This article is sponsored by Roof Tech. In this VOICES interview, Solar Power World spoke with Guy Wellman, Director of Sales for Roof Tech, about how field-proven waterproofing, flexible flashing and repair-ready mounting solutions are helping installers improve long-term solar reliability. Wellman shared insights on AlphaSeal® flexible flashing, the importance of real-world product performance, the growth of repair and reinstall projects, and how manufacturers can better support installers through training, guidance and decades of field experience.
Solar Power World: How AlphaSeal® flexible flashing helped Roof Tech achieve one of the strongest waterproofing track records in the solar industry.
Guy Wellman: AlphaSeal® has been a big part of that track record because it changed the way people think about flashing. A lot of people assume Roof Tech is flashless, but that is not really accurate. We use flexible flashing.
AlphaSeal® is a butyl-based compound and has been part of the same screw and AlphaSeal configuration Roof Tech has used for more than 30 years. In that time, we have had zero leaks outside of human error across roughly 30 million penetrations in North America and about 300 million penetrations between Japan and North America. That history is what gives installers confidence.
The system is designed to create a watertight seal at the point of contact. The screw is a double-helix, double-threaded screw, and as it goes through AlphaSeal®, it pulls the material into the void created by the penetration. So, as the hole is being created, the system is also sealing the hole.
The waterproofing record comes from that combination of the material, the screw design and the amount of time the system has been proven in the field. In my nearly eight years with the company, when we have been contacted about a leak concern, it has always turned out to be something outside of the Roof Tech product. Things like an existing roof issue, prior leak or improperly vented attic space.
What separates field-proven solar mounting systems from products that only perform well in laboratory testing, and why does long-term reliability matter more than ever today?
The crucial difference is the time in the field. Lab testing is important, and we absolutely do that. Before our products even go out for third-party testing, they undergo in-house testing at our parent company, Yanegiken. We test wind, rain and other conditions and try to recreate the conditions the product will see on a roof.
A lot of times, someone will say, “We have a mock roof in our office or warehouse, so we can do the training there.” And that can be useful, but everything usually works well in that kind of controlled setting. There are not many surprises.
But the field is different. Once you are on a real roof, you are dealing with real conditions, different roof types, crews, weather and jobsite challenges. Those are the things you cannot fully recreate in a lab or on a mock roof.
We have had outdoor testing since the company’s early days, and new products are constantly put through that kind of real-world exposure. By the time something is in the market, we are not just relying on what happened in a controlled environment. We are looking at how the product performs when it is exposed to the elements.
That matters more today because installers and homeowners are making decisions that must hold up for decades. These systems are expected to remain on roofs for a long time, and the mounting system must be able to support them.
We have had products on roofs in places like Nova Scotia, where hurricanes have gone through, and we have had zero issues. It is the same in places like Miami and other parts of Florida, where storms and hurricanes are part of the environment. We have a lot of products installed in those areas, and they have continued to perform.
Why are repair & reinstall (R&R) projects rapidly growing, and how can installers reduce labor, hardware waste and redesign time by reusing existing rails and L-feet during reinstallation projects?
R&R work is growing because solar has been around long enough that many systems are reaching the point where the roof beneath them needs maintenance. Some systems have been installed for 25 or 30 years, and in many cases, the roof was never going to last that long.
Sometimes it is just normal roof aging. Sometimes it is storm damage or hail damage. But once that roof has to be replaced, the solar system has to come off and then go back on. That can create a lot of extra work for installers. They must figure out which racking system is already on the house, who made it, whether that company is still around, whether replacement parts are available and how to get them.
That is where we see an opportunity to make the process easier. With our RT-MINI II, for example, it can work with anybody’s L-foot and rail. Instead of replacing the entire racking system, an installer can reuse the existing rails and hardware, add new feet, and give the homeowner new leak protection.
For the installer, it reduces the amount of research and redesign work they must do. If the system has a standard L-foot, they know they have a path forward with Roof Tech. For the homeowner, it can reduce the cost because they are not being told they need to buy an entirely new racking system to put the modules back on the roof.
It also cuts down on waste. If the existing rails are still usable, there is no reason to throw all that hardware away. The installer can reuse what is already there, move faster on the job, and still provide new leak protection with a new warranty.
With the RT-MINI II, they can reattach to existing hardware, and with the RT-PLUS®, which is a fixed L-foot, there are cases where we can attach to the existing cradle that connects to the rail. Either way, the goal is to make R&R work faster, cleaner, and less wasteful for installers and homeowners.
How can manufacturers better support installers during uncertain economic and policy conditions?
The biggest thing manufacturers can do is stay close to installers. That means continuing education, making sure they understand the product, and that it is being installed the right way.
This is important because it only takes one person to explain something incorrectly, and then that incorrect information can keep getting passed down. Manufacturers have to keep revisiting training, keep answering questions and ensure installers understand both how the product works and where its limits are.
We talk a lot about supporting installers at Roof Tech. Our products can be installed on many different roof types, but that does not mean every situation is the right fit. We will be the first ones to tell an installer, “You should not install it this way,” or “This application is not compatible.” That honesty matters, especially when installers are trying to move quickly and manage costs.
During uncertain economic or policy conditions, installers need manufacturers they can rely on for product availability and guidance. They need to know what will work, what will not work and how to avoid problems later.
For Roof Tech, much of that support comes down to experience. Flexible flashing is becoming more common, especially in the U.S., and more manufacturers are moving in that direction. But many of those products have not been in the field for very long.
We have been doing this for decades across North America and Japan, with a very large number of roof penetrations to our credit. That kind of experience helps us support the installer. We can tell them what we have seen in the field, what works, and where they need to be careful. This kind of support installers need when the market is uncertain.
Since 1994, Roof Tech has delivered field-proven solar mounting solutions trusted by installers across North America and Canada. From our industry-leading AlphaSeal® flexible flashing system to repair-friendly mounting systems like RT-MINI II and RT-PLUS, our products are designed to reduce callbacks, simplify installations, and protect roofs for the long haul. Learn more about smarter waterproofing and repair-ready solar mounting solutions at www.Roof-Tech.us or contact our team to request samples, training or product information.