In the first part of this two-part article, I explored the various types of roof membranes and roofing systems commonly found in commercial and industrial (C&I) buildings. Identifying the type of roof is a critical first step when planning for roof-mounted solar installations. This information directly influences design and engineering decisions, such as structural integrity, waterproofing needs, and balance of system (BOS) requirements. While these considerations come after the initial roof identification, they are just as essential—ensuring that solar arrays stay secure, don’t compromise the building’s structure, and prevent water leaks.
Structural Considerations
The structural evaluation is often the most crucial aspect of any C&I roof-mounted solar project. A thorough assessment ensures that the building can safely support the added weight and forces from the solar array. Here are some key areas to consider during the structural review:
Reserve Capacity Evaluation. Most existing C&I buildings are designed to meet minimum code requirements. Adding a solar array introduces new loads—both vertical and lateral—that could exceed the original capacity. A structural engineer should evaluate the building’s current condition, including reviewing as-built drawings or conducting an on-site inspection, to determine if the structure can handle the additional weight. Any modifications made over time, like new rooftop equipment or extra layers of roofing, must also be considered.
Mechanical Attachments. While ballasted systems are common for low-slope roofs, some projects or local codes require mechanical fastening. Mechanical attachments help reduce dead load by securing the solar array directly to the roof structure. The engineering plan will specify the number, location, and type of hardware required, such as U-bolts, OMG Power Grips, or S-5! clamps. For metal roofs with standing seams, it's especially important to inspect and understand how the roof panels are connected to the structure.
Roof Loading Plan. During installation, the weight of solar modules, inverters, and mounting systems is concentrated. A well-planned roof loading plan ensures that materials are staged over strong structural elements like beams or columns. It also provides guidance on how much weight each area can temporarily hold, helping to avoid damage or structural stress during the build phase.
Waterproofing Considerations
Beyond structural concerns, waterproofing is another critical factor in roof-mounted solar projects. Every penetration through the roof creates a potential entry point for water. Proper flashing, drainage, and protection are essential to maintain the integrity of the roof membrane and ensure long-term performance.
Courtesy OMG Roofing Products
Roof Flashing and Drainage. Effective flashing is essential to prevent water infiltration at penetrations, joints, and transitions. Coordination between the solar contractor and a qualified roofer is key to ensuring proper material compatibility and installation. Additionally, existing roof warranties may be affected if the work isn’t done correctly. Low-slope roofs are not truly flat; they rely on features like slopes, crickets, and drains to manage water runoff. Solar installations must not interfere with these systems, as blocked drainage can lead to water ponding, increased load, and premature roof failure.
Preventing Roof Damage. Single-ply membranes are vulnerable to damage during and after installation. Tools dropped, foot traffic, and environmental stress can all harm the roof surface. Installers can protect the membrane by using temporary walkways, slip sheets, or separator pads. These measures act as a barrier between the mounting system and the roof, reducing the risk of long-term damage. In some cases, permanent walkways may be needed to accommodate ongoing maintenance and access.
If you're looking to minimize risks and maximize performance in your C&I roof-mounted PV project, contact Pure Power Engineering. Our value-engineered design and construction drawing services are tailored to help you achieve safe, efficient, and durable solar installations.
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