Your Innovative Solution Partner - PiA Solar

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your innovative solution partner8.0 DETAIL A8.0 Product CatalogueSolar Mounting HardwareDETAIL BTrusted with the installation of more than 1 million PV modules.

IntroductionPiA Solar has been trusted with the installation of over 460MW of ground mounted systems as of October 2016 and is currentlygrowing to be one of the largest suppliers of rooftop structures and hardware, with more than 26 MW secured for 2016. PiA Solarssuccess is based on the dedicated supply of quality products to the solar industry. PiA Solar’s installation success is based on ZEROcompromise to safety, teamwork and our ISO 9001:2008 quality principals. This product brochure introduces the full range ofmounting hardware offered by PiA Solar, with in-house product development and a design team providing standard and non-standardsolutions to suit a clients project budget. PiA Solar’s product is designed and certified in accordance to SANS 10160-1-3.8.0 DETAIL A8.0 ISO 9001:2008 CertifiedLevel 1 BBBEE Certificatevalid until June 2017DETAIL B

Index1. Rooftop MountingsAPage No.12345671.1 KlipLock Clamps1.2 CraftLock Clamps1.3 Brown Built Clamps1.4 IBR Clamps1.5 Corrugated Clamps1.6 Tiled Roof Mounting Hardware1.7 Ballast Roof Mounting Hardware2. Standard Products8910111213142.1 Anchoring Solutions2.2 Purlins and Unistrut2.3 Module Clamps2.4 Thin Film Clamps2.5 Terraced Mounting Hardware2.6 Fasteners2.7 Safety Systems3. “Ground Mounted” Solar Structures3.115Fixed Tilted Structures3.1.1 Polycrystalline3.1.2 Thin Film3.1.3 Glass-Glass 1500V3.2B161617Tracker Structures3.2.1 Tracker Starter Kit18 - 204. Carport Solar Structures4.1 Single Carport Structure4.2 Double Carport Structure21215. Corrosion Guidelines5.1 Solar rooftop Installation Guidelines on Corrosion22 - 23

8.0 1. RooftopDETAIL A8.0 DETAIL B

1.1 KlipLock ClampsThe PiA Solar KlipLock Clamp, provides a cost effective solution for mounting solar structures and general hardware ontoKlipLock Roof Sheeting. For solar installations, the KlipLockKlamp is designed to suit both purlin and purlinless installations.The PiA ClipLock Clamp, clamps to the roof sheet using an M10caphead which locks it to the other side of the roof sheet. TheKlipLock Clamp can be ordered for three different mounting op-tions. 1. M6 is suitable for purlinless installations. 2. M8 is suitablefor trunking and equipment installations. 3. Dual M8 is suitablefor the PiA Top Hat Purlin installations. The clamp is designed tohave a minimum contact surface to the roof to protect againstcrevice corrosion. Also remember that galvanised clamps arethe only long term solutions for your roof and recommended bySAMCRA (South African Metal Cladding and Roof Association).Mounting SpecificationsVertical Pull off certified to 120 kg per clampClipLock Clamp torque for M10 3 NmCoating: HDG 55µmMaterial: ISQ230 3mm thick materialRoof loading to be determined by project certification.OptionsDescriptionPiA part No. TorqueHDG1M6Purlinless for Module clampPIA120006A5.5 Nm2M8M8 Unistrut/HardwarePIA120007A13 NmTop Hat Purlin/HardwarePIA120008A13 Nm3Dual M8Purlin Mounting Lengths (max distance between clamps)PiA Purlin3500 mmTop Hat PurlinUnistrutP1000/P20001200 mmP2000 UnistrutTop Hat PurlinP2000 UnistrutPurlinlessTypical Installation OptionsPurlinTerracedPurlinlessTrunking and hardwareIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.The Clip is only tested for vertical uplift and suitable to use on roof installations of up to 25 Tilt.Refer to the sheet on corrosion for installation guidelines.1

1.2 CraftLock ClampsThe PiA Solar CraftLock Clamp provides a cost effective solution for mounting solar structures and general hardware ontoCraftLock Roof Sheeting. For solar installations, the CraftLockClamp is designed to suit both purlin and purlinless installations.The PiA CraftLock clamp, clamps to the roof sheet using an M10caphead which locks it to the other side of the roof sheet. TheCraftLock Clamp can be ordered for three different mountingconfigurations. 1. M6 for purlinless installations. 2. M8 for trunking and equipment installations. 3. Dual M8 for the PiA Top HatPurin installations. The clamp is designed to specifically protectthe roof against crevice corrosion. Also remember that galvanised clamps are the only long term solutions for you roof andrecommended by SAMCRA (South African Metal Cladding andRoof Association).Mounting SpecificationsPull off certified to 150 kg per clampCraftLock Clamp torque for M10 3 NmCoating: HDG 55µmMaterial: ISQ230 3mm thick materialRoof loading to be determined by project certification.OptionsDescriptionPiA part No. TorqueHDG1M6Purlinless for Module clampPIA125025A5.5 Nm2M8M8 Unistrut/HardwarePIA125016A13 NmTop Hat Purlin/HardwarePIA125029A13 Nm3Dual M8Purlin Mounting Lengths (max distance between clamps)PiA Purlin3500 mmTop Hat PurlinUnistrutP1000/P20001200 mmP2000 UnistrutP2000 UnistrutTop Hat PurlinPurlinlessTypical Installation OptionsPurlinTerracedPurlinlessTrunking and hardwareIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.The Clip is only tested for vertical uplift and suitable to use on roof installations of up to 25 Tilt.Refer to the sheet on corrosion for installation guidelines.2

1.3 Brown Built ClampsThe PiA Solar Brown Built Clamp, provides a cost effective solution for mounting solar structures and general hardware ontoBrown Built Roof Sheeting. For solar installations, the BrownBuilt Clamp is designed to suit both purlin and purlinless installation. The PiA Brown Built Clamp, clamps to the roof sheet usingan M10 caphead which locks it to the other side of the roof sheet.The Brown Built Clamp can be ordered for three differentmounting options. 1. M6 is suitable for purlinless installations.2. M8 is suitable for trunking and equipment installations. 3. DualM8 is suitable for the PiA Top Hat Purlin installations. The clampis designed to have a minimum contact surface to the roof toprotect against crevice corrosion. Also remember that galvanised clamps are the only long term solutions for you roof andrecommended by SAMCRA (South African Metal Cladding andRoof Association).Mounting SpecificationsVertical Pull off certified to 120 kg per clampBrown Built Clamp bolt torque for M10 3 NmCoating: HDG 55µmMaterial: ISQ230 3mm thick materialRoof loading to be determined by project certification.OptionsDescriptionPiA part No. TorqueHDG1M6Purlinless for Module clampPIA127002C5.5 Nm2M8M8 Unistrut/HardwarePIA127003B13 Nm3Dual M8Top Hat Purlin/HardwarePIA127014B13 NmPurlin Mounting Lengths (max distance between clamps)PiA Purlin3500 mmTop Hat PurlinUnistrutP1000/P20001200 mmP2000 UnistrutP2000 UnistrutTop Hat PurlinPurlinlessTypical Installation OptionsPurlinTerracedPurlinlessTrunking and hardwareIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.The Clip is only tested for vertical uplift and suitable to use on roof installations of up to 25 Tilt.Refer to the sheet on corrosion for installation guidelines.3

1.4 IBR clampsThe PiA Solar IBR Clamps provides a cost effective solution formounting solar structures and general hardware onto IBR RoofSheeting. A IBR roof requires penetration of the roof to securestructures, as does corrugated sheeting. For solar installations,the IBR Mounting Hardware is designed to suit both purlin andpurlinless installations. The PiA 4xM6 self tapping screw, screwsthe fitting to the sheet through the insulating HDPE rubber provided. The clamp comes with mounting options 1. M6 is suitablefor purlinless installations. 2. M8 is suitable for trunking andequipment installations. 3. Dual M8 is suitable for the PiA Top HatPurlin installations. The clamp is designed to have a minimumcontact surface to the roof to protect against crevice corrosion.Also remember that galvanised clamps are the only long termsolutions for you roof and recommended by SAMCRA (SouthAfrican Metal Cladding and Roof association).Mounting SpecificationsPull off certified to 120 kg per clamp pointIBR Self Drilling ScrewCoating: HDG 55µmMaterial: ISQ230 3mm thick materialNote: Self tapping screws to be tightened until rubber is compressedRoof loading to be determined by project certification.OptionsDescriptionPiA part No. TorqueHDG1M6Purlinless for Module clampPIA110011A5.5 Nm2M8M8 Unistrut/HardwarePIA110010A13 Nm3Dual M8Top Hat Purlin/HardwarePIA110022A13 NmPurlin Mounting Lengths (max distance between clamps)Pia Purlin3500 mmTop Hat PurlinUnistrutP1000/P20001200 mmP2000 UnistrutP2000 UnistrutTop Hat PurlinPurlinlessTypical Installation OptionsPurlinTerracedPurlinlessTrunking and hardwareIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.The Clip is only tested for vertical uplift and suitable to use on roof installations of up to 25 Tilt.Refer to the sheet on corrosion for installation guidelines.4

1.5 Corrugated clampsA corrugated iron roof requires penetration of the roof tosecure structures, as does IBR sheeting. For solar installationshe corrugated clamp is designed to suit both purlin/purlinless installations. The PiA Solar corrugated clamp offers two mountingoptions, 1) which is mounted directly onto the roof purlin or 2)anywhere on the roof sheet using 4 x M6 self tapping caphead,therefore producing two solutions in one innovative clamp. Theclamp is supplied with a sealing rubber. The clamp comes withmounting options 1. M6 is suitable for purlinless installations.2. M8 is suitable for trunking and equipment installations. 3.Dual M8 is suitable for the PiA Top Hat Purin installations. Theclamp is designed to have a minimum contact surface to theroof to protect against crevice corrosion. Also remember thatgalvanised clamps are the only long term solutions for you roofand recommended by SAMCRA (South African Metal Claddingand Roof Association).Mounting SpecificationsPull off certified to 120 kg per clamp pointCorrugated Roof Clamp bolt hand finishedCoating: HDG 55µmMaterial: ISQ230 3mm thick materialNote: Self tapping screws to be tightened until rubber is compressedRoof loading to be determined by project certification.OptionsDescriptionPiA part No. TorqueHDG1M6Purlinless for Module clampPIA126001C5.5 Nm2M8M8 Unistrut/HardwarePIA126003C13 Nm3Dual M8Top Hat Purlin/HardwarePIA126014A13 NmPurlin Mounting Lengths (max distance between clamps)Pia Purlin3500 mmTop Hat PurlinUnistrutP1000/P20001200 mmP2000 UnistrutP2000 UnistrutTop Hat PurlinPurlinlessTypical Installation OptionsPurlinTerracedPurlinlessTrunkingIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.The Clip is only tested for vertical uplift and suitable to use on roof installations of up to 25 Tilt.Refer to the sheet on corrosion for installation guidelines.5

1.6 Tiled Roof Mounting HardwareThe tiled roof bracket is designed for simple and fast installation, yet provides a client with a secure and safe mounting system. The brackets are made of HDG steel to ISO 1461 minimal55µmm. The brackets are designed to mount with both, the PiASolar top hat purlins and unistrut. The top hat provides up to a3m span between mounting points at an angle of up to 30 oftilt, while the unistrut P1000/2000, requires a mounting bracketOptionsevery 1,2m. A client needs to ensure certification for the roof isobtained specifying the forces to determine the correct mounting spaces. The clamp is designed to have a minimum contactsurface to the roof to protect against crevice corrosion. Also remember that galvanised clamps are the only long term solutionsfor you roof and recommended by SAMCRA (South African MetalCladding and Roof association).PiA Part No.Description1Short Tiled Roof Bracket HDG P2000PiA100002A2Short Tiled Roof Bracket HDG PiA Top HatPiA100003APiA Top Hat PurlinPiA UnistrutPurlin Mounting Lengths (distance between clamps)PiA Purlin3000 mmTop Hat PurlinUnistrutP1000/P20001200 mmP2000 UnistrutTop Hat PurlinP2000 UnistrutTypical Installation OptionIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.Refer to the sheet on corrosion for installation guidelines.6

1.7 Ballast Roof Mounting HardwareThe ballast roof mounting system offered by PiA Solar is of amodular design. The tilt brackets allow, the module angle to varyfrom 0 to 30 . The system is supplied as a kit, which can be tailored to suit a client’s project and will be ready to install on site.Each of the concrete ballasts have a weight of 27kg, makingit easy to handle. The system is designed to work with the PiASolar top hat purlin, which allows for less trusses required in aclient’s project. To protect the roof and the structure, PiA Solarsupplies a correx board which fits under the purlin and concreteblock. Apart from protecting the roof, the correx board lifts thebottom rail off the ground to ensure drainage that prevents, dirtand moisture from building up and eliminating the risk of corrosion. PiA Solar Structure can be supplied with either, HDG (HotDipped Galvanized) or Pre-Galvanised. Also remember that galvanised clamps are the only long term solutions for you roofand recommended by SAMCRA (South African Metal Claddingand Roof association).Splicer PlateConcrete ballastwith correx roofprotectorpivot BracketAngle BracketBallast Mounting and Cross-section30 25 20 15 10 5 Landscape Terraced Mounting BracketDescriptionMaterialPiA Part No.HDGConcrete Ballast 27kg Concrete 25MPa PIA145003APivot U-BracketISQ 230/CQPIA131001DBallast Angle BracketISQ 230/CQPIA131002CBallast Splicer PlateISQ 230/CQPIA135004BBallast Correx PlateCorrex BoardPIA151003AUnistrut P2000S550Z275/HDGas per projectrequirementPiA Top Hat PurlinS350Z275/HDGas per projectrequirementConcreteLength oflong bracketwill beadjustedaccordingto specifiedproject tiltangleCorrex boardTypical Installation OptionsIMPORTANT: The quantity of clamps utilized must meet the requirement of the roof installation certification.Refer to the sheet on corrosion for installation guidelines.7

8.0 2. Standard ProductsDETAIL A8.0 DETAIL B

2.1 Anchoring SolutionsPia Solar manufactures, a wide range of anchors for the solarindustry. PiA Solar now boasting installation experience, of wellover 500 000 PiA Solar Anchoring Solutions which are designed for different ground types and can guarantee anchoringwhether in soft sand or rock. PiA Solars Patented Rock Anchor,installs in under 2 minutes and can be used in soil with a highrock density. The anchors PiA Solar offer are as follows.All of the Anchoring Solutions can be supplied as standardcomponents, for installing in concrete foundations. A wide rangeof mounting hole configuration, can be used with PiA SolarAnchoring Solutions, to suit a client with a full range of tubeclamps, which can be used for a client’s mounting hardware.Designs are tailored in-house for a project, at a clients request.2.1.1. 2013/05566 PiA Solar Rock patent Anchor’s for rockand dense soil typesSupplied with a Concrete Activator and requires percussion drilling(activated with percussion, without rotation using thePiA Solar ramming adapter) which is a single process.Anchor DiameterLengthMaterial GradeMaterial ThicknessPart NumberDepth Pull out resistanceØ63,5mm1,5 - 4.0mSAE10082,5mmPiA185000A1.2m800 kg Ø76,2mm1,5 - 4.0mS355 JR2,5mmPiA185001A1.2m1200 kg Ø76,2mm1,5 - 4.0mS355 JR3,5mmPiA185002A1.2m1200 kg 2.1.2 PiA Solar Earth Anchor’s for soft sandScrewed in using a rotation hydraulic head, (Bobcat, TLB or screwing machine), using a linear beam installer will improve accuracy.Anchor DiameterLengthMaterial GradeMaterial ThicknessPart NumberØ48 & Ø63,5mm /Ø111mm1,0 - 3,0mSAE10082,5mmPiA200005A1.0m700kgØ48 & Ø63,5mm /Ø111mm1,0 - 4.0mSAE10082,5mmPiA200006A1.0m1500kgØ48 & Ø63,5mm /Ø111mm1,0 - 4.0mSAE10082,5mmPiA200002A1.0m2000kgDepth Pull out resistance2.1.3 PiA Solar Ramming Anchor’s for dense soilInstallation with a recognized linear boom ramming machine.Anchor DiameterLengthMaterial Grade76x38 CH1,0 - 3,0mSANS EN50025-S355100xx55 IPE120x64 IPE1,0 - 4.0mPart NumberDepthPull out resistancePiA184001A1,0m to 1,5m700kg1,0 - 4.0m SANS EN50025-S355PiA184002A1,0m to 2m1500kgSANS EN50025-S355PiA184003A1,0m to 2,5m2000kgIMPORTANT: Ensure that proper ground tests are done before making your choice of anchor. PiA Solar canprovide guidance or conduct pull our tests or do the installation for our clients.8

2.2 Purlins and UNISTRUTPiA Solar provides a variety of purlins for use with ground, roofor ballast mountings. PiA Solar Purlins are designed with S350material to ensure, a lightweight, yet strong solution.Purlins can be made to suit a clients project or design, withrequired mounting holes and slots.2.2.1 PIA Top Hat PurlinPiA Solars Top Hat Purlin, has been trusted on large and small projects. The top hat purlin, can be mounted both top andbottom, making it perfect for carrying a long span up to 3,15m or as a tracker spreader beam. PiA Solars Top Hat purlin furtheroffers stability on steep tiled roofs and structures.Top Hat Purlin65 x 35 x 24 x 1,6/2mmMaterialS350CoatingLengthPiA Part No.Z275 / HDG1m to 10mPIA182.Range1,6mm/2mm2.2.2 Unistrut P1000/2000PiA Solar Unistrut P1000/2000, provides two options, a slotted unistrut allows for an easy installation, as the slots in the bottomallow for easy mounting, to suit a clients needs. Unistrut is supplied in P2000 1mm-1,6mm of high strength ISQ 550 material Z275plated. The standard P2000 unistruts, are a cost effective solution, where drilling needs to be done on site. PiA Solar can tailorin-house the unistrut, to suit a clients requirements as well as supply, all the mounting hardware required.Slotted P 1000/2000 PurlinMaterialTreatmentP1000/P2000 41 x 41 x 2,5mISQ 550Z275/HDG1m-6mPIA181008AP1000/P2000 41 x 41 x 1,0mISQ 550Z275/HDG1m-6mPIA181009AP1000/P2000 41 x 41 x 1,6mISQ 550Z275/HDG1m-6mPIA181010A2000 PurlinLengthPIA Part No.Standard P 1000/2000 PurlinMaterialTreatmentP1000/P2000 41 x 41 x 2,5mISQ 550Z275/HDG1m-6mPIA181011AP1000/P2000 41 x 41 x 1,0mISQ 550Z275/HDG1m-6mPIA181012AP1000/P2000 41 x 41 x 1,6mISQ 550Z275/HDG1m-6mPIA181013A2000 Purlin1,0mm/1,2mm/1,6mm9LengthPIA Part No.

2.3 Module ClampsPiA Solar offers a full range of module clamps for Standard, Thin Film, Glass-Glass products and First Solar, series 4 module clamps.Standard PV Mounting Hardware2.3.1 Zeta End ClampSizeMaterial GradeModule ThicknessTreatmentISQ2303mm x 55 mm35mmHDG 55PIA171009AISQ2303mm x 55 mm40mmHDG 55PIA171004AISQ2303mm x 55 mm45mmHDG 55PIA171005AISQ2303mm x 55 mm50mmHDG 55PIA171002APiA Part No.55mmStandardVariesAccordingTo modulethicknessZeta End Clamp2.3.2. Omega Mid ClampMaterial GradeSizeModule ThicknessTreatmentPIA Part No.ISQ2303mm x 55 mm35mm to 50mmHDGPIA170001A55mmEnsures adequatespacing betweenmodulesOmega Mid Clamp6,5mm square hole is used to accept round head square cup bolt.10

2.4 Thin Film Clamps2.4.1 First Solar Thin Film Mounting HardwarePIA Part No.MaterialWidthModule ThicknessZeta (end)WB 230BK100080mm6,8mmPIA160015AOmega (mid)WB 230BK100080mm6,8mmPIA160008AThin FilmTechnical SpecificationsMaterial SpecificationsUL 95 Flame deterrenceWB 230BK1000Meets first Solar resistivity requirementsPP, 30% Glass Fibre reinforcedPurlin M6 bolt torque 5nmHeat & UV stabilizer ME0073UVCoating: HDG 55µm 3mm thick materialNaturalMaterial: 30% fiber re-reinforcedThe clamp complies with First Solar’s resistivity requirementsOMEGA (MID)11ZETA (END)

2.5 Terraced Mounting HardwarePiA Solar offers a wide range of Terraced Mounting Hardwareand concrete Ballast Systems, designed for roof topapplications. A wide range of tilt angle (5 to 30 ) for bothportrait and landscape mounting are available.For steel roof tops, PiA Solar has designed ,a purlinlesslandscape option and for portrait, offer a combination withoutPiA Solar T

PiA Solar’s product is designed and certified in accordance to SANS 10160-1-3. . anywhere on the roof sheet using 4 x M6 self tapping caphead, therefore producing two solutions in one innovative clamp. the clamp is supplied with a sealing rubber. the clamp comes with

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