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How To Mount Solar Panels With Unistrut?
Mounting solar panels with Unistrut requires a structured approach using the channel system’s adjustable brackets and clamps. Secure Unistrut rails to your roof or mounting surface using appropriate anchors, then attach panel mounting feet to the rails with spring nuts and bolts. Ensure alignment matches panel dimensions, using mid-clamps for stability. Pro Tip: Apply anti-seize compound on stainless steel hardware to prevent galvanic corrosion between dissimilar metals.
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What components are needed for Unistrut solar mounting?
A complete Unistrut solar array requires P1000/P1100 channels, U-bolts, and mid/end clamps. Base components include 10-gauge galvanized strut (1-5/8″ size), stainless steel hardware, and tilt legs for angled installations. Roof attachments vary—use standoffs with flashing for pitched roofs or ballast blocks for flat commercial setups.
Unistrut systems rely on parallel rails spaced according to panel width. For standard 72-cell panels (40″x78″), position rails 48″ apart center-to-center. The channel’s 1.5″ slot width accepts M10 bolts with spring nuts for tool-less adjustments. Why does this matter? Unlike fixed racking, this allows millimeter-level alignment corrections during installation. A real-world example: On metal roofs, use S-5! clamps between seams to anchor Unistrut without penetrations. Pro Tip: Always torque bolts to 25 ft-lbs maximum—over-tightening distorts the channel shape.
How do you secure Unistrut to different roof types?
Attachment methods vary by roof material: composition shingles require lag bolts into rafters, while metal roofs use clamp-on brackets. For tile roofs, install mounting pads beneath tiles to avoid breakage. Flat roofs often employ weighted systems—concrete blocks prevent wind uplift without roof penetrations.
On asphalt shingle roofs, locate rafters using a stud finder and drill pilot holes through the weatherproofing layer. Apply butyl tape around each lag bolt head before driving them into the structural members. What about corrugated metal? Specialized S-5! clamps grip the raised ribs, letting you bolt Unistrut directly to these non-penetrative anchors. For example, a 10kW system on a barn roof might use 60 clamps spaced every 4 feet along the channels. Pro Tip: Always maintain 1″ clearance between roof surface and Unistrut rails for airflow and debris clearance.
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| Roof Type | Attachment Method | Load Capacity |
|---|---|---|
| Metal | S-5! Clamps | 60 lbs/ft |
| Asphalt | Lag Bolts | 75 lbs/ft |
| Tile | Mounting Pads | 45 lbs/ft |
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FAQs
Yes, when properly spaced. Use 12-gauge strut on 24″ centers for areas with 50+ PSF snow loads—supplement with mid-span supports if needed.
How far apart should Unistrut rails be?
Space rails based on panel dimensions: 40-48″ center-to-center for residential panels, verified through structural calculations for local wind/snow codes.
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