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In the first part of this two-part article, I discussed the common types of roof membranes and roofing systems found in commercial and industrial (C&I) buildings. Identifying the type of roof is a crucial first step when planning for roof-mounted solar installations. This information plays a key role in determining the structural, waterproofing, and balance-of-system (BOS) requirements that must be addressed to ensure the safety and longevity of the solar system.
While these follow-up considerations may not be the primary focus, they are absolutely essential. They help prevent issues such as structural failure, water leakage, or even the collapse of the roof itself. Proper design and engineering at this stage can make all the difference between a successful installation and a costly disaster.
### Structural Considerations
One of the most critical aspects of any C&I roof-mounted solar project is the structural assessment and engineering. A thorough evaluation ensures that the building can safely support the additional weight and forces imposed by the solar array. Here are some key areas to explore during this process:
**Reserve Capacity Evaluation**
Existing C&I buildings are typically designed to meet minimum code requirements, which means their structural capacity may be limited. Adding a solar system could push the structure beyond its intended limits, leading to serious consequences. Therefore, it’s vital to have a qualified structural engineer review the building's current condition.
The engineer will examine the original blueprints, if available, or conduct an on-site inspection to assess the actual conditions. They’ll evaluate whether the existing structure can handle the added gravity and lateral loads from the solar equipment. Any modifications made over time—such as new rooftop units or extra layers of roofing—must also be considered.
Depending on the findings, the building may already have enough reserve capacity, or it might require reinforcement. The engineer should have experience in similar projects to determine the most cost-effective and safe solution.
**Mechanical Attachments**
While ballast is commonly used to secure solar arrays on low-slope roofs, some projects or local regulations may require mechanical attachments. These can help reduce the dead load on the roof, especially when the structure has limited capacity.
A detailed engineering plan will specify the number, location, and hardware required for each attachment point. It’s important that these details align with the specific construction of the roof. For example, if there’s thick insulation between the roof deck and membrane, it may need to be replaced with wood blocking to minimize torsional deflection.
Different attachment methods are suitable for different roofing systems. U-bolts, OMG Power Grips, and S-5! clamps are commonly used. When installing on standing seam metal roofs, special attention must be given to the existing fasteners that connect the panels to the structure—these can be difficult to identify but are critical for the system’s integrity.
**Roof Loading Plan**
Once the solar system is installed, the weight is spread out relatively evenly across the roof. However, during the installation phase, the weight of modules, inverters, and ballast is concentrated. A well-planned roof loading plan ensures that materials are staged over structural elements like beams and columns, which are capable of supporting temporary heavy loads.
This plan helps determine where and how much weight can be placed on different parts of the roof, reducing the risk of damage during installation.
### Waterproofing Considerations
Even the best-designed solar systems can fail if proper waterproofing measures aren’t taken. Every penetration into the roof creates a potential pathway for water to enter. Additionally, the solar system must be installed in a way that doesn’t compromise the roof’s integrity or drainage capabilities.
**Roof Flashing and Drainage**
Flashing is a critical component of waterproofing, especially around penetrations and joints. Effective flashing requires coordination between the solar contractor and a qualified roofer to ensure compatibility and proper installation. Working with a professional can also help maintain the existing roof warranty.
Low-slope roofs, often mistakenly called "flat," rely on features like slopes, crickets, drains, and scuppers to manage water runoff. Solar installations must not interfere with these systems. If water pools on the roof, it can increase the load and accelerate roof degradation, potentially causing damage to the PV system as well.
**Preventing Roof Damage**
Single-ply membranes are particularly vulnerable to damage during and after installation. Tools dropped, foot traffic, and environmental factors like wind and temperature changes can all contribute to wear and tear.
To protect the roof, installers can use temporary barriers or cushioned walkways during the process. Permanent solutions like slip sheets or separator pads can act as a protective layer between the mounting system and the membrane. In some cases, new walkways may need to be permanently installed to accommodate ongoing maintenance and access.
If you're looking for expert guidance on de-risking your C&I roof-mounted PV system while maximizing performance, contact Pure Power Engineering. Our value-engineered design and construction drawing services are tailored to meet the unique challenges of commercial and industrial solar installations. Let us help you achieve a safe, reliable, and long-lasting solar solution.