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@lists.re-wrenches.org Subject: [RE-wrenches] Hardware request Wrenches, We have an unusual roof application. Its 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. Im 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. Well 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 engineers 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 isnt 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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