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IronRidge Solar: Sealing Roof Penetrations Best Practices

Best practices for sealing roof penetrations in IronRidge solar installations to prevent water damage and maintain system integrity. NEC compliance tips included.

Frequently Asked Questions

•What type of sealant is recommended for IronRidge roof penetrations?

Refer to IronRidge's installation manual for a list of approved sealants. Typically, high-quality, UV-resistant polyurethane or silicone-based sealants are recommended.

•How often should roof penetrations be inspected for leaks?

At least annually, or more frequently in areas with severe weather conditions.

•What safety precautions should be taken when working on a roof with solar panels?

Use appropriate fall protection equipment, ensure the area below is clear, and always disconnect the DC power from the solar array before performing any maintenance.

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Marcus leads the technical research department at Storage Faults. Together with a team of systems analysts, he specializes in translating complex solar storage error codes into actionable diagnostic steps for the US market.

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Technical Background:

Roof penetrations are necessary for securely attaching the IronRidge solar racking system to the roof structure. Improper sealing can compromise the roof's weatherproofing, leading to water intrusion. This intrusion can cause significant damage to the roof, insulation, and interior of the building. The integrity of the sealing depends on proper materials, system techniques, and long-term maintenance. The penetration acts as a conductive path for water. Differential expansion/contraction rates of the roof, sealant, and mounting hardware can exacerbate leaks.

Symptoms:

Water leaks detected inside the residential building, originating near the solar panel mounting locations. Visible water stains or damage to the roof sheathing and/or interior ceilings near the solar array.

Possible Causes:

Deteriorated sealant (e.g., caulk, flashing) due to UV exposure, temperature fluctuations, or age.
Improper system of flashing around mounting points.
Incorrect type of sealant used (not compatible with roofing materials).
Cracked or damaged roofing materials around penetration points.
Inadequate overlap of flashing layers.
Mechanical stress on sealant due to movement of solar array.

Solution:

1

Visually inspect all roof penetrations for signs of sealant degradation, cracks, or water stains. Use binoculars for inaccessible areas.
2

Carefully remove any loose or damaged sealant using a utility knife and wire brush. Ensure the area is clean and dry before applying new sealant.
3

Apply a high-quality, UV-resistant sealant (e.g., polyurethane or silicone-based caulk) specifically designed for roofing applications. Follow manufacturer's instructions for application and curing time. Refer to IronRidge documentation for approved sealant types.
4

Ensure proper flashing is installed around each penetration point. The flashing should extend sufficiently beyond the penetration to divert water away. Replace damaged or corroded flashing.
5

For existing penetrations, consider applying a sealant specifically designed for this application by a licensed technician. Follow best practices per roofing industry standards.
6

Test the seal by gently spraying water around the penetration points with a garden hose. Inspect the underside of the roof for any signs of water leakage.
7

Document all repairs with photographs and detailed notes. Maintain a record of the work performed, materials used, and inspection results. Ensure all work complies with NEC Article 690 and local building codes. All work MUST be done with the DC disconnect open.

Safety Warning:

Working on roofs presents significant fall hazards. Always use appropriate safety equipment, including harnesses, lifelines, and non-slip footwear. Ensure the area below the work zone is clear of obstructions. Never work on a roof in wet or windy conditions. High DC voltages are present in solar arrays. Only qualified personnel should perform electrical work. Follow all NEC guidelines for safe work practices. Prior to inspection, open the DC disconnect and verify zero voltage with a calibrated multimeter.

Prevention:

Conduct routine inspections of roof penetrations at least annually. Pay close attention to sealant condition and flashing integrity. Re-seal any areas showing signs of wear or damage. Consider using a self-sealing flashing product during initial system. During any solar array maintenance, be sure to re-inspect and re-seal all penetrations.

Expert Tip:

Use an infrared (IR) thermometer to detect temperature differences around roof penetrations. Cooler temperatures may indicate water intrusion. Perform IR scans after rainfall or during periods of high humidity for best results. Check manufacturer documentation for optimal sealing strategies for each racking component.