Fastening Systems for Solar Installations
Imprint Editor: EJOT Baubefestigungen GmbH 57334 Bad Laasphe, Germany Layout and Realisation: EJOT Baubefestigungen GmbH, 57334 Bad Laasphe, Germany Print: Vorländer GmbH & Co. KG, 57072 Siegen, Germany Legal Notes EJOT products are constantly enhanced. We reserve the right to make changes to the technical specifications as well as changes to the product range, During planning and use of our products please comply with
Your contact:
accepted engineering rules, planning laws as well as relevant safety regulations. The national technical approvals granted to our products can be downloaded on the internet at www.ejot.com. General terms and conditions: Our general terms and conditions can also be found at
www.ejot.com
www.ejot.com (footer: GTCT) © 2012 by EJOT Baubefestigungen GmbH EJOT®, ejotherm®, Delta PT® and PT® are registered trademarks of EJOT GmbH & Co. KG. CRONIMAKS®, Corremaks®, EJOFAST®, Dabo®, ECOmate ® FR-variotool® and Solar Ready® are registered trademarks of EJOT Baubefestigungen GmbH. DEKTITE® is a registered trademark of Deks Industries Pty. Ltd., Bayswater Victoria, AU. TORX®, TORX PLUS® and AUTOSERT® are registered trademarks of Acument Intellectual Properties, LLC, Troy Mich., US.
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COLEXON Energy AG
Table of contents EJOT® – Your Strong Partner
page 4
EJOT Building Fasteners
page 5
EJOT® Solar Fastener
page 6
®
Questionnaire EJOT Solar Fastener ®
page 12
EJOT Solar Fastener for Concrete
page 14
EJOT® Flat Roof Fastening System
page 16
Questionnaire EJOT® Flat Roof Fastening System
page 19
EJOT® Solar Fastener FD
page 20
EJOT® SUPER-SAPHIR Self-drilling screws
page 22
Dektite® Flashing for Cables
page 24
Tools
page 30
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EJOT® – your strong partner for fastening solutions in the building and solar industry
q Expertise With over 30 years of experience and development know-how “Made in Germany“, we know the needs concerning fastening requirements on building envelopes very precisely. Our knowledge is the base and source of our products and solutions to offer real benefits to our customers. q Quality and efficient assembly The quality of our products exceeds planning laws and legal requirements. Our aim is to ensure quick and easy assembly. q Customer-friendly service We make a point of building friendly and trustful relationships with our customers. If necessary our employees go directly to the building site. We share our know-how in training seminars. q Worldwide presence Our worldwide sales and service network with its own companies and partners as well as a worldwide project support team is glad to help our customers at any time.
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EJOT Building Fasteners: Over 30 years of building envelope expertise
1. Industrial Lightweight Construction (ILB) High-quality fasteners for fixing profiled sheets and sandwich panels in the industrial lightweight construction 2. External Thermal Insulation Composite Systems (ETICS) Special anchors for fixing insulation on external wall systems 3. Rear Ventilated Facades (VHF) Fasteners and anchors for fixing substructures and facade fascias of rear ventilated systems
ILB
ETICS 4. Flat Roofing (FLD) Fasteners, and installation tools for the efficient attachment of insulation and waterproofing membrane to flat roofs and slightly sloping roofs.
VHF
FLD
5. Industrial Window and Facade Technology (IFF) High quality fasteners for the window and door production and the use in aluminium/glass facade systems 6. Fastening Systems for Solar Installations (BSA) For fastening of mounting systems for photovoltaic and thermal solar installations.
IFF
BSA
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Abakus Solar AG
EJOT® Solar Fastener – To fasten mounting systems for thermal solar and photovoltaic installations
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With the EJOT Solar Fastener made from stainless steel (A2), you will be able to fasten your new rooftop solar installation securely and simply. They are suitable for all common substructures of wood, steel and concrete. This system guarantees watertightness and a high bearing capacity with easy installation. Moreover, it allows an exact height adjustment of the installation. The EJOT Solar Fastener is a combination of a building authorities approved self-tapping screw for steel substructures, or a wood screw according to DIN 571, which is connected to a set screw by a welded joint. A complete package consists of the EJOT Solar Fastener with weldedon set screw, a nut, a lock nut and the required washers. The most suitable sealing system (e.g. EJOT ORKAN Storm Washer or FZD sealing element) is chosen according to the application. The fastener is anchored in the substructure and transmits all tensile and compression loads exactly to where they can be absorbed securely. Consequently the characteristic load values are definable and can be found in the building authorities’ approval Z-14.4-532. The EJOT Solar Fastener is especially suitable for roofs with trapezoidal profiles, sandwich panels and fibre cement sheets.
EJOT® Solar Fastener – All advantages at a glance
q q q q q q q q q
Short delivery times Flexibility in case of special requests Expert advice High product quality through strict quality control Fast retrofitting on existing roofs No additional holes in the roof cladding Usage of proven sealing systems No special assembly tools necessary Extremely secure attachment due to fastening directly into the substructure q Building authorities approved fastening system q Project pre-analysis free of charge
Note: For existing roofs which are fastened onto steel substructures with Ø 5,5 or 6,3 mm screws, it is possible to remove the screws and replace them with Ø 8,0 mm EJOT Solar Fasteners. The pre-drilling diameter has to be observed at all times.
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Examples:
Internal hex drive A/F 5 Set screw DIN 913 M10 x Lg A2 Lock nut M10 DIN 985 (alternative: self-locking nut DIN 6923) Plain washer M10 Hex nut M10 DIN 934 (alternative: self-locking nut DIN 6923) Precise defined depth (control) stop Sealing washer E16 EJOT ORKAN Storm Washer Sealing washer FZD A2 EJOT self-tapping screw JA3 - 8,0 x L for wood substructures EJOT self-tapping screw JZ3 - 8,0 x L for steel substructures
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Product key: L
Example: JA3 - SB - D x L / Lg - E16 or FZD
D
set screw ø
width
Lg
angle
E16
D
= screw diameter (lower part)
L
= length of screw (lower part)
Lg
= length of set screw (upper part)
Type JZ3 = suitable for steel substructures Type JA3 = suitable for wood substructures Standard is Ø 8,0 with M10 set screw
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If the length of the set screw is not specified, it is automatically 50 mm.
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ø8
M10
70
JA3 - SB - 8,0 x 100 / 70 - E16 + EJOT ORKAN Storm Washer 41-32 32° 50
ø8
100
FZD (ø25)
ø10
JZ3 - SB - 8,0 x 100 / 50 - FZD
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COLEXON Energy AG
Standard product range (for Ø 8,0 mm versions): Version
Material Drive Threaded part
Sealing systems Ø (mm)
Screw length L [mm]
Special product range (for Ø 10,0 mm versions):
JZ3-SB-
JA3-SB-
JA3-SB-
for steel substructures
for wood substructures
for wood substructures
stainless steel A2
stainless steel A2
stainless steel A2
A/F 5
A/F 5
A/F 5
M10 x 50
M10 x 50
M10 x 50
M10 x 70
M10 x 70
M10 x 70
sealing washer E16 + storm washer
sealing washer E16 + storm washer
sealing washer E16 + storm washer
FZD
FZD
FZD
8,0
8,0
10,0
64
80
150
80
100
200
100
130
220
125
150
240
150
180
260
160
200
280
200 240 280
10
300
COLEXON Energy AG
Installation note:
Screw
Description
Substructure [mm]
Predrilling Ø [mm]
Drive of the set screw
Screw length/ Insertion depth [mm]
A/F 5
screw length: sandwich element thickness or trapezoidal profile height + 20 mm
steel JZ3-SB-8,0xL/Lg-E16 + 1,5 ... < 5,0 storm washer
6,8
5,0 ... < 7,5
7,0
7,5 ... < 10
7,2
≥ 10
7,4
wood
5,5
A/F 5
32 - 96
5,5
A/F 5
32 - 96
7,0
A/F 5
40 - 120
JZ3-SB-8,0xL/Lg-FZD
JA3-SB-8,0xL/Lg-E16 + storm washer
JA3-SB-8,0xL/Lg-FZD JA3-SB-10,0xL/Lg-FZD
wood
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Questionnaire EJOT® Solar Fastener
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Questionnaire EJOTÂŽ Solar Fastener
Our application engineers will gladly assist you in selecting the right EJOT Solar Fastener. Please fill in the questionnaire and send it to: Fax +49 27 52 908-731 or e-mail: solar@ejot.de.
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EJOTÂŽ Solar Fastener for concrete substructures The EJOT Solar Fastener for concrete substructures is developed upon the basic concept of the EJOT Solar Fastener. It offers the same technical advantages as a joint between the roof and the mounting system for solar installations. The important difference to the standard Solar Fastener is the usage of this fastener in concrete substructures.
All advantages at a glance
q Usage of an anchor screw A/F13 (material A4) q Usage of the EJOT SDF anchor (special anchor for fastening into concrete) q Shortest anchor length L=60 mm q Short delivery times q Flexibility in case of special requests q Expert advice q High product quality through strict quality control q Fast retrofitting on existing roofs q No additional holes in the roof cladding q Usage of proven sealing systems q Extremely secure attachment due to fastening directly into the substructure q Project analysis free of charge
Note: The shortest anchor length is L=60mm. The screw to be used is dimensioned with an allowance due to the elongation of the anchor during assembly. For the hole depth of blind holes at least 10 mm allowance has to be added to the anchor length.
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Variants:
Product range:
Set screw DIN 913 M10 x Lg A2
Internal hex drive A/F 5 Version
Lock nut M10 DIN 985
A/F13 / SDF anchor (D=10mm) for concrete substructures
Material
Plain washer M10
Drive
Sealing washer E16
Hex nut M10
A/F 5
Threaded part
Precise defined depth (control) stop
Sealing systems alternative: sealing washer FZD A2
EJOT ORKAN Storm Washer
stainless steel A4
M10 x 50 M10 x 70 sealing washer E16/2 + storm washer FZD
Ă&#x2DC; (mm)
7,0 87
SDF screw
107 127 Screw length L [mm]
147 167 187 207
SDF anchor
227
Installation note:
Screw + description
SW13-SB-7,0xL/Lg + anchor -E16 + storm washer
SW13-SB-7,0xL/Lg + anchor -FZD
Substructure [mm]
concrete
Predrilling Ă&#x2DC; [mm]
10
Hole depth [mm]
Drive of the set-screw
anchor length A/F 5 + min. (for M10 10 mm threaded part)
Screw length/ Insertion depth [mm]
min. screw length: sandwich element thickness or trapezoidal profile height + anchor length + min. 10mm min. screw length: sandwich element thickness or trapezoidal profile height + anchor length + min. 20mm
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EJOTÂŽ Flat Roof Solar Fastening System The simple and reliable solution to allow additional installations on your flat roof on a sustained basis.
Applications: q Basic system for installations on flat roofs, such as: - Mounting systems for solar and photovoltaic installations - Assembly and maintenance walkways - Air conditioning units, switch boxes, etc. q Suitable for: - Membrane systems - Bitumen systems - All common insulating materials - Unloading of waterproofing and insulating layers with low bearing capacity - Substructures with trapezoidal profiles, wood or concrete
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* edged from 250 mm side length onwards
EJOTÂŽ Flat Roof Fastening System
All advantages at a glance
q Load transfer directly into the load-bearing section q No additional compression load on the roof membrane and the thermal insulation q Ideal alignment of the mounting system for solar installations independent of: - the crown alignment of the trapezoidal profile on the substructure - the location of the building q Simple adjustment of unevenness and small height differences e.g. regarding the positioning of mounting systems for solar installations q Suitable for retrofitting q Simple, fast and clean installation q Secure sealing of the roof membrane and diffusion layer q No corrosion through usage of stainless steel and aluminium
Note: The adhesive has to be matched to the roofing membrane and it must be suitable for the application. Thoroughly clean the respective area of the roofing membrane before applying the adhesive. Apply the adhesive generously.
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Installation:
Product range: q Thickness of the insulating layer up to 240 mm q The base plate is designed for the existing substructure - Trapezoidal profiles - Concrete q Use of proven EJOT fasteners for anchoring into the substructure
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Questionnaire EJOTÂŽ Flat Roof Solar Fastening System
Our application engineers will gladly assist you in dimensioning the EJOT Flat Roof Fastening System for your project. Please fill in the questionnaire and send it to: Fax +49 27 52 908-731 or e-mail: solar@ejot.de.
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EJOTÂŽ Solar Fastener FD With the EJOT Solar Fastener FD it is finally possible to securely fasten mounting systems for photovoltaic modules on flat roofs (e.g. plastic pans, or suitable metal mounting systems) against wind suction without using ballast. Until now, the usage of additional ballast on flat roofs often exceeded the remaining bearing capacity of the roof. The innovative fastening system of the EJOT Solar Fastener FD prevents mounting systems from lifting and ballast for the systems is no longer required. It is now possible to equip numerous existing flat roofs by using this solution.
Features q q q q q q q q q q
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Light system to absorb tensile forces from wind suction Secure attachment with self-drilling screw EJOT JT3-2H-6,0 x 25 with trapezoidal profile substructure Calculation of the allowed tensile forces in accordance with the building authoritiesâ&#x20AC;&#x2122; approval Z-14.4-426 Protection against shifting (due to shear forces), e.g. in combination with the EJOT Flat Roof Fastening System The EJOT Solar Fastener FD is suitable for various types of plastic membranes (e.g. PVC, FPO, TPO, EPDM and EVA) Easy and simple sealing due to usage of EJOflex sealing material in combination with additional mechanical clamping process of the membrane Suitable for insulation thickness of approximately 250 mm (self-supporting insulation e.g. PS) Attachment of additional components on protruding threaded part (M10) and individually recommended adaptation for respective plastic pan/mounting system The adjusting spiral is pre-mounted to the individual insulation thickness but can still be adjusted to the optimal position Corrosion resistant system
Variants: Internal hex drive A/F 5 Threaded part M10
Adjusting spiral
Pressure plate
Sealing washer Self-drilling screw
EJOTÂŽ Solar Fastener FD
All advantages at a glance
q Fast and ballast-free installation q Secure absorption of wind suction forces due to attachment with trapezoidal profile substructure q Secure sealing of roofing membranes q Additional counter surface for improved mechanical clamping of the membrane (collar of the adjusting spindle below membrane) q Automatic fastening of adjusting spiral into the roofing membrane during installation process q Minimum opening of membrane during installation q One-stop-shop â&#x20AC;&#x201C; fastener and sealing system in one set q Integrated sealing of diffusion layer due to pre-mounted sealing washer q Applicable for all common plastic roofing membranes
Note: For further information and installation details regarding EJOflex sealing material, please read our installation manual and technical data.
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EJOT® SUPER-SAPHIR self drilling screws Features: q Hexagon drive or TORX® q Free Spin Zone under the head facilitates longitudinal joints q Small dead centre prevents misalignment on the component surface q Galvanised steel sealing washer or stainless steel with vulcanised elastomer. Excellent atmospheric and UV-resistance.
Product versions: EJOT Self-drilling screws
SUPER-SAPHIR JT3
Advantages: q q q q q
Connect components in one step Drilling, thread-forming and fastening Decrease assembly times Save tool changes and costs for drilling tools Available with captive sealing disk upon request
Approvals: Many EJOT products are building authorities approved or a general building authorities test certificate is available. The approved and tested products are marked.
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Screw material
A2 stainless steel with hardened drill point
For components made of
steel or aluminium
Building authorities approved
Ü
Max. drill capacity mm
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Product range: EJOT® SUPER-SAPHIR Self-drilling screw JT3-2-6,0 J3 APPLICATION RANGE • For fixing profiled sheets with/without intermediate insulation to thin-walled steel / aluminium substructure as well as timber substructure Ø mm
Length mm
Clamp thickness mm
Sealing washer E16, Ø 16 mm 6.0 25 0-7
PU
Order description
500 JT3-2-6x25-E16
Part number
3595511321
APPROVAL Z-14.4-426 Z-14.1-537 FEATURES • A2 stainless steel with hardened drill point • Stainless steel sealing washer • Pre-assembled sealing washer TECHNICAL DATA Drilling capacity tI + tII ....................................1,0 + 1,0 mm Drive ............................................................ hexagon A/F8
Note: Other dimensions or variants are available in the EJOT Building Fasteners product portfolio.
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DEKTITE® Flashings for Cables The DEKTITE® flashing enables a perfect sealing of cable or pipe feed throughs on roof or facade. Through the flexible rubber pleats thermal changes in length of the pipes or sheathing elements are not constricted. Fatigue fractures, which might occur with rigid cable/pipe feed throughs, are impossible with DEKTITE flashings.
Features: q q q q
Standard dimension for cable bundle or pipe diameters of up to 610 mm Weather resistant through the construction industry proven EPDM Unsusceptible to UV-radiation Adaptable to all roof profiles
Advantages: q Long lifetime q Thermal stability:
for a short time up to +150° C continuously up to + 115° C q Special solutions for higher temperatures upon request q Low-temperature resistance: up to - 50° C q Flexible adjustment - to different profiles - to all pipe materials - to pipe and cable bundle diameters up to 610 mm
Note: When using the DEKTITE® flashing, amongst others, the specifications of the DIN 18807 have to be considered. Pipe/Cable flashing may not be installed in the vicinity of horizontal or longitudinal joints.
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Variants: Absorbtion of the load through two flexible pleats
Easily identifiable pipe/cable bundle size Flexible conical sleeve Low profile
Improved watertightness
Large base Embedded aluminium frame
No twisting of the cone
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Product range: Dektite® Square Pipe Flashing Installation Kit APPLICATION RANGE • For waterproofing pipes on corrugated metal roofs • For waterproofing pipes on corrugated fibre cement roofs ADVANTAGES • Perfect seal on roof and facade • No interference of thermal elongation of pipes • No fatigue fracture NOTE Use Bulbtite rivets for corrugated fibre-cement sheets KIT INCLUDES 1 pipe flashing 1 cartridge of EJOPLAST joint sealant 1 EJOT® self-drilling screw set / optional EJOT® Bulbtite set
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For pipe Ø mm 0 - 35 5 - 55 5 - 120 110 - 170 160 - 220 160 - 300 290 - 440
Base mm 99 x 99 137 x 137 218 x 218 284 x 284 365 x 365 453 x 453 581 x 581
Roof Cartridge pitch capacity ° ml 0 - 60 80 0 - 35 80 0 - 35 80 0 - 35 80 0 - 35 80 0 - 35 310 0 - 35 310
Screws pcs. 8 8 16 20 28 32 40
PU 1 1 1 1 1 1 1
Order description
Part number
DFE 0-35 DFE 5-55 DFE 5-120 DFE 110-170 DFE 160-220 DFE 160-300 DFE 290-440
8200004704 8200104704 8200304704 8200404704 8200604704 8200704704 8200904704
Assembly Instruction
1. Adjust Dektite速 to the pipe or cable bundle
2. Adjust Dektite速 to the profiled sheet and mark
4. Adjust Dektite速 to the shape of the profiled sheet
5. Fasten Dektite速 with EJOT self-drilling screws or Bulbtite rivets.
3. Apply sealant
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Accessories: EJOPLAST Joint Sealant APPLICATION RANGE â&#x20AC;˘ For sealing the pipe flashing FEATURES EJOPLAST is a single-component universal sealant based on polycarboxylic acid copolymeric base. EJOPLAST adheres to all conventional materials such as steel, aluminium, copper, brass, glass, wood, ceramic, bitumen, concrete, masonry, plaster, plexiglas, tiles, roof tiles, polyester, roofing paper, etc. Smooth, non-porous substructures can even be wet, while porous surfaces should be dry. EJOPLAST can be cleaned with standard cleaning agents, but not with solvents. EJOPLAST hardens through the evaporation of solvents and is impervious to water from the beginning because it forms an immediate skin. The surface is adhesive-free after 20-30 minutes (depending on temperature), likewise immediately after contact with water (e.g. by planing).
Contents mm 80 310
Colour clear clear
PU
Order description
1 EJOPLAST 80 mm clear 1 EJOPLAST 310 mm clear
Part number 8200003000 8200001000
EJOTÂŽ Hand gun
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Order description
Part number
Hand gun
9559942000
Accessories: EJOT® Hose clamp
APPLICATION RANGE • A reliable seal between pipe and pipe flashing INSTALLATION NOTE Pierce the marking for the clamp or cable tie at the joint, pull through, place around the Dektite® Retrofit and close.
For pipe diameter mm
PU
40 - 60 60 - 80 70 - 90 90 - 110 110 - 130 130 - 150
1 1 1 1 1 1
Order description
Part number
Hose clamp 40-60 Hose clamp 60-80 Hose clamp 70-90 Hose clamp 90-110 Hose clamp 110-130 Hose clamp 130-150
8200006300 8200008300 8200009300 8200011300 8200013300 8200015300
EJOT® Universal hose clamp
APPLICATION RANGE • A reliable seal between pipe and pipe flashing FEATURES • For diameters from 150 mm onwards ORDER NOTE Universal hose clamp consisting of tightener and universal cable tie. Length of universal cable tie ≥ pipe circumference + 50 mm Width mm 7
PU 1 1
Order description
Part number
Tightener Cable tie
8200077300 8200076300
INSTALLING THE CABLE TIE Tip back the hinged screw in the tightener, insert one end of the universal cable tie through the clamp lock and twist about 15 mm. Place universal fastener strap around Dektite®, insert through the tightener and tighten by hand. Hinge the screw inwards and tighten as far as possible with a screwdriver.
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EJOT® Tools and Accessories
Hexagon Driver Bit FEATURES • External hexagon drive as per DIN 3126 Type and size TECHNICAL DATA Drive ................. external hexagon drive 1/4“≈ 6,3 mm
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A/F 5
Drive C
Length in mm Order description 25 Hexagon A/F 5-1/4"/Cx25
Product range:
Precision drill bit HSS Form S APPLICATION RANGE • For structural steel Ø mm Form S 4.5 4.5 4.5 5.5 5.5 5.5 5.5 5.5 5.5 6.8 6.8 6.8 7.0 7.0 7.0 7.0 7.2 7.2 7.2 7.2 7.4 7.4 7.4
Length mm
Rotation speed Order description rpm
60 125 175 65 95 125 175 220 250 75 175 225 75 125 175 225 75 125 175 225 125 175 225
900 900 900 750 750 750 750 750 750 600 600 600 600 600 600 600 600 600 600 600 600 600 600
Bohrer S 4,5/60 Bohrer S 4,5/125 Bohrer S 4,5/175 Bohrer S 5,5/65 Bohrer S 5,5/95 Bohrer S 5,5/125 Bohrer S 5,5/175 Bohrer S 5,5/220 Bohrer S 5,5/250 Bohrer S 6,8/75 Bohrer S 6,8/175 Bohrer S 6,8/225 Bohrer S 7,0/75 Bohrer S 7,0/125 Bohrer S 7,0/175 Bohrer S 7,0/225 Bohrer S 7,2/75 Bohrer S 7,2/125 Bohrer S 7,2/175 Bohrer S 7,2/225 Bohrer S 7,4/125 Bohrer S 7,4/175 Bohrer S 7,4/225
Part number
9250434000 9250435000 9250436000 9250420000 9250421000 9250422000 9250408000 9250423000 9250492000 9250430000 9250680175 9250510000 9250440000 9250499000 9250500000 9250493000 9250442000 9250504000 9250505000 9250494000 9250506000 9250507000 9250497000
ADVANTAGES • Special polish to ensure high drilling capacity in case of low drilling pressure • Short chip flute • Insensitive to breaking FEATURES • Long service life
SDS-plus hammer drill bit APPLICATION RANGE • For masonry, concrete, natural stone, artificial stone etc. Ø mm
Effective length mm
10 10 10 10
100 200 300 400
Total length Order description mm 160 260 360 450
SDS-plus 10/160 SDS-plus 10/260 SDS-plus 10/360 SDS-plus 10/450
Part number 9200000034 9200000047 9200000049 9200000050
ADVANTAGES • For fast dust removal • Assured for service life and performance
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EJOT Baubefestigungen GmbH In der Stockwiese 35 57334 Bad Laasphe, Germany
403-GB/1/10.12
phone +492752908-0 fax +492752908-731 e-mail: solar@ejot.de Internet: www.ejot.com