When metal roofing manufacturer McElroy Metal required a complex solar conversion project at its facility in Clinton, Ill., it went with an attachment solution provided by an award-winning metal roofing company.

The large-scale, multi-faceted project at the McElroy Metal plant required a two-fold approach, as the facility consists of two different metal roof types: a face-attached trapezoidal profile on one section of the facility and a standing seam profile on another. The mission was to convert the roof to solar.  

McElroy Metal turned to S-5!, a metal roofing attachment solutions company, to participate in the project. S-5! recently received the 2019 Gold Level Industry Advocate Award from the Metal Building Manufacturers Association and previously worked on other McElroy solar projects. 

“We would never consider any attachment to our roofs other than S-5!'s,” said McElroy Metal Vice President of Marketing Ken Gieseke. “The S-5! brand is iconic in the metal roofing industry. Their commitment to tested, engineered products and a decades-long history of prudent metal roof attachment solutions is unsurpassed. We simply know from experience their products perform for the life of our roof.” 

S-5!’s engineering team collaborated with McElroy Metal to determine which clamps and brackets were most appropriate based on the two different roof types, their respective load capacities, resulting load distribution and best fit of mounting components. They analyzed roof-specific data and CAD drawings to determine precise attachment points across the massive solar array and to determine the bill of materials, including clamps, brackets and PVKITs.

There's a Clamp for That

S-5-T Mini clamps were selected to attach the solar panels to the facility’s new 238T symmetrical standing seam roof system. Their two-piece design allows for easy installation anywhere along the length of the panel seam and are specifically designed to fit profiles with a “T” shaped seam configuration like the 238T.

Beyond the “fit,” the clamp was specifically load tested on the 238T in the gauge used for the project, enabling comprehensive system engineering specific to this project. This process is routine for S-5!, and its 500-plus load test results are published and accessible on their website.

The solar installation on the facility’s existing Multi-Rib Panel roof system required S-5!’s RibBracket II, which are specifically designed to attach to this type of roof profile. S-5! said the RibBrackets provided the best fit and more than enough tested-holding capacity for the dimensions of the rib.

The entire solar array was mounted using S-5!’s PVKIT 2.0 Solar Solutions, comprised of MidGrabs and EdgeGrabs, which enabled solar installers to mount the solar panels directly onto the clamps and brackets. The PVKIT’s pre-assembled components reduced installation time and cost for PV mounting, eliminating the need for an elaborate rail system and a better load distribution into the roof and substructure.

The Results

This is McElroy’s third manufacturing facility to have a solar upgrade installed in conjunction with a roof recover. It features a 390.6 kW solar panel system with five inverters designed for an annual output of 829,289 kWh.

“As a leader in the metal construction industry, we have had the privilege of working alongside McElroy in many venues, industry trade groups and supply relationships, now spanning almost 40 years,” said S-5! Founder and CEO, Rob Haddock. “We are proud industry partners and look forward to continuing working together in expanding the use of solar.”