This solar mounting system combines key components for secure and versatile installation of photovoltaic panels on various roof types, particularly those requiring strong, adjustable attachment points. The system is centered around robust aluminum mounting rails, which provide the primary structural support. It integrates hanger bolts for secure fastening into wooden roof structures (like rafters) and L-foot clamp brackets for attaching the rails to these hanger bolts or directly to other roof interfaces. This combination ensures a stable, corrosion-resistant, and adaptable solution for residential and commercial solar installations.

Definition

A solar mounting system utilizing aluminum rails, hanger bolts, and L-foot clamp brackets is a specialized assembly designed to securely install solar photovoltaic (PV) panels on rooftops. Each component plays a crucial role:

• Aluminum Mounting Rails: These are extruded aluminum profiles (e.g., H-shaped, C-shaped, or square/rectangular) that form the backbone of the mounting structure. They span across the roof, providing a stable platform to which solar panels are attached using clamps. Aluminum’s inherent corrosion resistance and high strength-to-weight ratio make it ideal for outdoor solar applications.
• Hanger Bolts: Also known as double-threaded screws, these fasteners have a machine screw thread on one end and a lag screw thread on the other. In solar applications, the lag screw end is driven into wooden roof rafters or purlins, providing a strong anchor point. The machine screw end protrudes above the roof surface, allowing for attachment of other components. They are typically made from stainless steel for corrosion resistance.
• L-Foot Clamp Brackets: These are L-shaped aluminum brackets used to connect the mounting rails to the hanger bolts or directly to other roof base supports. The L-foot has a slot or hole to connect to the hanger bolt’s machine thread (often with a nut) and usually a top plate with slots or holes for bolting the aluminum mounting rails. Their adjustable nature allows for precise leveling and positioning of the rails.
• Mid and End Clamps: (Implicitly part of a complete system) These small aluminum clamps secure the solar panels themselves to the mounting rails. Mid clamps sit between panels, while end clamps are at the array’s perimeter.

This integrated system is widely used for pitched roofs, offering flexibility, strength, and durability.

Key Features

• Modular Aluminum Rail System: Provides a lightweight, strong, and corrosion-resistant framework for panel attachment, with designs often allowing for easy extension and customization.
• Secure Hanger Bolt Anchorage: Hanger bolts thread deeply into wooden roof substructures (rafters/trusses), providing extremely strong pull-out resistance and load-bearing capacity. Made of stainless steel for durability and rust prevention.
• Adjustable L-Foot Brackets: L-feet connect the rails to the hanger bolts, often featuring vertical adjustment to accommodate roof undulations and achieve perfectly level rail installation.
• Versatile Roof Compatibility: This system is particularly well-suited for asphalt shingle roofs and metal roofs, where hanger bolts can penetrate the roofing material to reach sturdy wood framing. It can also be adapted for tile roofs with appropriate flashing.
• Corrosion-Resistant Materials: All primary components (aluminum rails, stainless steel hanger bolts, aluminum L-feet) are selected for their excellent resistance to weathering and corrosion.
• Ease of Installation: Designed for efficient assembly, reducing labor time due to standardized components and adjustable features.
• Integrated Flashing Capabilities: Often used with rubber washers and adhesive-backed flashing to ensure watertight seals where hanger bolts penetrate the roof.

Applications

• Residential Pitched Roof Solar: Ideal for most residential homes with sloped roofs, especially those with asphalt shingles or metal roofing over wood framing.
• Commercial Rooftop Installations: Suitable for smaller commercial buildings with pitched roofs, providing a dependable mounting solution.
• Carports and Ground Mounts: While primarily for roofs, similar components can be adapted for carport structures or small ground-mount systems.
• Retrofit and New Construction: Applicable for integrating solar into both existing buildings and new construction projects with suitable roof structures.

Advantages

• High Structural Integrity: Hanger bolts provide robust anchorage directly into the roof’s structural members, ensuring excellent wind and snow load resistance.
• Adjustability and Flexibility: L-feet allow for fine-tuning of rail height and alignment, simplifying installation and compensating for roof irregularities.
• Long-Term Durability: The combination of aluminum and stainless steel ensures a mounting system that will last for decades with minimal degradation.
• Cost-Effective: Offers a balance of high performance, durability, and relatively straightforward installation, contributing to the overall economic viability of the solar system.
• Reduced Roof Penetrations (compared to some systems): While penetrative, hanger bolts are typically fewer in number than direct attachment to every rafter, and are designed for effective waterproofing.
• Universal Panel Compatibility: The rail and clamp system can accommodate virtually all standard framed solar panels.