T.I.P.V. TILE INTEGRATED PHOTOVOLTAICS HYBRID GREEN ROOF SYSTEM

Control number: 0493-1604

Manufacturer Importation

Exportation

Clay Products 9455 SW. 78 ST * MIAMI, FLORIDA 33173 * PH (305)595-4577

SUSTAINABLE ENERGY EFFICIENT HURRICANE RESISTANT

For Profit Small Business: Artezanos Inc. 305-595-4577 / fax 305-274-1992 9455 S.W. 78th St. Miami, Florida 33173 HYBRID TILE INTEGRATED PHOTOVOLTAIC (TIPV) Estimated total DOE funding request: $1,500,000.00 Business/Technical Point of Contact: (President) Daniel Arguelles 305-710-6659 / arguelles67@aol.com

Application due date: June 9, 2011

Ref: Application to #DE-FOA-0000493 Extreme Balance of System Hardware Cost Reductions (BOS-X) Topic 1: Transformational Building Integrated Photovoltaic (BIPV) Modules

TABLE OF CONTENTS

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ABSTRACT-------------------------------------------------------------------------------------------------------------2 BRIEF HISTORY OF BARREL ROOF TILE------------------------------------------------------------------3 Traditional Barrel Tile Recycling-----------------------------------------------------------------------------------4 Contemporary Barrel Tile use in Florida-------------------------------------------------------------------------5 HYBRID BARREL ROOF TILE SYSTEM----------------------------------------------------------------------6 HYBRID TILE INTEGRATED PHOTOVOLTAICS (TIPV) -----------------------------------------------9 Atlantis Energy Systems c-Si BIPV Modules---------------------------------------------------------------------9 Unisolar / United Solar Ovonics------------------------------------------------------------------------------------10 SoloPower---------------------------------------------------------------------------------------------------------------10 Furthering the Goal of U.S. Solar Exports Abroad------------------------------------------------------------11 RETRO-FIT HYBRID TIPV OVER EXISTING ASPHALT SHINGLES-------------------------------11 THERMAL RESISTANT BARREL ROOF TILE------------------------------------------------------------12 HYBRID ROOF TILE SYSTEM AND LOCAL GOVERNMENT APPROVALS---------------------12 STATEMENT OF PROJECT OBJECTIVES------------------------------------------------------------------12 ARTEZANOS PROPOSED TASKS------------------------------------------------------------------------------13 Recent Roof Tile Activity of South Florida Clay Roof Tile Market----------------------------------------16 Artezanos Justification of the use of Colombian Barrel Tile-------------------------------------------------17 HOW TO OVERCOME RESIDENTIAL SOLAR ROOF TOP MARKET BARRIERS-------------18 Current State of the South Florida Residential Solar---------------------------------------------------------19 MERIT REVIEW CRITERIA-------------------------------------------------------------------------------------20 Cost Impact Table 3 - Residential Rooftop----------------------------------------------------------------------23 Cost Table Discussion------------------------------------------------------------------------------------------------23 References--------------------------------------------------------------------------------------------------------------25

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ABSTRACT: Artezanos Inc. is a manufacturer, supplier and roofing installer of a patented (U.S. Patent 7’513’084, 7’870’700 and other U.S. & Foreign Patents Pending); Miami Dade County approved "Hybrid Green Roof System" known as the Hybrid Universal Roof Tile System (NOA 09-0422.05).

The Hybrid Universal Roof Tile System employs the use of a "Universal" metal pan that makes compatible the use of any manufactured barrel roof tile of any dimension and also functions in the integration of various solar P.V. technologies within a roof tile form factor known as the Hybrid Tile Integrated Photovoltaic (T.I.P.V.). Artezanos is currently working with notable U.S. Solar PV companies.

Typically, traditional barrel tile roof installations and similar roof tile profiles are already popular in the Sun Belt areas of the United States. The Florida Solar Energy Center has determined through extensive testing that barrel tile roof systems have two features that contribute to the excellent thermal performance. #1. The tile has a large thermal mass, so the temperature stays quite low and #2. There is airspace under the tile from the tiles barrel shape. Hence, barrel tile roofs are energy efficient.

UNIVERSAL PAN TILE

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Artezanos Inc has a clay formulation to produce enhanced thermally resistant clay barrel roof tiles with a low energy embodiment technique in an effort to build upon FSEC's energy efficient research.

The Hybrid T.I.P.V. design offers a generic solar integration standard that serves to lower BOS costs for the residential sloped solar integrated roof market independent of solar racks and penetrations. This standard can be used by PV manufacturers and emerging solar technologies to facilitate lower solar module costs due to economies of scale.

The Hybrid T.I.P.V. is lightweight and can serve as an affordable energy efficient retro-fit over a less sustainable existing asphalt shingle roofing. The Hybrid T.I.P.V. favors an energy efficient sustainable design that incorporates compatibility of any traditional barrel roof tile with that of any c-Si rigid panel or flexible thin film technology. This product's versatility enhances the solar component flexibility in favor of lower BOS costs.

Artezanos Inc's Hybrid T.I.P.V. design can facilitate early market adoption of BIPV/TIPV and foster penetration into the residential sectors by creating a "common ground" between American manufacturers of roof tile systems and solar PV systems via cross-cutting game-changing technology.

Resources would be used to fund production prototype manufacturing equipment, high performance BOS components, and testing in order to secure product approvals for existing UL certified American manufactured solar PV technologies to enable an actual grid tied Hybrid T.I.P.V. residential installation as early as 6 months. This proposal can deliver affordable BIPV/TIPV sloped roof integrated photovoltaic technology and seeks to make good on President Obama's vision of renewable roof top energy on every home.

BRIEF HISTORY OF BARREL ROOF TILE True two piece barrel roof tile has been used for thousands of years. Where clay was used, convex roof tiles in combination with a convex tile (pan) or a flat tile (pan) were fashioned by hand, sometimes over the thigh of the ancient artisan.

Even today, some Spanish tiles have this characteristic convex shape, wide at one end and narrow at the other (Baker 1980). Handmade barrel tiles date as far back as 10,000 B.C. to Neolithic Chinese culture.

Different versions of barrel tile exist today and are still in use around the globe, sometimes as the only water shedding mechanism without underlayments.

View of Spanish barrel tile over wood purlins.

Ceiling view of Spanish barrel tile.

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Terracotta tiles have also been found in Greek and Roman ruins. As craftsmen progressed in knowledge, guided by practical rules of experience, material and design improvements were made in barrel tile roof systems. Interestingly, the original molding of the tile led to the serendipitous design that enhances both energy efficiency and the durability of barrel tile roofs. The airspace formed by the single lap tile combined with the introduction of plywood decking (Rose 1995) provided for a path for natural ventilation above the sheathing.

Traditional Barrel Tile Recycling The recycling of true two piece barrel roof tile is common place around the world. Often different barrel tiles of different dimensions and textures from more than one manufacturer find their way on the same roof structure as most have been known to outlast the structures they are originally laid upon. In 1995, the Miami Dade County Commission unanimously adopted a resolution creating an ordinance for the re-use and application of ancient handmade barrel roof tiles brought to the U.S. from Cuba. For the specific purpose of making new homes look old, they were originally shipped to Cuba from Spain in the 18th Century and then during the 1920’s Construction Boom Era they again made their way to the most notable Florida developments of the time.

Miami Herald January 23, 1994

Miami Daily News April 26, 1925

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Chapter 1 Section 104.11 of the South Florida Building Code provided for the salvage, re-use and reapplication of ancient handmade barrel roof tile on any structure that originally bore it when constructed regardless of its historical designation, citing that the roof tiles had passed the “Test of Time”. This was also amended into the Florida building Code in Chapter 11 Section 1107.

The ancient barrel tile imported to Florida during the 1920’s has been documented to be 200-500 years old when they reached the U.S. Many of these original roofs still stand to this day having sustained multiple hurricanes over the course of their useful life.

Contemporary Barrel Tile use in Florida

During the last “Building Boom” the use of Barrel Tile was the choice of many high-end homes.

Some of the advantages of barrel roof tile include: a. Energy Efficiency / Longevity It has been documented, both the airspace created under the convex barrel tiles and their thermal mass contribute to their excellent thermal performance and longevity over 100 years. b. Aesthetics True barrel tile roofs deliver a much more authentic and fortified look than other similar looking roof tiles that only copy the “barrel tile” look but not the “barrel tile” performance. Barrel tile installations are versatile and can be designed with details to accentuate a variety of architecture from a wide range of cultures. c. High Wind Uplift Performance From the Miami Dade County Approvals, the average wind attachment is much greater for barrel tile than similar looking conventional roof tiles (“S” Tile) The disadvantages of Barrel Tile Roofs are: a. Cost Because this system uses more tile per 100 sq.ft. this increases labor and material expense b. Weight Barrel tiles systems traditionally weigh more than 1200 lbs per 100 sq.ft. and may require additional structural support. c. Difficult to Mount Solar Panels with Racks and Penetrations High profiled roof tile systems including barrel tile are popular in the Sun drenched parts of the U.S. and are notoriously difficult to adapt for solar technology. Miami Dade County requires

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solar contractors to have the homeowner sign an affidavit to acknowledge the damage roof penetrations might inflict on ones existing roof and or revocation of leak warranty possibly held by previous contractor.

When properly installed a barrel tile roof can last over 100 years. They are energy efficient and have exceptional wind uplift characteristics when installed with PolyFoam adhesives. True barrel tiles are often confused with other high profile conventional roof tiles that only resemble traditional barrel tile, for example: (“S” Tile). “S” tiles lack the performance of true barrel tile for wind uplift and rely heavily on the underlayments to keep a structure waterproof. Whereas, barrel have been installed over open decks on wood purlins for centuries and can keep a structure waterproof without the need of any underlayment. In other words, the “S” tile profile is an inexpensive facsimile of a barrel tile that does not match the same performance.

Clay “S” Tile

Concrete “S” Tile

Low Profile Concrete Tile

Clay Barrel Tile

Artezanos Clay Barrel Tile

Hurricane force wind testing at Florida International Universities “Wall of Wind” has determined “S” tile clay and concrete roofs fail catastrophically when tested to 120 mph hurricane force winds.

True barrel tile roofs are a sustainable and green alternative to most conventional tile roofs. The Florida Solar Energy Center measured summer performance of tile roof systems for hot, humid climates in 1994.

The testing results indicated that barrel tile roofing systems have two features that contribute to their excellent thermal performance. #1. The tile’s large thermal mass, so the temperature stays quite low and #2. There is airspace under the tile from the tiles shape. Hence, barrel tile roofs are energy efficient.

HYBRID BARREL ROOF TILE SYSTEM

Artezanos Inc. proposes the use of an affordable Hybrid Barrel Tile Roof System to increase a structure’s energy efficiency, wind performance and facilitate solar integration.

The afore mentioned barrel tiles all share one aspect of their design, in that the common denominator to all barrel roof tiles make use of an inverse pan tile made of the same material. The hybrid design, simply

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replaces these same pan tiles with a step-formed metal pan that substitutes the use of heavier more expensive tiles. A modular metal pan tile 7 ft long replaces 5 individual natural barrel tile pans and reduces tile count and weight by roughly 50%. This metal pan is “Universal” to all barrel tile designs and has many advantages: 1. Less Labor Intensive The Hybrid system eliminates minimum 50% barrel tile and puts it on par with conventional “S” tiles at minimum 83 pieces per 100 sq.ft. Roof loading and transportation costs are also cut in half.

2. Light Weight The system weight per 100 sq.ft. is only 425 lbs compared to 800 lbs. per 100 sq.ft. for “S” clay tile and 1200 lbs. per 100 sq.ft. for barrel tile.

3. High Wind Uplift Resistance The Hybrid System is currently Miami Dade County Approved for standard asphalt underlayments at 190 ft. lbs of wind uplift resistance. It is the highest in the industry using PolyFoam adhesives. Optional EPS blocking increases uplift and economizes on the use of Polyfoam adhesive. Informal testing at the PolyFoam lab suggests uplift values greater than 200 ft.lbs. of uplift with the PolyFoam Ah-100 polyurethane adhesive.

4. Energy Efficient It has been documented, both the airspace created under the convex barrel tiles and their thermal mass contribute to their excellent thermal performance. The optional use of our EPS blocking increases thermal mass and economizes on PolyFoam adhesive by 20% when compared to conventional “S” roof tile.

5. Longevity The life cycle of a barrel tile roof has been documented to last over 100 years.

6. Economical The Hybrid System is economical when used with a mechanically fastened synthetic underlayment as a retro-fit over existing asphalt shingle roofing or over a wood deck for new roofing / re-roofing. (Pending performance testing) 7. Facilitates Solar Integration BIPV/TIPV The “Universal Pan” can be used to facilitate the integration of many solar technologies without the use of unsightly racks and penetrations, (Pending performance testing) and can offset additional costs for barrel roofing tiles by replacing them with a lighter weight metal product.

8. Retro-Fit over Asphalt Shingles Roof

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Can be retro-fit over existing asphalt shingles for roof upgrade whether it may be for aesthetics, increased energy efficiency, storm hazard mitigation or simply solar integration. (pending performance testing) 9. Versatility/ Flexibility The Hybrid System can use any manufactured barrel tile regardless of size, thickness or dimension. The Hybrid can be adapted so as to emulate any barrel tile roof design and adapt to architecture of many cultures. The “Universal” metal pan is roll formed from pre-painted metal coil and is a high production low cost material.

10. Ornamental Horticulture (GREEN ROOFING) The Hybrid System can support the weight of pre-vegetated mats and plant life. “Green Vegetative Roofing” is by far the most natural way to lower roof surface temperature and minimize heat flux to the attic. The Hybrid System is Miami Dade County approved for use with Artezanos proprietary soil less medium and is the only affordable, light weight, vegetated green roof for the sloped residential roof tile market.

EPS Purlin Option

Integrated Solar Thin Film Option

Green Roof Option

Integrated Solar Thermal Tubing

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HYBRID TILE INTEGRATED PHOTOVOLTAICS (TIPV)

Atlantis Energy Systems c-Si

Unisolar Amorphous Si

SoloPower CIGS

The “Universal” metal pan is the key element of the Hybrid Roof Tile System and serves as the base to integrate a wide variety of solar technologies using a simple universal spec to facilitate solar manufacturers to scale the residential BIPV/TIPV markets.

One preferred embodiment makes use of a frameless c-Si module or flexible thin film module in a vertical array. The application of solar technology to a flat metal pan simplifies solar integration of profiled roof tiles such as barrel tile roofing systems in an elegant manner. This type of solar integration minimizes costs associated with labor and materials on both solar and roofing.

The Hybrid TIPV can easily integrate with commercially available UL Certified solar products designed for the industrial/commercial flat roof market and more expensive metal roof market.

Leveraging the use of mainstream commercially available solar technology, yields a lower cost per watt and increased availability because these same technologies have already achieved economies of scale and for the most part, have passed the “learning curve”.

The Hybrid TIPV makes conservative use of the solar technology available today without the use of racks and penetrations.

Artezanos Inc. is working with Atlantis Energy Systems BIPV/ c-Si modules, and is cooperating with Unisolar’s PVL Semi-Flexible Amorphous Si Modules and SoloPower’s SFX-1 Flexible CIGS Thin Film Modules.

Atlantis Energy Systems c-Si BIPV Modules

Artezanos Inc has entered into a Collaboration Agreement with Atlantis Energy Systems to create a Hybrid TIPV utilizing their c-Si technology. Atlantis Energy Systems has been credited for being the first solar company to commercialize BIPV worldwide. 99% of the American solar market is c-Si technology from China. Atlantis Energy Systems is one of a handful of American c-Si BIPV companies left in the U.S. The Hybrid TIPV c-Si design will leverage Atlantis Energy

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Systems in the BIPV niche market with a total systems BIPV product solution that can compete against other foreign solar technology.

Atlantis Energy Systems is recognized globally as a premier BIPV manufacturer and has active sales in Europe and other countries for many years. Our goal is to support Atlantis Energy Systems and support their efforts to win market share from foreign based c-Si manufacturers to help secure America’s energy future.

Flexible Solar Thin Film Flexible Thin Film technology holds great promise to lower cost per watt and increase solar market penetration. Light weight, flexible and without glass, thin film offers great design integration creativity for many products including BIPV/TIPV. American thin film solar manufacturers such as 1st generation thin film pioneer “Unisolar/United Solar Ovonics” and second generation flexible thin film by SoloPower are in the race to increase efficiency/watt and lower cost/watt to make America the leader in renewable energy technology.

Unisolar / United Solar Ovonics

Unisolar is currently the market leader in thin film technology. This company manufactures and distributes their UL Certified photovoltaic laminate semi-flexible amorphous Si technology worldwide. The technology was developed for industrial/ commercial and metal roof form factors. Their existing product line can be integrated with the Hybrid TIPV easily. The Hybrid TIPV is backed by a manufacturer/distributor warranty from AGT, the SouthEast United States distributor for Unisolar. As mentioned, there are major advantages for the Hybrid TIPV integration with commercially available certified solar technologies, in that we can achieve near term success to the F.O.A objectives.

Artezanos Inc. has one existing display mock-up with three Unisolar PVL 68’s in a series and some minor solar integration in an actual residential Hybrid TIPV in Miramar, Florida. We have used both installation techniques approved by AGT/UNISOLAR. We are currently waiting on Unisolar’s “Steering Committee” to offer us a direct warranty and recognition on their corporate website.

SoloPower

This 2nd generation 200 million dollar start up recently received the first UL Certification for its CIGS based flexible SFX-1 module on September 10, 2010. It really comes as no surprise that it has a similar form factor as its Unisolar predecessor. Many other solar CIGS manufacturers in the U.S. such as GlobalSolar, Ascent, and Xunglight to name a few, have adopted similar encapsulated flexible form factors as well. By default they automatically qualify for Hybrid TIPV

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integration. At present SoloPower’s SFX-1 module is light weight and twice the power density of Amorphous Si Semi-Flexible Thin Film.

Since 2010, we have been cooperating with SoloPower to integrate a series of three SFX-1 solar modules to determine installation procedure and aesthetics on the back of a Hybrid Barrel Tile Roof on a residence in Miami, Florida. Computer analysis by SoloPower engineers with real world input determined the TIPV design array does not suffer any shade penalty. The SFX-1 installs similar to the Unisolar PVL but has a smaller width that enables one to pack on more power density in a given area of the roof. CIGS technology is predicted to be the predominant solar technology because of its economic high production roll to roll process that eliminates the use of Si. Furthering the Goal of U.S. Solar Exports Abroad This proposal responds to the F.O.A. goals to further American technology in the U.S. and abroad. The strategy of employing existing UL Certified American technology lowers BOS costs and improves our chances of near term solar use of BIPV/TIPV in residential roofing application with commercially available solar technology. It would offer some much needed economic buoyancy to these same manufactures currently suffering from temporary political policy shifts regarding feed in tariffs in Europe, if back in the United States we were to use the same modules for residential/commercial TIPV market application.

RETRO-FIT HYBRID TIPV OVER EXISTING ASPHALT SHINGLES The Hybrid TIPV is light weight and may be used as a retro-fit upgrade to increase thermal mass to the existing roof while one lowers the PV requirement via lower demand side usage. Asphalt shingles are roughly 85% of the re-roofing market and they aren’t very energy efficient. Asphalt shingles also have a low life cycle and are vulnerable to wind damage. The retro-fit application of a Hybrid TIPV over existing asphalt shingles would yield some benefits, here are a few:

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Aesthetics Increased Energy Efficiency Class “A” Fire Rating Economical Solar integration Increased longevity Increased Wind Uplift Resistance Divert Existing Asphalt Shingles from the Landfill Optional Vegetative Green Roofing Retro-fit Easy installation/affordable

(Before)Existing Asphalt Shingles

(After)Artezanos Hybrid TIPV

TIPV test on back of home 11

THERMAL RESISTANT BARREL ROOF TILE Artezanos Inc proposes the use of a thermally resistant low energy embodiment roof tile for use with the “Universal” metal pan to create a complete affordable, energy efficient, high performance, Hybrid Roof Tile System. Artezanos Inc. has 20 years of experience in roofing installation and barrel roof tile manufacturing. Artezanos Inc. proposes to manufacture a high performance barrel tile utilizing thermally diffusive clay. Artezanos Inc would use F.O.A funds to test this system with the Florida Solar Energy Center to validate our projected improvements over their existing research regarding energy efficiency of barrel tile roofs in hot and humid climates.

HYBRID ROOF TILE SYSTEM AND LOCAL GOVERNMENT APPROVALS Artezanos Inc’s patented Hybrid Roof Tile System has been recognized by Miami Dade County Board of Rules and Appeals as an innovative technology and has been designated as a new category of roofing called the “HYBRID GREEN ROOF SYSTEM”. As such, the Hybrid System has been assigned a Roofing Subcommittee to smooth over any differences with Miami Dade Product Control Staff. The Hybrid System is currently approved over conventional asphaltic underlayments over a plywood decking.

The newly proposed Hybrid Green Roof System is allowed to be PolyFoamed over a mechanically fastened synthetic underlayment over a plywood deck and also serve as a retro-fit over existing asphalt shingles (Pending Performance Testing).

The Florida Building Code specifically forbids the retro-fit of existing asphalt roofs with roof tile or metal panels. Only metal and asphalt shingles are allowed over existing asphalt shingles without the use of an underlayment.

The designation of “Hybrid Green Roof System” enables Artezanos Inc to circumvent this code as allowed by the Miami Dade Board of Rules and Appeals (Pending Performance Testing).

As mentioned, the Hybrid System is designed for use with any barrel tile manufacturer, American solar technology and has the only approved affordable sloped residential vegetative green roof option for a roof tile form factor.

STATEMENT OF PROJECT OBJECTIVES A. PROJECT OBJECTIVES Artezanos Inc. objectives are to demonstrate an aesthetic BIPV/TIPV that is optimized for energy efficiency of sloped residential roofing projects in re-roofing, new roofing and retro-fit over existing asphalt shingles B. PROJECT SCOPE Topic 1: Transformational Building Integrated Photovoltaic (BIPV) Modules

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Develop a business case for integrating PV into a roofing product with the potential for gigawatts (GW) of installations into the residential/commercial market Develop a partnership with a roofing company Demonstrate a business case for achieving a $2 per watt total installed PV system cost goal at large scale Develop a high reliability product with lifetimes of 25 years or more Demonstrate a form factor that can be quickly and easily installed. This may include: o Prefabricated PV systems that include the roof decking, insulation and the roof substrate o Lightweight materials Demonstrate a BIPV system that is optimized for energy efficiency performance of the building Develop hardware to be evaluated by a third party Use high efficiency PV cells Work with codes and standards entities to ensure timely approval of new products Minimize or eliminate roof penetrations

Demonstrate near term market penetration of a complete BIPV/TIPV product ARTEZANOS PROPOSED TASKS: Budget Period 1 Task 1.0 POLYPROPYLENE UNDERLAYMENT TESTING Astm E-108, 114j Vacuum Test, Wind driven Rain, and Slippage Test to qualify Miami Dade County designated Artezanos Hybrid Green Roof for an N.O.A. approval for use in Re-Roof, New Roof Construction and Retro-fit over existing asphalt shingles. A new high performance synthetic underlayment is needed to remove roofers from dependence on asphaltic petroleum based underlayments.

This underlayment is higher performance, light weight and inexpensive. This would remove BOS costs for Solar Hybrid TIPV installations and make them more affordable.

Task 2.0 SOLAR MODULE TESTING FOR HYBRID TIPV Artezanos Inc contemplates the use of three different solar technologies two of which are commercially available and one that is design specific to the Hybrid TIPV. Artezanos Inc will demonstrate to other American Solar Manufacturers the great design flexibility of the Hybrid TIPV System to stimulate participation.

Subtask 2.1 Solopower Sfx-1 CIGS Module Testing Astm E-108, 114j Vacuum Test, and Accelerated Weathering Test for SoloPower CIGS Thin Film for use on Artezanos Hybrid Green Roof.

Subtask 2.2 Unisolar PVL 68 Module Testing Astm E-108 for use with Artezanos Hybrid Green Roof System Subtask 3.2 Atlantis Energy Systems c-Si Module Testing Astm E-108, 114j Vacuum Test to procure Miami Dade County N.O.A. Approval

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Task 3.0 ARTEZANOS HYBRID TIPV DEMONSTRATION 2000 sq.ft. Roof top Hybrid TIPV demonstration within 6 months of funding.

Task 4.0 HIGH PRODUCTION METAL ROLL FORMING EQUIPMENT A&B Design and Production of Universal Pan and Solar Pan Roll Formers based on already working prototype.

This equipment will lower labor per part, ideal for mass production.

Task 5.0

UPDATE WEBSITE

Increase website exposure in different languages for potential marketing in Budget Period 2.

Task 6.0 TEST EPS WITH HYBRID BARREL TILE SYSTEM ASTM E-108 Test, Wind Driven Rain Test, 114j Vacuum Test. These tests are needed to prove fire resistance and wind uplift. EPS can be used to reinforce roof against impact, increase R-Values and facilitate installation while economizing approximately 20% of the polyurethane adhesive used to bond the Hybrid System together.

Subtask 6.1 FSEC test of energy efficient Hybrid Barrel Tile System This test will secure data on how this new and improved energy efficient Hybrid Barrel Tile System compares to the prior art improving potentially upon previously constructed testing data by FSEC.

Budget Period 2

Task 1.0 RAW CLAY MATERIAL AND LAND ACQUISITION Land use for production of low energy embodiment barrel roof tile specific to the Hybrid Barrel Tile System. This 1.5 acre land plot in Cucuta, Colombia will serve as a base of operations for production of Colombian barrel tile and receiving of U.S. manufactured Universal metal pans for distribution in Colombia. The location is very safe and at a high security checkpoint.

Subtask 2.1 Production of Barrel Roof Tiles with Thermally Diffusive Clay Artezanos Inc. will produce a high performance low energy embodiment clay barrel tile as a cover for the Hybrid Barrel Tile System. The enhanced barrel roof tile will be manufactured from a light weight thermally diffusive clay body.

Task 3.0 PILOT AND EARLY COMMERCIALIZATION OF HYBRID TIPV IN THE U.S. Magazine advertisements and media along with conventions and conferences. We will move product through nationally recognized roofing outlets.

Task 4.0 ADVERTISEMENT AND EDUCATION

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Artezanos will advertise and hold workshops to educate roofers and electricians how they can cooperate and overcome uncertainties of solar integrated roof systems.

Subtask 4.1 Promotion of Hybrid TIPV Retrofits Artezanos will advertise and actively seek to gain attention in sustainable Hybrid TIPV retro-fits over existing asphalt shingles where Artezanos can make the most significant difference.

Budget Period 3

Task 1.0 ADVERTISEMENT AND PROMOTION TO NATIONAL MARKET AND EXPORT MARKET Artezanos Inc. will attend international shows and promote U.S. Solar technology with the Hybrid System.

Task 2.0 TESTING HYBRID TIPV WITH DIFFERENT U.S. ROOF TILE MANUFACTURERS Increase participation of American roof tile manufacturers and testing their products so they may qualify as approved under Artezanos Inc existing N.O.A Approval for the Hybrid TIPV.

Task 3.0 PROMOTION OF ECONOMIC VERSION OF HYBRID TIPV TO LOW INCOME MARKETS Through the use of various roof tile manufacturers and solar manufacturers, Artezanos seeks to put an affordable Hybrid TIPV System for low income housing.

Task 4.0 INTERNATIONAL PROMOTION OF AMERICAN MANUFACTURES SOLAR MODULES WITH HYBRID TIPV Artezanos will promote the use of American Manufacturers with HYBRID TIPV systems in Europe where they make sense in the Historical Districts where traditional rack mounted systems are frowned upon and BIPV still has an aesthetic upper hand.

Task 5.0 TESTING OF SOLAR THERMAL INTEGRATED HYBRID ROOF TILE OPTION FSEC testing to acquire SRCC certification for the harvesting of heat energy from the Universal metal pans as a form of heat dissipation for roof top c-Si BIPV/TIPV. The same system may act as a thermal hot plate collector for domestic hot water use. This project is in conjunction with Atlantis Energy Systems

Task 6.0 DEVELOPMENT OF GREEN ROOF OPTION

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Roof top vegetation has some very positive benefits. Artezanos seeks to promote this option at every turn in conjunction with solar energy systems because it is by far the most visual way to educate others on renewable energy and sustainable residential sloped roofing.

Recent Roof Tile Activity of South Florida Clay Roof Tile Market Artezanos Inc, an American manufacturer/importer of clay roof tile systems, has 20 years experience producing clay roof tiles and other clay building products. Our signature product has been our Artezanos World Class Handmade Barrel Roof Tile developed in Cucuta, Colombia by our sister company Artezanos Clase Mundial Ltda. of whom we have had a business relationship for over 20 years.

For the last 25 years, the popular clay roof tile market was monopolized by a few Venezuelan roof tile manufacturers producing roof tile in their country under then free market conditions. The popularity may have risen from a combination of the large population of Hispanics that live in South Florida and the fact that native Floridians have historically had a fondness for clay roof tile imports being closer in proximity to more economical sources of clay raw material than other destinations of clay roof tile production in elsewhere in the U.S. In Florida today, U.S. made clay barrel tiles are more expensive because of logistics due to weight constraints. Florida does not have a suitable clay source or local clay tile manufacturing and therefore it is difficult to source a domestic sustainable clay product that is also affordable. Generally speaking, clay as a raw material for roof tile production has better positive thermal characteristics than concrete known for absorbing heat.

In 2006 Artezanos Inc transport and ocean freight costs, skyrocketed because of large demand and escalating fuel costs. This hurt our business because we would often price out large residential developments and we were held to our original quoted price. That same year Artezanos applied for utility patents on roof tile designs that would minimize labor and materials in an attempt to offset some of the escalating costs due to ocean and land transport. By 2007 another utility patent was applied for involving the use of our Barrel Roof Tile (Covers) laid over a “Universal” metal pan. With this new Hybrid design we would be able to eliminate the waste of using a perfectly good Barrel pan tile and offer it for sale as a cover tile. The Universal metal pan lowers freight, installation and roof top loading costs by a minimum of 50%. As demand and market conditions have deteriorated 2008- to present, we have accomplished the following: 1.

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Website installation video since 2009 with 20,000 + hits Website showing Hybrid TIPV mock –up with 3 Unisolar PVL 68’s Small production prototype roll former for Universal Metal Pan 6 residential Hybrid Barrel Tile installations 2 Residential HYBRID TIPV solar module integrations Signed Collaboration Agreement with Atlantis Energy Systems Relationship with key members of SoloPower Relationship with Engineer Unisolar/United Solar Ovonics Local/State Approvals for Hybrid System PolyFoamed to single mechanical fastened synthetic underlayments over plywood and as a retro-fit over asphalt shingles (Pending Performance testing).

The use of metal pans also eliminates breakage and the lengthy firing process inherent to all clay roof tiles. The prototype production is in Lakeland, Florida where there exists a large hub of labor and painted

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metal coil providers. Our equipment design is based on an economical roll former/ die stamp process that lends itself to very high production with low cost.

In an attempt to shift our business practices to be green and sustainable and to promote American made products in our design, the metal pan product alone represents over 50% of the design Made In USA. Other products such as the EPS Blocking, Synthetic Underlayment, PolyFoam Adhesive and Photovoltaics are all made in USA. Optional is the use of the hybrid system with other American made barrel tile.

Artezanos Justification of the use of Colombian Barrel Tile The business family of Artezanos Inc is American Colombian just like its Hybrid Roof Tile Design. Since our product is unique, many liken it to high end roofing and our quality has always been held in high regard. The market barriers for solar are cost and aesthetics. In South Florida, at present time of writing, the economic conditions are so severe; customers are demanding much more for their hard earned money.

At present, our Hybrid System delivers greater wind uplift performance at the price of a conventional “S” tile roof and this is still a hard sell. Having an approved TIPV system enables Artezanos the competitive edge to further its sales but then nobody wants to be first! It’s very difficult to break the ice with a new roof system and new solar installation technique especially when anyone that’s still in business as a solar contractor is still out trying to push traditional China-made rigid c-Si panels on racks and penetrations.

We now know that if we are to make a real difference in the market, we need to deliver the Hybrid roof product closer to that of an asphalt shingle price and motivate those interested in solar to desire an integrated system utilizing the most competitive U.S. made solar technology currently available on the market today. This can be done!

If Artezanos obtains the funding for performance testing for the synthetic felt in a bid to lower BOS costs even further, the Hybrid System would be rid of the asphalt petroleum based spec that typifies all other traditional roof tile systems and bring the price of a real barrel tile roof much closer to the price of a typical asphalt shingle roof. This move would yield a much higher performance system and lower costs by 30%-50% depending if it’s an asphalt shingle retro-fit or not. In doing so, the BOS costs for solar BIPV/TIPV substantially decrease and the roofing demographic for TIPV would be substantial. More economical extruded barrel tiles could be coupled with metal pans for a weight per 100 sq.ft. of 385 lbs. or high end barrel tiles for a weight of 425 lbs per 100 sq.ft.. Either way the integration of solar would be the same standard. One could simply pick out from the available solar and not have to worry about a roof’s water tight integrity.

Rex Synfelt Polypropylene Underlayment

Roofers foam adhere Universal Pans to deck.

5 inches of water test SharkSkin Polypropylene Underlayment 17

HOW TO OVERCOME RESIDENTIAL SOLAR ROOF TOP MARKET BARRIERS At present, the construction market is at a virtual standstill. Manufacture of those same Venezuelan tiles has faded because of the political condition there and has given way to production in Colombia.

Colombia’s roof tile sales to the U.S. are also at a halt. As mentioned before almost all clay roof tile in South Florida is imported. Colombia is the county with the most Miami Dade County Approvals for clay roof tile products and this exacerbates the situation because competition is rife with extruded clay roof tile products. Artezanos sets itself apart from the rest because we have a unique handmade roof tile that delivers an aesthetic unmatched by contemporary extruded clay tile products. It is our intention to overcome this difficult market situation by catering to the retro-fit market to existing asphalt shingle roofs and re-roofing with Hybrid TIPV. By offering our Artezanos Barrel Tiles as a Hybrid TIPV lower priced than what it would cost to pay for a conventional clay tile roof, we feel that can use simple economics and aesthetics to steer roofers, suppliers, homeowners, architects and engineers to overcome their fears of “EXPENSIVE SOLAR”.

We would need a showcase roof with a pitch of 4/12 with a combination of solar technologies and another one selected with a 3/12 pitch with a second story. Also we should demonstrate how to expand an existing HYBRID TIPV with additional solar panels and demonstrate the advantages over the prior art of traditional rigid c-Si panels with racks and penetrations. We propose to use FOA funds to complete these objectives.

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We propose to do trade shows, advertisements and roofing workshops. To illustrate our commitments to the DOE initiative of bringing solar to residential markets, Artezanos is not married to its own barrel tile product because it is a unique product in itself and can compete along side other roof tile manufacturers.

We have no qualms with licensing other roof tile manufacturers, roofing companies and other thin film solar manufactures the use of the hybrid system standards we have developed. We can use our unique barrel tile product to act as a catalyst to “sweeten the pot” and deliver market penetration of TIPV in residential and encourage widespread usage.

Artezanos Inc can also assist these same American solar technologies to find markets in Colombia and other countries in South and Central America where distributed energy can be made a reality for those who live so far from the grid. The system would be affordable because one could simply use local barrel tile or recycled barrel roof tile and in volume a metal pan or solar thin film would be relatively inexpensive because of their light weight, low cost high production product for shipping purposes. For the affluent, they love American technology and a light weight roof resistant to seismic and hurricane wind force activity would be a plus. This would fulfill the intentions of the FOA by making America a leader in exporting renewable energy technology.

Current State of the South Florida Residential Solar At this current time of writing, the solar business suffered some major setbacks as the State of Florida Legislative Session decided again to give most of the control of solar to the utilities. There is very little incentive in most of the Sunshine State. Last summer, the Florida State rebates ended and left only the 30% federal tax credit. This put many a small solar business out in the street. Almost all of these solar businesses sell China made traditional c-Si panels with racks and penetrations. Even with the availability of these panels at very low prices, they become very expensive by the time they get on a roof with all the BOS costs and labor intensity. Actually most solar panels on roofs for the last 30 years have been seen only as an appendage and never an integral part of the roof. Because of this, any innovative integrated solar solution here in South Florida may be looked upon as nothing more than a fad because it would differ greatly than the normal accepted product offering of the average solar installer at large.

Solar contractors are not as competitive as roofers or electricians because there are not as many solar contractors in comparison. This keeps the price high and out of reach of many that could have afforded solar. To many, it doesn’t make sense to spend a lot of money to make your roof look ugly and then worry about leaks because of the rack penetrations. This dismay and general distaste towards existing solar prices and perceived roof complications also needs to be overcome in an industry where there is little work and those that do, don’t want to waste time learning something new.

The Hybrid Roof Tile System is a simplified version of a barrel tile roof and when foam adhered to a mechanical synthetic underlayment and can narrow the price gap substantially closer to that of an asphalt shingle roof price. This gives a great incentive! Achieving maximum performance of wind-up lift, energy efficiency and aesthetics. Adding solar only makes it easier because the installation is also simplified and can be coordinated by roofers and electricians substantially reducing their respected labor expenditures. A roofer is much happier laying down a large 1.5’x 10’ panels in a series over 1000 sq.ft. and offsetting the purchase and installation of 18” long heavier roof tiles. An electrician is content connecting the wiring left by the roofer and connecting the inverter to the grid. The homeowner is content because they have more choices and can use tried, proven and available American solar products at a competitive price. The Hybrid TIPV can be expanded with additional solar in the future with less effort than would be required for traditional rigid panels with racks and penetrations. There is a benefit in that the 30% federal tax credit now covers the entire investment regardless of the solar footprint or cost per watt of the solar BIPV/TIPV because the investment is an integrated solution that produces energy for the home of the American

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taxpayer. The Hybrid TIPV supports the use of commercially available solar at low cost and can channel the participation to other roofing and solar manufacturers that otherwise do not have an entrance into the residential BIPV/TIPV residential market. A total system solar solution that reduces the ambient roof top temperature for more efficient PV and increases the thermal mass to minimize the heat intrusion is responsive to this FOA. Roofers, suppliers and homeowners need a market catalyst to jumpstart BIPV/TIPV into the market and help overcome traditional market barriers. Artezanos Inc can make the difference and lead the way by example.

MERIT REVIEW CRITERIA a. Topic Area 1: Transformational Building Integrated Photovoltaic (BIPV) Modules Criterion 1: Merit and Impact Technical Merit:

Artezanos Inc will address the objectives of the F.O.A. for near term implementation of solar BIPV/TIPV roofing utilizing commercially available roofing products and solar technology. Artezanos Inc will demonstrate the integration of three different solar technologies in a Hybrid TIPV and their implementation in the residential/commercial market before 12 months time. We will achieve the first grid connected residential Hybrid TIPV within 6 months time of funding inclusive of all local government permits and approvals. The technology fits within the future market because it offers energy efficiency and simplifies a sustainable roof tile system with familiar construction components that offer benefits for solar integration while lowering BOS costs. Artezanos Inc will demonstrate the versatility of the system with use of different barrel tile manufacturers and commercially available barrel roof tile and show how they become compatible with different solar technologies.

Impact and Relevance: Artezanos Inc will demonstrate three cost impact tables for c-Si modules by Atlantis Energy Systems, Amorphous Semi-flexible Si Thin Film by Unisolar and CIGS Thin Film by SoloPower.

Uniqueness or Innovation: Artezanos Inc forecasts the escalation of petroleum roofing products and seeks to eliminate them in favor of lowering BOS costs that yield substantial price advantages to both the roof system and solar system integration. Artezanos Inc’s design is based on a “Universal” application concept that can be used with any barrel roof tile in the world.

Full building Impact: The Hybrid System is an energy efficient roof tile system because of the use of the profiled barrel tile, already known for its heat dissipating effects because of their increased air circulation under the tiles in combination with their own thermal mass.

The advantages for this system incorporating an aluminum metal pan tile adhered to the substrate by an adhesive polyurethane patty only serves to compound the energy saving

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advantages and increase its nocturnal emissivity. Clay Barrel Roof Tile and Metal Pan Tile are two very traditional materials that have never been employed together until now.

Together they yield very sustainable benefits.

Criterion 2: Management and Plan Project Management:

Artezanos Inc. has 20 years experience in the manufacturing of clay barrel tiles in Pre-Uribe Colombia and Roofing Contracting in South Florida. Artezanos Inc has planned this transition to Hybrid TIPV since 2005 and knows how to maneuver itself within the industry. Artezanos has painstakingly minimized the risk by acquiring all local government approvals to date. Artezanos Inc is a Construction Family Related Business.

Verification, Decision Points and Deliverables Artezanos Inc has already procured Local and State government approvals (Pending Performance testing) . Special permission has been granted by the governing authorities because of the Hybrid Systems performance on existing Miami Dade County Approvals and laboratory testing over standard industry asphaltic underlayments.

Commercialization Plan: Artezanos Inc. will develop a direct marketing approach beginning with homeowners and generating demand with roofing companies and ultimately roofing distribution centers ect.

Artezanos Inc will reach out to those who want to learn and use this method to network through education, seminars, advertisements, news media to reach markets beyond Florida.

Our partners at Atlantis Energy Systems have offices in San Diego and Sacramento California and a growing international market. We intend on distributing immediately to Colombia, South America, Central America and Caribbean.

Partners: Artezanos Inc has a Collaboration Agreement with Atlantis Energy Systems to gain market share for both companies. We have many years of client roofer/supplier relationships within the roofing supply market. We are open to other American manufacturers of Flexible Thin Film Modules, as they come online they will compete against each other for market share and lower price per watt to the consumer.

Criterion 3: Qualifications, Resources, and Capabilities Artezanos Inc has the capabilities to alter local and State local codes for the benefit of BIPV/TIPV roof installations. We very knowledgeable in building construction and roofing for the integration of BIPV/TIPV with near term results. Our team members have decades of experience above and beyond the project requirements.

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Resources: Artezanos Inc. can support high volume BIPV/TIPV with our high volume production roll forming equipment combined with Artezanos barrel tile and/or other commercially available American roof tile manufacturers and solar module manufacturers. The Hybrid Roof Tile System is designed for scale and broad participation of existing solar and roofing technologies.

Commitment: Artezanos Inc has support from Atlantis Energy Systems, a leading BIPV innovator and manufacturer with U.S. and Foreign markets.

Criterion 4: Demonstration Artezanos Inc. has years of preparation for the implementation of BIPV/TIPV and can begin commercializing to residential/commercial within 12 months.

Artezanos Inc will demonstrate the capability of the Hybrid TIPV to incorporate energy savings to offset additional PV costs via use of an energy efficient barrel tile roof utilizing thermally diffusive clay barrel tiles with a good solar reflectance.

The applicant has enjoyed extensive media coverage on code changes and knowledge regarding traditional barrel tile roofs and can use this to the advantage for the early market penetration of residential / commercial BIPV/ TIPV. The applicant has successfully exempted the use of 280 year old traditional barrel roof tile from the strictures of Miami Dade Product Control during the building code aftermath of Hurricane Andrew. Artezanos has successfully established quality and name brand recognition for its clay barrel tile in the high end market. Artezanos Inc seeks both high-end , low-end and retro-fit markets through the education of its use with solar BIPV, solar thermal, vegetative green roofing and sustainable benefits for general marketing purposes.

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Cost Impact Table 3 - Residential Rooftop (Note: Baseline Present figures represent a rackmounted system. Topic 1 applicants are asked to complete this table as an illustrated comparison of the proposed technology against a traditional, rack-mounted residential system):

Combiner boxes

Units $/W

$0.0188

Improved FY 2011 $0.0188

DC, AC-Disconnects

$/W

$0.0117

$0.0117

$0.0117

$0.0117

Electrical Labor

$/W

$0.3019

$0.289

$.289

$0.289

Fuses and Holders

$/W

$0.0060

$0.0060

$0.0060

$0.0060

Grid interconnect

$/W

$0.3025

$.3025

$.3025

$.3025

Hardware Labor

$/W

$0.3260

$.19

$.0994

$0.0000

Inverter

$/W

$0.4200

$.42

$.42

$.10

Land

$/W

$0.0000

$0.0000

$0.0000

$0.000

Markup on materials

$/W

$0.8864

$.819

$.819

$.229

Meter

$/W

$0.0226

$0.0226

$0.0226

$0.0226

Module

$/W

$2.1450

$2.1450

$2.1450

$.50

Mounting (racking) hardware

$/W

$0.2952

$0.0000

$0.0000

$0.0000

Overhead

$/W

$0.3390

$.252

$.1893

$.064

Permitting

$/W

$0.0818

$.0818

$.0818

$.0818

Profit

$/W

$0.1884

$.14

$.1058

$.0361

Sales Tax

$/W

$0.2603

$.2603

$.2603

$.2603

Site Prep

$/W

$0.0000

$0.0000

$0.0000

$0.0000

Storage

$/W

$0.0000

$0.0000

$0.0000

$0.0000

System Monitor

$/W

$0.0867

$0.0867

$0.0867

$0.0867

Tracker

$/W

$0.0000

$0.0000

$0.0000

$0.0000

Wiring (including connectors, conduit) Total

$/W

$0.0203 $5.71

$0.0203

$0.0203

$0.0203

$5.06

$4.87

$2.02

Cost Component

$/W

Baseline Present

Improved FY 2014 $0.0188

Improved FY 2017 $0.0188

Cost Table Discussion FY 2011, Electrical and Hardware labor have been reduced by 25% from the Baseline present.

The applicant is using the same labor rates for electrical and hardware per hour derived from the recommended NREL (Installed Systems Prices). Since our design eliminates the use of rack mounting hardware FY 2011 through to FY 2017, we eliminate rack mounting costs and have allowed 12 hours of Electrical and Hardware labor respectively for FY 2011 based on a 2.5 kW system using Unisolar PVL 68’s at 68 watts each. As per this FOA, we will not recognize labor and material savings to roofing, however one of the cost saving advantages of BIPV is that it can offset these costs and they should be considered. We contemplate a total roof BIPV/TIPV 23

solution, however only the direct solar costs are being elaborated in this discussion. Since the Universal metal roof pans are a component of the entire roof system and already figure as a roofing cost, for the sake of this discussion we will not include the cost.

FY 2014, the applicant feels justified in supporting the same 12 hours for the Electrical Labor but has reduced the Hardware Labor to 6 hours instead of the 12 hours for the same 2.5 kw system. This conservative approach has been adopted as a result of solar rooftop hardware being eliminated from FY 2011.

This translates to a 44% reduction hence the figures for Overhead and Profit reflects these changes.

FY 2017, Electrical Labor remains the same; however we have eliminated Hardware Labor from the cost table FY 2014. The combined reduction in Electrical and Hardware Labor is 81% from the Baseline Present.

Mark-Up on Materials, Overhead and Profit have all been reduced respectively FY 2011 through FY 2017.

Major labor savings and quality control can be achieved by eliminating rack mounting systems especially where they penetrate the deck for wind load compliance. The applicant would also like to mention the savings one may have considering the roofing Underlayment as part of the BOS cost for a true BIPV/TIPV. This reduction in materials can serve the goals of the FOA and help offset solar costs.

The Hybrid System is made up of 50% metal pans that can be used with Thin Film Solar Technology or medium size frameless c-Si panels and do the same job as traditional roof tile.

The drawing below demonstrates the theoretical 2.5 kW roof. Note the whole back of the roof is covered with 36 PVL’s. This configuration can be also be used with Atlantis Energy Systems cSi and SoloPowers CIGS Thin Film with comparable aesthetic results. It should be noted that an additional 2.5 kW could also be placed on the opposite side of the home. Where the opposite side is the front entrance, one may use a more aesthetic technology in the same configuration for increased aesthetics.

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REFERENCES  Baker, M. C. 1980. Roofs. Montreal, Quebec, Canada: Polyscience Publications.  Rose, W.B. 1995. The history of attic ventilation regulation and research. Proceedings of ASHRAE Therm VI, Thermal Performance of the Exterior Envelopes of Buildings VI. Dec. 4-8.

Clearwater, Florida.

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