.

What makes a quality tracker?
Much like any PV system component, different tracker products will offer a variety of features and benefits. Installers should be prepared to do their homework to find a tracker that offers the ideal combination of affordability, performance and reliability. Poor tracker selection can be a major pain point for installers — low-quality products can lead to time-intensive work and cut into profits.

A key indicator of tracker bankability will come from third-party validation. Certification bodies like the Underwriters Laboratories (UL) and the International Organization for Standardization (ISO) regularly perform a number of tests related to product safety, performance and durability in extreme environments. The highest quality trackers will meet or exceed evaluation criteria in areas ranging from accelerated aging to wind resistance and will be fully compliant with safety-focused manufacturing codes. UL recently launched its 3703 certification standards specifically for the tracker market.

Strong product warranties also speak volumes to a tracker provider’s commitment to its customers. If a PV system is expected to return dividends for a minimum of 25 years, its trackers should be held to those same standards of longevity.

System design and installation
It should come as no surprise that numerous factors must be taken into account when designing a tracker-equipped PV system. As with any ground-mount project, site assessment begins with an evaluation of land size, cost, topography and weather patterns. When adding trackers to the mix, additional considerations include potential gains in energy capture, levelized cost of energy (LCOE) and projected payback time. An essential design aspect is ground cover ratio (GCR), which is the ratio between the PV modules’ area and the total ground area. An increase in GCR corresponds to a linear negative impact to system output. This is because the higher the GCR, the smaller the distance between the tables, thus increasing panel-on-panel shading. Unlike fixed-tilt systems, trackers with integrated backtracking program can position tables to avoid shading the adjacent panels.

In terms of installation, advanced trackers are far less cumbersome and complex than their predecessors. Today’s system integrators can benefit from trackers based on modular designs to significantly decrease the amount of time, tools and manpower required at a jobsite.

Figure 2 — Yield increases 20.16% with trackers.

Case Study
With a smart tracker system design in place, PV plant developers and investors can immediately see financial benefits. Figure 2 is an example of the annual performance of the PV plant in Chowchilla, with and without tracker technology. While fixed-tilt systems might offer a minor performance advantage in the winter months, tracker-equipped plants will achieve significant gains throughout the summer, in this case yielding an average production increase of 20.16 percent.

As we can see here, the increased output offered during summer months will more than offset production loss during the winter.
Solar tracker technologies have come a long way in recent years. Today’s solutions offer the simplicity and reliability PV plant stakeholders need, at the price points they want. With the right tracker technology — accompanied by an optimized plant and smart tracker implementation — installers can offer their customers a safe, long-term solar investment opportunity.

-- Solar Builder magazine

A major first for South Carolina turns to trusted names for support.

South Carolina is in the heart of solar country. Its neighbor North Carolina is ranked 10th in the nation for solar jobs (3,100 total) and can power nearly 40,000 homes with solar energy. Georgia to the west has 146 solar companies. In the south, Florida (you know, the Sunshine State) powers more than 20,000 homes with installed solar power.

So why then does South Carolina rank 29th for solar jobs (1,000 total), can only power 400 homes with solar and has a measly 33 solar companies? Some blame the state’s strong support of nuclear power. In fact, South Carolina’s V.C. Summer Nuclear Station is in the midst of a multibillion-dollar expansion, receiving new reactors (two of only four new nuclear reactors being built in the United States in 30 years). Nuclear power supplied more than 57 percent of the state’s electricity generation in 2013 (according to the U.S. Energy Information Administration), so solar isn’t especially attractive right now.

But big players are starting to make that change in South Carolina. This January, a revolutionary solar project was commissioned in Walterboro. Santee Cooper, the state-owned electric utility, built a 3-MW solar farm on an old cotton field as a test bed for understanding how solar fits in with the grid and how to go about building more. Schletter and Array Technologies Inc. were the lucky manufacturers chosen to jump-start South Carolina’s solar construction.

Colleton Solar Farm is unique not only for being the first utility-scale solar farm in the state, but it was also built in nine weeks — astounding in itself even for an experienced group of solar installers. Alder Energy Systems, based in Charleston, S.C., won the bid to develop the 3-MW solar farm, installing 1.8 MW with Schletter’s FS System and 1.2 MW with Array Technologies’ DuraTrack HZ single-axis tracker. Donald Zimmerman, principal/owner of Alder Energy Systems, says commercial operation began on Dec. 20, 2013, 67 days after initial construction.

“There were a number of Doubting Thomases that didn’t believe we could get it done,” he says. “Contracts weren’t even signed until the first week of October. It took a lot of trust of all the participants that we were going to get this done. We didn’t have time to validate, double check, wait for the ink to dry. That [trust] was one of the reasons we were able to get it done.”

Photo credit: Santee Cooper

The project had to be completed quickly to ensure all appropriate tax breaks were used.

“We had to get it done by the end of the year because bonus depreciation was going away,” Zimmerman says. “The economics of the project really required that tax credit.”

Zimmerman says the project was able to be completed quickly because there was a well thought-out and well-planned design from the get-go. Alder Energy had procured all major equipment prior to winning the RFP from TIG Sun Energy, a subsidiary of Intertech Group, so there wasn’t an equipment hold-up to get things started. Having a good group of South Carolina-based contractors — those from Alder Energy, Gregory Electric and Sunstore Solar — helped things move smoothly, especially when installing both a fixed-rack and tracking system.

“We only had something like three-and-a-half weeks between order and driving our first pile for the fixed system,” Zimmerman says. “The Array Technologies tracker was another week or two behind that. [The installation schedule] was all based on availability of equipment and materials.”

Since Santee Cooper was taking a chance on this project in a state where solar is in its infancy, the utility chose to do a mix of fixed and tracking for research purposes.

“This was originally set up with Santee Cooper to provide insight into what solar will do to their network and how to best plan for putting more solar into their network,” Zimmerman says. “They looked at it as a research tool. We have 455 string monitors, all five inverters are identical, they’re strung identically, they’re all the same panels. Everything is identical except the racking systems — 40 percent is tracking, 60 percent is fixed.”

Alder Energy chose to work with Schletter, Array Technologies, SMA America inverters and Canadian Solar modules because, as Zimmerman says, they’re the best of the best.

“We decided essentially right from the get-go on this project to use only Tier 1 manufacturers, guys that were leaders in the industry,” he says. “Being it was our first one, it was the proven chosen to make. Let’s face it, there’s a reason they’re leaders in the industry.”

Kyle Petty, senior account manager with Schletter, says it was extremely gratifying to be considered the best for this project when the market is full of quality products. He hopes to work with Alder Energy and in South Carolina in the future.

“This project was an excellent step for solar in the state of South Carolina,” Petty says. “I am already hearing rumors of similar size projects in the works. With individuals like Don pushing for more solar in the state, I am expecting to see more and more action as the years progress.”
Zimmerman says he likes how Schletter handles everything and makes sure the project is the best it can be.

“They sent out a soils crew with a couple test piles. They drove them in, they pulled on them and yanked on them and got all the appropriate engineering parameters necessary to provide a fully-engineered system for that site,” he says. “It was essentially one phone call, one responsible party for that whole process. That was really a key selling point. If I get these guys on the job, I know they’ll get the job done, and they’ll get it done right. I don’t have to coordinate my soils guy with my structural engineer. It can all be done under one umbrella.”

Array Technologies equally impressed Zimmerman, sending a field representative in the first couple days of construction to walk the crew through the installation process.

“This was the first time Gregory Electric and Alder Energy worked with our DuraTrack HZ single-axis tracker, but they put such a great team together and were such exceptional planners that they basically had it all figured out during the early stages of the tracker installation,” says Edgar Pedrego, project manager with Array Technologies Inc.

“It is important to us that the hard work Array Technologies Inc. has put in over the years is validated by solar industry leaders that choose our product due to its reputation for reliability, longevity, ease of installation and the high level of customer support that comes with it.”
Mostly, the project went off without a hitch. The weather was great and everything got done in record time. The only hiccup was working with the old cotton farm’s loose soil conditions.

“The first 2 ft of soil was so loose it didn’t have any holding power,” Zimmerman says. “We ended up going with 12 ft of pile embedment which is a lot deeper than most people. We did have problems securing a pile driver with enough length/height in order to drive these piles. We didn’t really have a good backup to the pile driver.”

Overall, everyone — including Santee Cooper — was impressed with the project.

Photo credit: Santee Cooper

“We had tremendous compliments,” Zimmerman says. “When the SMA tech came out to commission the inverters, he told us a little story: ‘Going out to South Carolina and these guys have never done one of these before, so expect a bunch of yahoos.’ But when he got here, he said this was one of the easiest commissionings he’s done. There were no problems. Everything was just right. He was very impressed.
“I felt good about that,” he continues. “It was our first one, and the experts said us yahoos did OK.”

Hopefully it’s a sign of good things to come. Santee Cooper plans to be very open about the research availability of the farm. All the collected data from the Colleton solar farm will be made available to all public utility companies. Another local utility, South Carolina Electric & Gas (SCE&G), has already made plans for a 2-MW solar farm at the Lake Murray dam outside of Columbia.

“Surrounding states are really hot with solar right now, and there is no reason why South Carolina can’t catch up. The sun is not going anywhere,” Pedrego says. “Once everyone is on board — meaning regulatory committees, utilities, etc. — the solar market will grow naturally on its own.”

“In the state, power companies are beginning to embrace solar. I see more [projects] coming,” Zimmerman says. “It’s a sign of great things to come in South Carolina, and it’s great to be a big part of it.”

-- Solar Builder magazine

The landfill and brownfield market is growing for solar installations, and SunLink has worked out a system that will last.

Massachusetts isn’t that big. It’s the seventh smallest state in the union, and the only states it beats are its surrounding New England friends. But it’s the 14th state by way of population — more than 6.5 million people call the Bay State home. The state’s population density is third in the nation with 840 people per square mile. That’s a lot of people on top of each other; space is tight.

Now consider that Massachusetts has 594 inactive or closed landfills and 23 still actively filling with waste. That’s a lot of uninhabitable land in a state that seems pretty crammed. Parks, shopping malls and golf courses have been built on old landfills, but there are often settlement issues or reports of methane gas escaping when not properly monitored. The better and safer option for these brownfields? Solar installations.

Massachusetts knows this. The state has installed more than a dozen in the last few years — Washington Gas Energy Systems built six, Gehrlicher owns a few, Clean Focus recently announced 19.5 MW of new projects, and Borrego Solar has used its PPA experience to construct solar on capped landfills, too. In 2012, Borrego worked with mounting system manufacturer SunLink on two projects in the towns of Ludlow and Easton.

Constructing solar on capped landfills requires a certain expertise and knowledge of the many installation issues that can arise — differential settlement, weight limits and increased expenses, to name a few. But SunLink has the experience, says Yury Reznikov, vice president of product and strategy.

“We’re warranting these products for 15 to 20 years, so we’ve learned a lot about how to install them, how to make sure the landfill caps survive for the next 15 to 20 years,” he says. “We believe our solution is one of the few that is going to be out there for the long term.”

LIGHTWEIGHTS
When you see a capped landfill, it often just looks like a large, grassy field; you wouldn’t know there’s a mound of trash hiding underneath. Although the ground looks fairly normal, a traditional penetrating ground-mount solar installation won’t work, says Joe Harrison, senior project developer at Borrego Solar.

As landfills fill up with trash, areas are compacted and covered with layers of soil and sand. Generally since the late 1980s, landfills in the Northeast have been capped with a geomembrane lining. About 2 ft of soil is then spread on top of the cap and grass is grown. Vegetation is monitored annually to ensure root systems don’t damage the cap.

Two feet of soil is nowhere near deep enough for a penetrating system, and since nothing can puncture a landfill cap, ballasted is the way to go when installing solar at landfills. But even weight is a concern on top of that geomembrane film.

“Our ballast blocks are around 1,500 lbs a piece, so it doesn’t create an issue for the cap, but the challenge is moving them around and getting them in place,” Harrison says. “We have a staging area during construction off of the cap, then only tracked equipment is moving around on the landfill. When you have a [machine] pick up a ballast block and start driving around, the point load on all four tires is too great for the landfill and cap. You have to use tracked equipment to spread out that weight.”

SunLink is a big proponent of pre-panelization — the act of assembling systems off-site to speed installation and cut down on unnecessary weight loads on unstable ground. Its two ground-mount systems — the Ballasted Ground Mount System (GMS) and the Large-Scale GMS (a penetrating system) — can both be assembled and installed quickly. The ballasted system situates panels one-by-one in portrait orientation while the penetrating system uses four panels on top of each other in landscape orientation. The Ballasted GMS works well on landfill caps, but it was not chosen for the Ludlow or Easton landfill projects. Instead, Borrego and SunLink decided a reformatted version of the Large-Scale GMS would be more efficient for the scale of the landfill projects.

“If you have the right crew, the right equipment, the right project, we believe that the four-in-landscape [orientation] is more cost-effective in terms of installation,” Reznikov says. “Borrego thought, because they know how to build these projects, they were going to be better off with the four-in-landscape product.”

UNDERGROUND MOVEMENT
The Ludlow project was a 2.6-MW installation, while the landfill in Easton received a 1.9-MW solar installation. Usually projects of that size are installed in long, continuous rows of panels. But differential settling of things underneath landfill caps prevents long rows from happening.

“If you think about things in landfills, things decompose at different rates so it’s not a steady settling that occurs,” Harrison says. “You might have a bunch of material in one section that decomposes quickly, and you get an indentation in the landfill. Eighty percent of the settling occurs in the first 10 years, so we won’t install on a landfill that is less than 10 years old.”

Since settling still happens after the 10-year mark, solar modules are best situated into tables, usually four panels high by five panels wide using SunLink’s system, to accommodate possible movement. The tables are secured to two posts and ballasted a few inches apart so there’s enough space that the racks won’t hit each other when differential settlement does occur.

“We do offer enough adjustably in the system to provide for differential settlement, but with the lifetime of a system at 20 years, we can’t predict everything,” Reznikov says. “We want to make sure if there is an unexpected amount of differential settlement, a two-post, non-continuous system gives a little more flexibility.”

MAXIMIZING PROFIT 
There are a lot of added expenses to a landfill-based solar system, including concrete costs for ballast blocks, transportation costs for getting ballast blocks to sites and wiring costs for securing and protecting wire above ground since it can’t be trenched underground. Finding any way to save a few dollars elsewhere on a system is really beneficial, Harrison says.

“It’s already more expensive to construct on landfills, so it really makes sense to maximize the system size as much as you can,” he says. “Maybe you tighten up the row spacing, maybe you use a more efficient module — we’re really focused on driving down the cost of solar.
“SunLink is a good partner,” he continues. “We really work together with them to drive down the cost and come up with the best solution. The SunLink system has a better coverage ratio, and we can fit more PV on the site.”

SunLink is committed to meeting its customers’ needs.

“We’re there to support our customers with whatever they need,” Reznikov says. “We’re here to help our customers solve problems. We pride ourselves on going the extra mile to get a project to a successful state. We have the engineering chops to answer the need.”

Since these two Massachusetts projects in 2012, SunLink has continued to partner on landfill installations. Reznikov says the company is working on around 20 MW of landfill projects in 2014.

“We’ve seen the market expand quite a bit,” he says. “Before it was a couple hundred-kilowatt jobs. [Then] with Borrego we saw almost 4 MW, and we’re seeing that expand more and more. When we look at landfills or brownfields, that’s just land folks can’t necessarily use. It’s a perfect place for solar. It’s something that we believe is going to keep growing. Given the number of landfills out there in the U.S., developers are focusing on that. They’re growing, and we’re growing with them. We’re big believers in the landfill space.”

-- Solar Builder magazine

Here are the latest product announcements from the best mounting and racking companies in the business. See what’s new and what has evolved over the last year. And make sure to visit their websites for a full list of available products in 2014!

Advanced Racking Solutions metal roof mounting systems
Advanced Racking Solutions Inc. designs and delivers innovative mounting systems for all types of metal roofs. The VICERACK clamped, non-penetrating system attaches to the standing seam on metal roofs and was developed in conjunction with engineers at S-5!. The VICERAIL system for screwed-down metal roofs attaches to the purlin with proper weather sealing. All Advanced Racking Solutions mounting systems are wind tunnel tested. Proprietary system design will not increase wind loading on the building.
VICERACK and VICERAIL can be installed on the north pitch offering greater roof coverage and reduced roof loading — less than 2 psf. Aisles and walkways create access to all modules in the array. Available in a variety of tilts with site-specific layouts provided for each project, including landscape or portrait module orientation. advancedracking.com

AET RAYPORT ECO solar mounting solutions
Designed for cost-driven projects, AET’s all new RAYPORT ECO solar mounting solutions include all the features installers look for in a cost-competitive package: industry-leading installation, high shipping density (lower freight bill), compatible with all panels, layout/loading analysis included, galvanized for corrosion resistance, lightweight for easy handling on the jobsite and turnkey installation services.
Save time and money with AET’s turnkey installation services available for all AET RAYPORT ECO solar mounting solutions. From the initial phases of design and engineering to manufacturing and installation, AET’s turnkey installation services offer a single point of contact for solar projects. aetenergy.com

AP Alternatives
AP Alternatives’ core focus is providing the highest quality solar racking and installation services for commercial and utility scale systems. AP’s modular solar racking is manufactured and assembled in a quality controlled environment ensuring each system meets strict quality standards. The pre-assembled and prepanelized racking allows for rapid installation times and reduced on-site labor. With more than 25 years of manufacturing knowledge and a proven track record of successful installations, simply send AP Alternatives your modules and let the experts do the rest. apalternatives.com

Array Technologies DuraRack
A perfect blend of industry leading technology and cost-saving elements, Array Technologies Inc.’s DuraRack fixed-tilt mounting system has proven itself as the premiere fixed-tilt system of the future. Several of DuraRack’s leading product features include the lowest number of posts per module, an all-bolted coupler solution that eliminates the need for field welding, customizable tilt angles between 10° and 40°, the industry’s fastest install rates and availability in portrait or landscape module configurations. With more than 53 MW installed at five different sites in just less than six months, DuraRack is ramping up to become a leading solution for fixed-tilt ground-mount sites across the solar industry. Photo credit: AMEC, arraytechinc.com

Daetwyler Clean Energy
With Daetwyler Clean Energy’s (DCE) experienced engineering and global fabrication facilities, the premier solar racking hardware manufacturer provides economical solar racking hardware direct to installers and project developers for small- to utility-scale installations. Each of DCE’s solar solutions is designed specifically to achieve maximum output while optimizing economics. The Eco-Top and Secure-Top rooftop mounting systems feature modular designs with minimal parts which makes system design and installation fast and easy. The Modu-Rack ground-mount systems are available in several configurations to address any soil condition. The Modu-Rack SA is DCE’s single point anchoring system, and the Modu-Rack DB is a driven beam system. And, the Cap-Rack systems are designed to address conditions encountered with landfill sites. daetwylerce.com

DPW Solar Power Rail pre-assembled module clamps
DPW Solar expands the Power Rail family with the addition of pre-assembled PV module clamps. Designed with the solar installer in mind, the new clamps feature the patented RAD lock-in-place fastener and require no additional field assembly. Simply twist the clamp assembly into any Power Rail channel and slide up the PV module. No loose parts and quick quarter-turn insertion reduce overall assembly times and lower costs on projects. Available with a factory-assembled integrated ground disk, the clamps also feature stainless steel construction for higher strength and reliability in harsh environments. Pre-assembled clamps are now available for mid- and end-clamping of most framed PV solar modules. dpwsolar.com

B-Line by Eaton mounting systems
Eaton’s B-Line business offers a market-leading Fixed Tilt Ground Mount and Ballasted Flat Roof racking systems for commercial and utility-scale solar projects. The Ground Mount system is configured to match each project site, featuring pre-assembled components, optimized adjustment process and an innovative module mounting process. The result is a simple, fast and structurally reliable solution. The ARISTA rooftop racking system couples a simple, pre-assembled product with an elevated racking system, helping improve system performance while allowing better access to the roof. The solar team from Eaton’s B-Line business is available to provide assistance for all solar projects from the design stage to on-site training and support. bline.com/solar

EcoFasten GreenFasten
EcoFasten Solar was founded by a former roofer with decades of experience to bridge the gap between the people who design solar arrays and the people who install them. Utilizing a patented watertight bushing and backed by IAPMO Certification, the GreenFasten solar roof-mount system is the strongest, most straightforward solar attachment point in the industry. Compatible with a variety of EcoFasten Solar compression brackets, GreenFasten delivers a mounting solution for virtually all new or existing composition shingle roofs. Utilizing lag bolts to secure this system to a roof means durability you can trust. All EcoFasten products are made with pride in Vermont using recycled materials. ecofastensolar.com

Ecolibrium Solar EcoFoot2+
The EcoFoot2+ is engineered to yield all the benefits of the EcoFoot2, plus the added benefit of a universal pre-assembled clamp, a lower part count and innovations that reduce the heat buildup on the racking system. There are only four parts: base, deflector, high tower clamp assembly and low tower clamp assembly. The reduced part count plus pre-assembled clamps increase install speed and lowers the end cost. Additionally, the new clamping mechanism improves module compatibility, spacing flexibility and reduces attachment requirements. Ecolibrium Solar continues to seek the equilibrium between what is economically competitive, ecologically conscious and where innovation can be used to insure integrity. ecolibriumsolar.com

GameChange Racking Pour-in-Place Ballasted Ground System
This innovative new ground system from GameChange Racking utilizes self-leveling technology which substantially reduces install time. The Pour-in-Place forms are placed and supported, the concrete is poured and panels are mounted. Ballast/concrete is added only after leveling is completed. This makes installation much faster than precast systems since it is easier to adjust light systems than heavy ones. The simplicity of the process ensures Pour-in-Place can be installed 68% quicker than any precast system. The large ballast footprint reduces landfill cap loading. It’s available in both one- and two-panels-up portrait and comes with an integrated tray for easy wire management. Pour-in-Place is wind tunnel tested, rated for 120 mph wind speed and meets IBC and ASME standards for structural loading. gamechangeracking.com

Hollaender Speed-Rail fittings
Hollaender offers Speed-Rail fittings designed specifically for installation of solar racking systems in areas that experience extreme wind. New fittings include a tee and elbow for use with 2-in. IPS pipe. On a Speed-Rail fitting, the component that produces pipe holding power is a single integrated proprietary internal/external reverse-knurl cup-point set screw that securely attaches the fittings to the pipe and provides tremendous resistance to loosening and pullout. The new fittings are designed with two set screws, producing a substantial increase in pullout resistance. Testing on the 2-in. IPS fitting shows the addition of the second set screw increases pullout capacity from 3,900 to 8,200 lbs on galvanized pipe, an increase of 110%. solar.hollaender.com

IronRidge Roof Mount
IronRidge Roof Mount is a rail-based solar mounting system for residential and commercial rooftops. The unique curved profile of the XRS Rail enables it to achieve a 12-ft span between attachments. This reduces the number of roof penetrations and attachment points per installation, reducing cost and liability. Additionally, IronRidge Roof Mount is certified for Integrated Grounding (UL 2703). The Grounding Mid Clamps bond solar modules directly to the rails, eliminating the need for separate module grounding hardware.
Base installation is also simplified by IronRidge FlashFoot, an all-in-one roof attachment for shingle roofs. FlashFoot integrates a standoff, flashing and L-foot into a single assembly, reducing base installation procedures by up to 40%. ironridge.com

KB Racking EkonoRack 2.0
The KB Racking product development team has taken the intuitive design of EkonoRack and redefined it to meet customer demands. The affordable, flat roof mounting system now features pre-assembled roof protection mats, 20% less aluminum and a sleeker design. The ETL-certified system consists of three major components and has been praised for its simplicity by installers across the United States and Canada. With EkonoRack 2.0, rapid installation and long-lasting durability are now available at a lower price and in more locations. kbracking.com

Legrand Cablofil FAS Rack
The Cablofil FAS Rack PV mounting system from Legrand is a line of supports for ground-mounted PV arrays. The FAS Rack system is designed for fast installation with minimal on-site labor requirements. Prefabricated components eliminate time-consuming and expensive “stick built” installations. The system has been engineered to be installed by two-person crews without special tools or large equipment. Designed to ASCE 705 requirements, FAS Rack is engineered and tested to withstand extreme wind and snow loads. Array tables are joined by a slotted splice that allows for thermal expansion and contraction. This feature maintains the system’s UL 2703 rating and eliminates the need to run bonding jumpers or ground each individual table. legrand.us

Mounting Systems Inc. Alpha+ and Tau+ on-roof systems
Alpha+ and Tau+ are new pitched roof racking systems that employ Mounting Systems’ all-new Clickstone technology. The Clickstone works on a simple principle: Click into the rail, position, tighten, done. Alpha+ can be mounted on various pitched surfaces while Tau+ is specifically for trapezoidal sheet metal roofs. The Clickstone’s symmetrical design lets the installer insert the Clickstone into the rail more easily, adjust it more accurately and secure it more quickly. This and new economical rails result in exceptionally fast assembly and easy system installation. Newly designed planning software (Quick Configurator) also speeds project planning and permitting. mounting-systems.us

PV Racking Power Carport
The PV Racking Power Carport is a 60-panel solar carport designed to provide coverage for four vehicles. The three-post carport is engineered to withstand 130 mph wind loads and 35 psf ground snow loads. The bolt-together design makes on-site installation very simple; no welding required. The carport will come equipped with PV Racking slide-in rails, making module installation much quicker than standard clamp based systems. Complete kits are available with modules and inverters. Carport and racking installation services available in the mid-Atlantic region. pvracking.us

Quick Mount PV E-Mount
E-Mount uses the patented QBlock Elevated Water Seal technology to provide superior waterproofing on composition/asphalt shingle roofs. Priced at a modest premium over commodity roof-mounts, E-Mount makes it possible to deliver Quick Mount PV quality even on price-sensitive jobs. All stainless steel hardware included for fast, single bolt installation. E-Mount comes with a 10-year limited product warranty. quickmountpv.com

Quickscrews Stone Coat Steel Roof-Mounting Series
Quickscrews International now has five different hooks developed for the Stone Coat Steel style of metal roofs. These products have become the No. 1 style for mounting on metal roofs that have the appearance of tile. The parts are mounted under the steel sheet and slip through the overlap, leaving a sturdy mounting base for a wide range of racking systems. The two newest hooks are able to cover wider areas in cases that require it. Quickscrews also added an adjustment capability to compensate for surprises that cannot be seen until the metal sheets are removed. quickscrews.com

RBI Solar Carport Solutions
RBI Solar has included a wide range of solar carport solutions to its product selection including single slope, double slope, inverted slope and full coverage designs. RBI Solar focuses on creating durable, functional and cost-effective custom solutions for each project. RBI Solar’s capabilities also extend into the installation portion of projects. Multiple crews and a fleet of post-driving machines allow RBI Solar to meet the demands of shorter construction schedules. Leveraging more than eight decades of experience in the commercial design-build specialty structures market, RBI Solar works with clients to identify the most economical, low maintenance and robust solar mounting structures. RBI Solar mounting systems are highly engineered and backed by a 20-year product warranty. rbisolar.com

Renusol MS system
Renusol MS is a simple, compact and cost-effective pitched roof solution developed specifically for mounting PV modules to trapezoidal sheet metal roofs. Uniquely, the system attaches directly to the sheet metal, eliminating the need for long rails and attachments to purlins or rafters. Made of stainless steel and aluminum, it consists of a clamp base for quick installation, self-piercing and self-tapping screws with hardened tips that eliminate rooftop drilling and pre-assembled, adjustable mid- and end-clamps for securing the PV panel EPDM gaskets under all clamp bases. The system has been third-party tested for waterproof assurance. The Renusol MS system is compatible with all widely used sheet metal roofs 26-gauge or thicker with flat trapezoidal peaks at least 3/4-in. width. renusolamerica.com

Schletter Fix-EZ Ballasted Flat Roof System
Fast and easy to install, Schletter’s Fix-EZ ballasted rooftop mounting system is now ETL-listed. The Fix-EZ allows for module tilt ranges from 5° to 15°, depending on the length and orientation of the system. The system is designed with multifunctional components and includes integrated ballast blocks, which act as ballast weight in addition to serving as the system’s support mechanism. Module mounting rails support modules and perform as the system’s windbreak with Schletter’s ETL-listed Rapid2+ modules clamps for bonding/grounding the modules to the rails. The ETL-listed Fix-EZ is now available for flat roof projects in every state. schletter.us

S:FLEX LEICHTmount
S:FLEX Inc. provides a complete range of rooftop and ground-mount solar structures with in-house custom design expertise. LEICHTmount is a highly flexible flat roof low-ballast system. Designed for hassle-free installations, it can be installed as a non-penetrating system or as an anchored system with minimal strategic attachment points. The combination of variable row spacing, tilt angles between 0° and 35° and extendable base rails allow for individually customized projects. Arriving on site with pre-assembled parts guarantees a simple time-saving install. In addition, it is adjustable to conform to unforeseen design changes or unknown obstructions on the roof. The patented technology of LEICHTmount provides absolute stability by using precisely calculated weight distribution. Photo credit: S:FLEX, sflex.com

SolarDock
Invented in 2003, SolarDock was designed to meet the needs of commercial property owners and tenants for racking that would protect their building while providing a strong ROI. SolarDock is engineered to: Protect the roof — SolarDock makes no penetrations, even at high angles, and has no metal parts that touch the roof, eliminating the chance of roof leaks and damage; Protect the solar panels — SolarDock’s full-frame support protects the panel from micro-fractures created by wind uplift forces while enclosed sides and back protect the wiring from damage caused by weather, animals and birds; and Protect the bottom line — SolarDock saves money throughout the life of the system, with reduced installation costs, little or no operations costs,and increased power generation. solardock.com

Solar FlexRack Tracker
The Solar FlexRack Tracker offers a distributive drive system allowing this single-axis tracker to be installed on sites not usually considered for conventional trackers. Solar FlexRack’s design and flexibility creates maximum ground coverage ratio, accommodating two- or three-high landscape panel orientations. The Solar FlexRack Tracker has gone through extensive third-party testing and validation including wind tunnel testing, full bankability study and full life-cycle testing. The intelligent design allows for a quick and easy installation with no field welding or special equipment required. The SFR tracker’s movements are provided by a maintenance-free actuator, and nylon bearings are also used that require no lubrication. solarflexrack.com

Sollega FastRack FR5°
Sollega’s FastRack FR5° one-piece mounting system was recently installed on a multi-roof array of 820 kW at the Westin Hotel located on the Caribbean Island of St. Maarten. The FR5° utilizes HDPE plastic with UV inhibitor and coated fasteners for superior corrosion resistance. The arrays were ballasted and anchored utilizing Sollega’s heat-weld solution to a fully adhered TPO roof requiring no holes to be drilled in the roof. sollega.com

SunLink Precision-Modular RMS
Precision-Modular RMS is the newest addition to SunLink’s quality engineered Precision RMS roof-mount racking family. Precision-Modular RMS is constructed of aluminum and features roof-friendly rubber feet that prevent any metal from touching the roof surface. The system is also fully connected north/south and east/west to better distribute loads and does not rely on the module frame as a structural element. The system is assembled, laid out and installed module-by-module to maximize layout flexibility, dramatically reduce costs through standard inventory and facilitate last minute on-roof changes. The building block design is so lightweight and easy to install that it can be assembled by one person. Precision-Modular RMS is available for 60- and 72-cell modules and 5° and 10° tilt. sunlink.com

SunModo
SunModo Corp. was formed with the mission of driving down the total cost of solar systems through product innovation and system integration. Its patented flashing mount product has been used to install more than 10,000 solar projects. Moreover, SunModo continues to improve its existing products and develop new products. The new SunBeam system is one of those innovations with the following key features: robust, versatile and advanced engineering that’s designed for multiple configurations; spanning over obstacles to take full advantage of roof space to maximum the system size, offering increased ROI; lightweight for structural loads, and strong for high costal winds; and made of all-aluminum to resist costal salt air corrosion. sunmodo.com

Zilla Store
The new Zilla Store is now open for business, making it easier for solar professionals to select and purchase Zilla products, reducing time delays on installations. The Zilla Store allows users to order the newest line of Zilla products including Zilla Flashings, Zilla Rac Pacs and other popular Zilla products. The new PVC Electrical Flashings is the newest iteration of the best-selling Zilla Electrical Flashing which is designed for a water-tight seal to protect solar installations’ electrical components and the roofs on which they are installed. The new Zilla Rac Pac offers racking and attachment components for two modules included in one easy package. zillarac.com

-- Solar Builder magazine

1. Locating rafters
Rafter-finding techniques include attic rafter mapping, rubber mallet roof tapping, drilling two to three holes through the sheathing to locate the edge of the rafter or using sophisticated stud finders like the Bosch D-tect 150.

2. Centering attachment point
Take care to center your lag bolt in the middle-third of the rafter. This ensures the fastener has the structural capacities listed by the American Wood Council charts.

Failure to remove nails is the most frequent mistake when installing flashing. Removing nails allows the flashing to extend up under the third course of shingles for code-compliant, reliable waterproofing.

3. Piloting holes
Drilling pilot holes is critically important when using 5/16- or 3/8-in. lag bolts in a 2x rafter. This is true even with the newer generation of self-drilling fasteners (like those from GRK). While these specialty fasteners can be installed in wider lumber without pilot holes, failure to drill pilot holes in the outer chord of 2×4 or 2×6 rafters will likely result in split rafters.

4. Remove shingle nails
Always remove the nails on composite shingles to allow the upper edge of flashing to be 1/2-in. above the butt edge of the third course shingles. Failure to remove nails will prevent the flashing from being positioned up under the butt edge of the third course of shingles and thus become a leak risk, especially when the flashing is positioned under a butt joint between two adjacent sections of shingles.

5. Acceptable working temperature
Shingle temperatures should be between 45° and 85° F to avoid damaging the shingles. When installing on asphalt shingles above 85° F, care must be taken to avoid compression deflection of the flashing from over-torquing the lag bolt. Special roofing shoes or protective mats can be used to minimize the risk of bruising on warm or cold days.

This diagram shows the acceptable position for flashed roof-mounts. Most mounts will require at least one nail be removed.

6. Flashing width
Asphalt shingle flashings should be at least 9 in. wide to comply with roofing industry best practices. This assures at least 4 in. of coverage from the edge of the hole to the edge of the flashing. More width provides additional protection from wind-driven rain making 12-in. wide flashing very popular. Tile flashings typically are 18 in. or wider to meet Tile Roofing Institute (TRI) guidelines.

This flashed Quick Hook uses a three-course sealing system that is approved by the TRI guidelines. Mastic applied to fiber mesh provides long-term waterproofing of the top and sides of the base flashing to the rolled roof underlayment.

7. Flashing material
Flashings should be made from an NRCA-compliant metal (aluminum, stainless steel, lead or galvanized steel). The TRI requires curved tile flashing be made from malleable metal. SMACNA (Sheet Metal and Air Conditioning Contractors’ National Association) considers galvanized steel to be suitable only for 15 years of service life, and any breach of the zinc coating will cause corrosion and rust staining. For this reason, galvanized is inadvisable in coastal and industrial environments as well as any installation with more than 15 years of expected life.

8. Seal design matters
Select flashed mounts with a robust seal. Seals that are elevated above the waterline will provide longer life than seals at the waterline, especially in freezing climates. Please note that sealant is a helpful addition to a properly installed flashing; however, when used alone, sealant is not an alternative to metal flashing required by building codes.

The Tile Roofing Institute guidelines require a base flashing be used at the underlayment level. The TRI guidelines are code-required for most tile roofs. Underlayment bibbing is one of two accepted methods for waterproofing the base flashing.

9. Install base flashing on all tile roof mounts
This frequently disregarded code requirement will cause premature leaks on tile roof installations within five to 10 years. All major tile manufacturers abide by TRI’s guidelines which mandate flashing at both tile and underlayment levels. All tile standoffs need a “base flashing” that is bibbed or three-coursed to the underlayment. Then the “tile-level flashing” is installed either on top or just below the tile. Tile hooks also require base flashing, but tile-level flashing is not required since the tile is not penetrated.

10. The benefits of re-roofing under the array before solar installation
Most arrays are installed on roofs with less than 10 years of remaining life. It is strongly advised that the installer replace the shingles or tile underlayment under the field of the array before installing solar. Replacing the roof under an average-sized array prior to PV installation will add $1,000 to $1,500 to the initial installation cost. Homeowners who ignore this advice will pay an additional $3,000 to $5,000 to remove and reinstall an average-sized system for the inevitable roof replacement. Simply stated, unless your roof is relatively new, re-roofing prior to PV installation is the most effective strategy to getting the best financial performance from a solar investment.

-- Solar Builder magazine

SAN RAFAEL, Calif. – SunLink Corp. continues to solidify its leadership position in the commercial and utility solar market by finalizing the acquisition of the SunLink ViaSol Tracker — proven on such high profile, multi-megawatt projects as Arizona State University and USAA’s Phoenix Campus sites, as well as a Southern California community solar project for NRG Energy. Applying SunLink’s engineering expertise to the tracker market for the first time, the SunLink ViaSol Tracker features installation and O&M benefits through the utilization of industry standard, off-the-shelf components and a streamlined design.

“As the leader in ground-mount solutions, SunLink is the perfect company to enhance and scale this proven single-axis tracker technology,” said Michael Maulick, CEO of SunLink. “We’ve been watching this segment with keen interest for quite some time, and now thanks to significant gains in module efficiencies, the economics of trackers have finally gotten to the point where an investment made sense for our company and for our customers. Lowered project costs, coupled with the current ground-mount market boom, motivated our move to command the tracker space with a reliable and extremely price-competitive solution for our partners.”

According to GTM Research and the Solar Energy Industries Association (SEIA) in the U.S. Solar Market Insight 2014 Year in Review, 8.1 GW of PV is forecasted to be installed in 2015. Of that total, approximately 5 GW is likely to be utility-scale and commercial ground-mount projects. Now offering a full range of trusted fixed tilt and tracker ground-mount solutions, SunLink is better able to support customers that are tapping into this market potential, especially the more than 65 percent of ground-mount projects being built with tracker technology today.

SunLink’s ViaSol single-axis tracker features a robust central drive that delivers 25+ year durability, lower hardware costs and higher reliability while requiring significantly less maintenance than distributed driven products. Using drive components that have been proven over decades in the heavy equipment industry, each power unit drives up to 1 MW of solar modules. The product offers market-leading pricing in both the utility sector and the commercial space – particularly for commercial projects of 1 to 5 MW.

-- Solar Builder magazine

Railless solar mounting and racking systems rely on a direct interface between the module and roof attachment. This low-profile design can improve aesthetics while reducing part counts and installation time.

The Evolving Roof Mounting Market with Quick Mount PV

The roof-mounted solar project has plenty of parameters. A successful installation starts with proper panel location and correct angle to the sun, but that install list will be both long and with limitations. As long as the roof is free of shade and faces south (east and west are good too, but south is optimal), there will be plenty of sunshine for those panels. A contractor needs to compare mechanical build plans to as-built roof conditions. Crews need to check layout specs to confirm dimensions, obstructions and quirky roof features, as well as understand local legislation (like California fire codes).

Of course, the ideal installation also requires the perfect product.

In the solar industry, a project often specifies the product. For instance, many mounting companies focus on specific applications — like metal rooftops or landfill caps — while others focus on different materials — like fiberglass or HDPE.

Railless mounting approaches, which remove long spans of aluminum from the installation process, are becoming more and more popular in the sloped roof market. Railless systems rely on a direct interface between the module and roof attachment. This low-profile design can improve aesthetics while reducing part counts and installation time. Some railless systems even offer integrated grounding and wire management features and are compatible with a variety of roof attachment solutions.

A good example is Quick Mount PV, a Walnut Creek, Calif., manufacturer focused on high-quality waterproof mounting systems; the company also has an interesting addition to the rail-free solar mounting market. The company’s Quick Rack Rail-Free Mounting System integrates the roof mount and the racking together to significantly reduce material handling, installation time and labor costs.

“This patented QRack technology eliminates the need for rails to support the modules and the time intensive step of rail installation on the job — just mounts to modules vs. mounts to rails to modules,” said Anne Wright, vice president of sales for Quick Mount PV. “The Quick Rack system also has UL 2703 certified integrated grounding, eliminating the need for grounding each module. One ground lug per contiguous array.”

The key to railless mounting and racking systems is ease of delivery, ease of installation and a good-looking result. First off, how the equipment and products will be handled and staged is a big element to any project’s success. A contractor needs to identify where delivery trucks should unload, how equipment and materials will be lifted to the roof and where they will be staged for maximum efficiency during installation.  By eliminating long rails, products like the Quick Rack can be packaged in small boxes, making the entire mounting system easy to transport, from pulling it out of the warehouse to lugging it up to the rooftop.

“Quick Rack has been used on residences from Massachusetts to Southern California — on roofs with 45-degree slopes to the lower slopes of California homes — in portrait and landscape and even combination configurations,” Wright said.

Once on the roof, the speed and ease of installation is paramount. Quick Rack, for instance, works with standard module frames and requires just a single tool for install. Micro-inverters and optimizers attach to the module frame with simple mounting brackets designed by Quick Mount PV. Wire management is easily achieved by clipping the wires to the module frames. The company says Quick Rack cuts close to 30 percent off installation time compared to rail mounting products. Contractors just need to measure out the roof, put the mounts in and start laying modules.

Quick Rack has three parts. The base mount incorporates a pre-assembled, adjustable top slider, the panel clamp attaches the modules to the mounts and a snap-on skirt gives the finished array a clean, distinctive look.

To keep it simple, the product basically has three parts. The base mount incorporates a pre-assembled, adjustable top slider and features Quick Mount PV’s patented Elevated Water Seal for waterproofing. The panel clamp attaches the modules to the mounts and also functions as a self-leveling patented bridge to securely connect the modules together, transforming the module frames into structural components of the array.

Integrated grounding pins eliminate the need to run long copper wires across the roof and require only one grounding lug for the entire array, while a snap-on skirt gives the finished array a clean, distinctive look. If that sounds complicated, the company has created an app to help contractors get it right the first time.

“The Quick Rack Designer is an app-based array designer that allows the installer to design an array and produce permit-ready drawings as well as an engineering report,” Wright said. “Because it is app based and all designs are stored in the cloud, the installer can modify and re-engineer the design on the jobsite with a tablet or phone. Arrays can be designed in landscape, portrait or mixed orientation, and the design software readily accommodates any obstructions on the roof.”

Quick Mount PV certainly isn’t the only manufacturer making railless solar mounting and racking products. Brands from Roof Tech to SolAttach have launched quality railless mounting hardware products, but the folks at Quick Mount PV like to think they standout with their patented technology, warranty (10 years) and their waterproofing focus. Waterproofing penetrations for solar mounting is actually a fairly serious issue. A solar array on a new roof can last 30 years, but long-term waterproofing is a challenge as mounts flex daily due to wind loads and the difference in expansion/contraction of wood roofing vs. the metal PV racking.

Solar waterproofing is a statistical challenge. Solar installations require dozens of penetrations, meaning even a small leak rate can still be a big problem.  A small 1 percent leak rate, meaning 1 percent of all roof penetrations, after 10 years equates to 30 to 50 percent of your PV installations leaking, according to Quick Mount PV. Fixing leaks will cost most PV owners more than replacing their inverter.

“We like to think of quality, waterproof mounting systems as cheap insurance,” said Meghan Vincent-Jones, marketing director for Quick Mount PV. “This is not where you want to cut corners. Use high-quality products, get educated about roofing best practices and learn how to install solar mounts properly, and you can rest assured you will not be dealing with a costly roof leak down the road.”

Keith Gribbins is associate publisher of Solar Builder.

-- Solar Builder magazine

A 580 kilowatt solar array was recently added to the roof of Baltimore Operation’s e-Motor building, where electric motors and drive units for the Chevrolet Spark EV are built. This new array is made up of approximately 2,420 panels and covers 87 percent of the e-Motor building’s roof.

Applied Energy Technologies (AET), a supplier of commercial and utility-scale racking systems and one of the top 10 solar racking companies in the United States, was selected by Empower Energies to provide its Rayport-B roof ballast mounting system at GM’s Baltimore Operations facility in White Marsh, Md. This manufacturing campus already featured a 1.23-MW rooftop solar array. The new system will add approximately 2,420 5-by-3 solar panels, covering 87 percent of the roof area of the GM e-Motor building, a 110,500-square-foot addition that manufactures electric motors and drive units for the Chevrolet Spark EV.

“Our roots are in the automotive industry,” said Aaron Faust, VP of business development at AET. “The precision and rigorous specifications required to manufacture quality products in the automotive industry are traits embodied in GM, and ones that we bring to our solar racking systems. Our Rayport-B roof ballast system, being the only stainless steel system on the market, brings unprecedented quality and reliability to the PV installation at GM’s facility.”

AET has more than 30 years of product development and engineering experience in both automotive and solar industries.

-- Solar Builder magazine

Welcome to the 2015 edition of the Solar Builder Mounting Guide. Within this year’s guide, we look at all of the advancements in mounting technology currently driving the industry forward and what additional trends are on the horizon; we discuss the effects of severe weather and what you can do to protect your investment; we look at how regulations and codes are playing into mounting strategy; and we roundup some of the top mounting products on the market.

The Mounting Guide is one of our favorite issues here at Solar Builder because solar mounts are really the unsung heroes of the industry. If the entire PV system was analogized to a football team, the panels and the inverters would be the quarterbacks and running backs. They light up the scoreboard and make the splashy headlines. They appeal to the broader audience; whereas mounting systems are like the offensive line. They set the foundation. They do the dirty work.

And nowadays, no matter the style of offense (sorry, analogy over) there is a mounting system that will fit the job. As you’ll read in our Mounting Tech Trends feature (page 20), through the evolution of technology, and because of the demands/desires of project financers and install teams, there are more universal, streamlined, turn-key and customizable mounting solutions than ever before. Through both simplified designs and greater site-specific adaptability, mounting systems are truly helping to remove limitations that used to exist for certain projects and to drive the industry forward.
Enjoy the issue. (Ready — break!)

Chris Crowell, Managing Editor,
ccrowell@benjaminmedia.com

-- Solar Builder magazine

The story of solar mounting technology is a familiar one, in which original technology is slowly replaced by newer options that improve upon certain aspects of the original. Where the initial equipment was focused on establishing a viable product to build an industry, the next wave of trends works to improve, yet simplify what’s already been established. In speaking with dozens of mounting technology companies, this picture emerges. More cumbersome applications with multiple pieces are streamlined and costs come down, all of which eases certain project headaches for contractors. Let’s look at some of these trends specifically, and what you should be thinking about before starting your next project.

Preassembly

According to multiple manufacturers, preassembled and prewired commercial racking solutions are hitting the market and deliver a sizable level of efficiency for any installation while providing installers with a comprehensive, commercial-scale system solution.

Preassembled and prewired racking solutions deliver a sizable level of efficiency for any installation while providing installers with a comprehensive, commercial-scale system solution.

“They are the fastest, easiest way for installers to deploy decentralized, commercial rooftop systems,” says Brad Dore, director of marketing for SMA America. “They include all balance of system (BOS) components and can be assembled in minutes, simplifying and speeding project completion.”

When paired with an advanced three-phase inverter, these racking solutions offer design flexibility, high efficiency, enhanced safety and full grid management features. “Contractors are increasingly looking for products they can understand and quickly master to reduce on-site time and costs,” says Andrew Savage, chief strategy officer for AllEarth Renewables. “There has been a notable evolution on mounting products that strive to speed up install time at the jobsite.”

For commercial mounting technologies, financers are becoming more interested in turn-key products that do not require a new spec for each deal, and turn-key projects they can sell off to investors with low transaction costs.

Universality

Modularity and standardization are keys to the latest mounting technology developments. These trends are driven less by the need to improve the function of the technology and more by the needs of the client. Essentially, a standardized or universal mounting application will lead to a more consistent, repeatable installation process, with fewer project-to-project variables and fewer installation questions.

“A quick, reliable and safe installation process is important to reach time-sensitive installation schedules,” says Martin Beran, head of system support at Fronius USA. “Mounting systems that provide a common installation procedure throughout the product portfolio of a manufacturer ensures high quality, even when performed by inexperienced personnel.”

A universal solution includes a wide range of mounting orientations, that can be utilized on different surfaces (brick, wood or sidings) as well as racks (car port, roof mount or free standing) and with one-size-fits-all inverter racking. With a universal mounting option, there is less of a chance to encounter a situation that will need troubleshooting during an installation.

Simplicity and Speed

Mounting is getting leaner and meaner. The need for universality and preassembly have also led to simpler designs. Beran mentioned that today, high power density leads to lightweight devices that can be easily lifted, installed and serviced by small crews. Fully integrated subcombiner options, such as string fuses and DC disconnect, reduce BOS and labor cost.

“Mounting technology should be easy to install; no special tools or hardware should be required. Small crew size, ideally one-person-only requirements for pre-installation and/or mounting the inverters,” Beran says. “Self-explaining products and intuitive installation procedures ensure high quality of work, long lasting systems as well as production performance.”

Some of these mounting technology advances are a result of improved inverter technology. Utility inverters no longer require massive skid solutions, which can be costly to integrate and ship.

“Inverters are being manufactured with such a high degree of integration that a simple three-piece solution consisting of the inverter, medium voltage transformer and bus bar connection can be assembled on site,” Dore says. “A simple concrete pad can be poured where the kit is assembled. With these advancements in utility inverter mounting, EPCs and construction companies are saving significant costs through the reduction of transportation, logistical and field labor costs.”

Improvements in solar trackers are helping developers, OEMs, EPCs and system owners overcome issues in terms of

Contractors are increasingly looking for products they can
understand and quickly master to reduce on-site time and costs.

layout constraints, an excessive number of foundations and needing too much expensive steel. Some solar project developers are focusing on a tracker-centric strategy for ground-mounted systems to improve project economics, according to Alex Au, chief technology officer for NEXTracker, with forecasts showing more than two thirds of utility-scale projects incorporating trackers by 2018. Au says the latest innovation here is for the tracker to use integrated solar power to move the arrays, enabling them to power themselves using small dedicated PV panels. Some include a backup battery in case PV power output is lost, which removes the need for a separate, costly backup uninterrupted power supply system.

And of course, like many other products that started out as a metal-only solution, plastic applications are hitting the market to offer a further simplification.

“Plastic has had to overcome much discrimination, but because of engineering, testing and especially successful case studies, plastic is here to stay,” says Christopher M. Genco Jr., R&D specialist with Kanzo.

Price Point

“The days of high part counts are gone as utility-scale plant costs approach $1.30 per watt in the southeast now,” says Andrew Barron Worden, CEO of GameChange. The changes are driven by simple, fast installation systems with minimal components that reduce total system cost. By achieving these price drops, solar technology now makes sense on many sites where cost was once prohibitive, with total cost dropping from $2 per watt to nearly $1.50 per watt for large sites, according to Worden. One option here is cast-in-place concrete for ballasts, which has become a prevalent choice for cost and install speed reasons.

“For utility and commercial segments, we continue to see market pricing being driven down to unprecedented levels,” says Steve Daniel, EVP of sales and marketing at Solar FlexRack. “In order to stay competitive, all mounting systems must continue to find cost reductions through product innovations and appropriate usage of materials.”
According to Daniel and other manufacturers we talked to, those cost reductions come from optimizing materials and reducing components — many of the trends discussed earlier.

“I think contractors need to be more aware about what they are buying,” Genco says. “With technologies rapidly emerging in the mounting space, plenty of companies are making promises they cannot keep. Become familiar with a racking company — what they do and what they offer. Look for something well engineered, but easy to use and install.”

Speed and efficiency of a project can often come down to the module interface bracket (MIB) due to the amount of labor associated with module installation. Mike Orshan, director of sales for Array Technologies, says there are MIBs now that use only one single-bolt bracket per module, which can glide easily onto the torque tube and be ready for module installation. Systems that feature independently driven rows with no central drive linkages can provide a lower operating cost, according to Au, because there are fewer moving parts to maintain.

Land variability, labor markets and logistics of every project are important factors when choosing any mounting technology.

“Two 80-module rows can be turned toward one another, such that 160 panels can be cleaned in one pass, versus 20 to 30 panels per pass in a linked row tracker,” Au says.

Each project site is different and specifics like land variability, labor markets and logistics need to be taken into consideration. Custom solutions that appropriately match any project type can enable developers and EPCs to successfully complete projects on time and on budget. But at the same time, Savage says many contractors can lose sight of all the other costs involved when designing custom systems and procuring the necessary equipment.
“As margins get thinner and competition for a sale increases, any mounting solution that helps incorporate both design and procurement will help boost the profitability of these companies,” he says. “This will become even more acute of an issue if there are reductions to the ITC in the coming years.”

Contractors have realized they need to account for more than just racking material price and look at the total cost of implementing an installation, taking into account material, mobilization, delivery, logistics and installation costs. So, any technological solutions that provide ease of installation, adjustability and generous tolerances for field assembly all contribute to the overall project cost and probability of success, according to Daniel.

“Services to accompany the racking are very important,” he says. “Factors offered by the racking supplier like level of project management, field installation training and ongoing support must be considered. There are a number of hidden costs if a contractor is buying on price alone, which can have a detrimental effect on project cost and level of success.”

Chris Crowell is managing editor of Solar Builder.

-- Solar Builder magazine

Installers should avoid positioning systems in areas of the roof that might experience ice dams or accumulation of snow under the array.
Graphic Courtesy of Quick Mount PV.

To successfully harness the sun’s power, all other environmental elements must be controlled or defeated.

First, a disclaimer: As with any weather-related discussion, considerations vary by region. Technical engineering reports for racking systems must reflect local weather conditions and the type of application.

“Snow and wind will greatly influence the design and engineering, which includes the number of required posts or piers and all additional factors of safety built into the system,” says Maria Verros, senior sales and marketing manager for PV Racking. “Each and every quote that we provide for racking requires our design experts to do additional research to confirm this loading information.”

For example, ground mounts in California or Florida will typically be governed by wind design since there is little to no snow load. More northern locations will need to really consider loads of 50 or 60 pounds per square foot (psf). In-between areas, according to Matt Gilliss, independent engineer with Solar SpeedRack Inc., are likely to be governed by “a load combination in the code that combines both wind and snow but with a small reduction to each since it is unlikely to have worst-case snow and wind loads occur at the same time.”

Check out the Mounting Trends Feature from our 2015 Mounting Guide

Snow

Gilliss sets the snow load bar at 15 to 20 psf for many typical types of installs; beyond that, the racking design will need changes, such as limitations on the span of framing and additional posts/foundations.

“When it comes to snow retention, we estimate that panel psf is no more than 50,” says Jolene Ciosek of EcoFasten Solar. But many regions in the United States can see loads above that mark. If snow loads are ignored in regions where they shouldn’t be, an installer may attach the racking at 8-ft spans, but in a very heavy, wet snow storm the racking could collapse.

But even then, ice and snow present different threats both to the solar structure and its surroundings depending on circumstances. Some typical rooftop setups are less at risk from snow.

“For roof-mounted arrays, typically wind is the governing element as the arrays and racking tend to be low to the roof and require frequent anchor points in order to transfer loads evenly to the structure’s framing below,” Gilliss says. “This ends up limiting the spans of the racking, which reduces the stresses caused by heavy snow loads.”

According to Quick Mount PV’s Jeff Spies, senior director of policy, and Duane Menton, mechanical design engineer, “Installers should avoid positioning systems in areas of the roof that might experience ice dams or accumulation of snow under the array. If snow does build up under the array, the inevitable freeze/thaw cycles can create iceberg action that can literally pry the array off the roof.”

This is a major concern with dual pitch roofs that have a steeper upper slope that transitions into a lower slope pitched roof. If the snow doesn’t slide off the array and the roof, the accumulation of snow downhill of the array can freeze, expand and create a damaging uplift effect.

There is also the possibility of accumulated snow sliding off the slick array surface, ripping off gutters and avalanching onto whatever or whomever is below. Ciosek recommends snow management devices or snow guards.
High tilt ground mounts are less susceptible to snow loads, which means wind loads will often take precedence over snow loads, even in the extremely snowy climates.

Wind

Even the most mild climates will need to consider the area’s history of wind, the geography of that specific project location and the geometry, the height and total exposure of the system.

-- Solar Builder magazine