[RE-wrenches] Hardware request

[Matt Lafferty]

Hi Allan,
 
Sounds like this is a government or similar caliber job. Some better quality
metal-roof products have an actual filler/shim for this purpose. One of
those things that architects tend to like. Depending on the age of the
construction, it may just be possible that there are some records regarding
the actual make/model of the corrugated products. If possible, check with
the original contractor for the roof system &/or the architect.
 
If that doesn't pan out, here is a homemade version made out of Trex (or
similar) on a bandsaw.
http://www.buildingwithawareness.com/blog/2008/12/how-to-mount-photovoltaic-
pv-solar-panels-to-a-corrugated-metal-roof/ . This lets you make your
penetration at the peaks. Note the drain-through notches for the trough
sections. I've made similar spacers in the past but never came up with the
drain-through notches. Instead, I labored with tapering the up-slope side of
the part to allow water to run "over" the block. I really like the
simplicity of the notch and all to the material it saves!
 
I also like Bob-O's description of the DP&W "H" profile for a couple
reasons... Mostly that it won't dam the troughs and your penetration is at
the peak.
 
Best of success!
 
Matt Lafferty


  _____  

From: Allan Sindelar
Sent: Thursday, March 26, 2009 11:02 PM
To: re-wrenches at lists.re-wrenches.org
Subject: [RE-wrenches] Hardware request



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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