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<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2>Hi Allan,</FONT></SPAN></DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2></FONT></SPAN> </DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2>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.</FONT></SPAN></DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2></FONT></SPAN> </DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2>If that doesn't pan out, here is a homemade version made
out of Trex (or similar) on a bandsaw. <A
href="http://www.buildingwithawareness.com/blog/2008/12/how-to-mount-photovoltaic-pv-solar-panels-to-a-corrugated-metal-roof/">http://www.buildingwithawareness.com/blog/2008/12/how-to-mount-photovoltaic-pv-solar-panels-to-a-corrugated-metal-roof/</A> .
This lets you make your penetration at the peaks. </FONT></SPAN><SPAN
class=317402600-28032009><FONT face=Arial color=#0000ff size=2>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!</FONT></SPAN></DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2></FONT></SPAN> </DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2>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.</FONT></SPAN></DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2></FONT></SPAN> </DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2>Best of success!</FONT></SPAN></DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2></FONT></SPAN> </DIV>
<DIV dir=ltr align=left><SPAN class=317402600-28032009><FONT face=Arial
color=#0000ff size=2>Matt Lafferty</FONT></SPAN></DIV>
<DIV><FONT face=Arial size=2></FONT><BR></DIV>
<DIV class=OutlookMessageHeader lang=en-us dir=ltr align=left>
<HR tabIndex=-1>
<FONT face=Tahoma size=2><B>From:</B> Allan Sindelar<BR><B>Sent:</B> Thursday,
March 26, 2009 11:02 PM<BR><B>To:</B>
re-wrenches@lists.re-wrenches.org<BR><B>Subject:</B> [RE-wrenches] Hardware
request<BR></FONT><BR></DIV>
<DIV></DIV>
<DIV class=Section1>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">Wrenches,<o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">We have an unusual roof application.
It’s for a roof-mount array on a commuter rail station canopy in <st1:City
w:st="on"><st1:place w:st="on">Santa Fe</st1:place></st1:City>. 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. <o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial"><o:p> </o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">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 1˝” 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.<o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial"><o:p> </o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">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.<o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial"><o:p> </o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">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.<o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial"><o:p> </o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">Thank you for any
ideas,<o:p></o:p></SPAN></FONT></P>
<P class=MsoNormal><FONT face=Arial size=2><SPAN
style="FONT-SIZE: 10pt; FONT-FAMILY: Arial">Allan Sindelar, Positive
Energy<o:p></o:p></SPAN></FONT></P></DIV></BODY></HTML>