[RE-wrenches] Hardware request

[Allan Sindelar]

Wrenches,

We have an unusual roof application. It’s for a roof-mount array on a
commuter rail station canopy in Santa Fe. The roof is made up of a coated
corrugated steel top layer, in the shape of a series of sine waves, over
roofing felt, 5/8” plywood sheathing, and a corrugated metal base called
Epicore. The array will be one long single row of modules in portrait mode
on Solarmount rails. I’m leaving out some details in order to get to the
point. 

 

We intend to base our mounting of the rails on a through-bolt mounting
attachment, using threaded rod with the necessary nuts, washers, and sealant
layers to create a compressed sandwich approach. The corrugated top layer
has peaks and troughs of about 1½” radius. We’ll use L-feet to mount the
module rails to the through-bolts, which will likely be made from 5/16” or
3/8” threaded rod (size to be determined as we work out the details at the
site). We will drill through the troughs of the corrugations, rather than
the peaks, to avoid compressing the corrugated roofing; drilling the troughs
has the project engineer’s approval.

 

What we need is something like half-round anodized aluminum or powder-coated
steel stock material. The idea is that the convex round profile fills the
corrugated trough, and the flat surface forms a base for the L-foot. We
would expect to cut the stock to lengths, say 4-6”, drill one hole through
the center cross-section for our through-bolt, and mount the sections in the
troughs, one at each through-bolt location.

 

What product, likely used in some other industry or manufacturing process,
would work for our half-round stock? The job isn’t big enough to justify a
custom extrusion – we probably need two dozen of the finished pieces.

 

Thank you for any ideas,

Allan Sindelar, Positive Energy

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