Sika SolaRoof Systems and Services for Flat Roof Solar Energy Installations

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1 Sika SolaRoof Systems and Services for Flat Roof Solar Energy Installations

2 Sika s Involvement in the Solar Energy Business Pohlen-Solar GmbH 2

3 Sika s Activities with Photovoltaic Technologies (PV) The focus of Sika s Solar Energy activities is with Photovoltaic (PV) related technologies. The special Sika products, systems and services for this sector are all integrated under the Sika SolaRoof brand. Other solar technologies, such as those involving Concentrating Solar Power (CSP) and Solar Thermal energy (ST), are not part of Sika s Roofing activities. PV Photovoltaic Energy As the leading global manufacturer of both liquid applied and sheet roof waterproofing membranes, Sika has had a strong focus on Roofing for many years. PV installations on flat roofs are an important part of the trend to cleaner energy production and can make an attractive investment for many building owners. When these systems are professionally designed and installed they can give outstanding customer benefits, not least through significantly reducing their energy costs and even a financial return through the various Feed in Tariffs (FIT) available. This brochure is intended to give you an overview of Sika s solutions and services for high performance solar roofs, which have been developed from more than 50 years experience in Roofing and more than 10 years experience with PV systems. This includes guidance on the typical processes involved in designing and installing a PV roof project and how to find the optimal solution for your long term satisfaction. CSP Concentrating Solar Power Content ST Solar Thermal Energy Suitable Roofs for Photovoltaic Installations 4 Roof Analysis / Condition and Local Influences 6 Financial Considerations 8 PV Selection Guide: Mounting Systems and Installation 10 PV Selection Guide: Cell Technology 12 PV Selection Guide: Panel Technology 14 The Sika Solar Parks: Practical Long-Term PV Experience 16 Sika Roofing Solutions for Exposed Roofs 18 Sika Roofing Solutions for Ballasted Roofs 20 Sika s Roofing Experience and Possibilities 22 Sika s Range of Accessories for Roofing 24 PV and Roofing Guarantee 26 Sika Support for Your PV Project 27 3

4 Suitable Roofs for Photovoltaic Installations Pitched Roofs The shapes of this roof type and pitch varies according to their environment and tradition from region to region. The materials of the outer layer that provide the primary waterproofing function are usually traditional roof tiles, slates or shingles, but also sheet roofing systems are common for non-domestic buildings. Most traditional building roofs are constructed from relatively small individual roof tiles / units, which combine to provide good durability with minimal maintenance. A pitched roof with the right orientation can frequently provide a good location for PV installations because there is natural drainage of water. The slope of the roof and its orientation has a great influence on the selection of the most appropriate PV system. Basically a PV system could be installed on every pitched roof, but its performance will be strongly dependant on its orientation. Roof orientation is the most important factor rather than the slope: orientation towards the south has a more positive influence than any optimized tilt angle of the panels, which usually simply corresponds with the roof slope. The installation of a PV system can therefore be made to most pitched roofs, be it as an addition to the roof or as an integrated component, which then also has a waterproofing function. There is a variety of different PV system fixing solutions available on the market and it is important that they are designed for at least the same life expectancy as the PV panels selected. Roof tiles Metal roof Corrugated fibre cement roof Sika s focus is on large exposed or ballasted flat roofs, often in industrial areas. 4

5 Flat Roofs Even in regions which are not exposed to extreme levels of year round sunlight (e.g. Central Europe) it would be possible to generate huge amounts of energy, if all roofs were to have PV installations. There are vast areas of retail and distribution centres, warehouses and industrial buildings etc., with many millions of square metres that are not utilized for this purpose today. It is a sound and sustainable idea to use these roof areas as a base for Photovoltaic power plants. The most efficient PV installations are also possible on flat roofs, this is because of the much larger areas involved and the economic advantages of scale on these larger installations. The following are the most common types of flat roofs that today generally have efficient single-ply roof waterproofing membranes, whilst bituminous roofs still make up the largest percentage of existing and older flat roofs. Sika is your most competent partner when it comes to selecting the flat roof buildup and system that is durable and to meet your PV system requirements. Exposed Roofs On these roofs the membrane is either mechanically fastened or adhered to the substrate according to the build-up. Adhered membranes can be fully or partially adhered dependent on the system selected. Mechanically fastened membranes can be spot or linear fastened. Ballasted Roofs Due to the nature and large weight of soil, aggregates, gravel or paving used on top of the waterproofing membrane, the substructure needs to be solid to support this load and is therefore usually reinforced concrete. The standard classifications of ballasted roofs are: Gravel Ballasted Roofs Green Roofs Utility Roofs Exposed roof Green roof Utility roof The main waterproofing membrane layers for these types of roofs are polymeric sheets (FPO / PVC / EPDM), liquid-applied membranes or traditional bituminous products. 5

6 Roof Analysis / Condition and Local Influences Assessment of the Roof Condition Photovoltaic installations are cost intensive applications. Usually the aim is that they should perform for at least 20 or more years, which also has durability and other implications for the substrate they are to be positioned on. These requirements can be considered for two different situations: PV installation on a new roof construction PV installation on an existing roof that needs to be refurbished / upgraded The following table details the main factors that need to be carefully evaluated in the earliest stages of design for each of these situations. Structural capacity of the roof for a PV system The waterproofing layer Thermal insulation layer under the waterproof membrane Lightning protection Water drainage PV installation on a new roof construction The roof must be designed so that it is able to support a ballasted PV system. Have future changes of structural codes in mind and plan accordingly with reserve load capacity. Design for easy and secure fixing of the PV system. The most suitable and long-lasting waterproofing membrane system can be selected from Sika s extensive range of proven single-ply and liquid applied materials. The most efficient and best suited thermal insulation layer should be selected. Consider the Compressive load due to the PV installation, as well as the local fire regulations. A modern lightning protection system needs to be designed and installed by specialists familiar with the needs of the building and the PV system. Especially with PV systems integrated into the roof waterproofing membrane, it is mandatory to avoid standing water on the roof. PV installation on an existing roof Evaluate the maximum load capacity of the roof. Check with the responsible structural engineer in existing drawings and also make calculations according to the latest structural codes. Strengthening may also be an option (Sika also have expertise in this field) (Consider the PV installation and mounting system at the same time) Qualified personnel must carefully evaluate the condition and the remaining life expectancy of the existing waterproofing layer. Consider localised load influences of different PV systems. A new membrane can be the right solution Old buildings were frequently not insulated according today s standards. Usually in these instances the waterproofing layer is also not sufficient anymore and must be replaced, together with new thermal insulation. Take the opportunity to save future heating energy It is likely there is already a lightning protection system installed on the roof, however it usually it cannot be used with the PV system without modification. A new lightning protection system is a must A sound roof and adequately draining slope has to be ensured Consider adding the optimum slope with specially shaped insulation 6

7 PV panels on a snow covered flat roof Local Influences Next to the roof design and condition analysis, it is also an important task to check the local site conditions. Dependent on the specific buildings location and roof orientation, there can be situations where a PV installation does not make sense i.e. Shade: The best sun radiation is no guarantee for power output from panels that are mostly in the shade Always check early in the design process Weather: Sun irradiation has the main influence on the energy generation Not single peaks but the annual average Pollution: Dependent on the environment the PV panels can get dirty quickly if this is a possibility consider a regular cleaning / maintenance regime Snow, wind and hail For most countries there are now published wind zone maps. These map zones of comparable wind speeds as parameters for the calculation of the maximum roof load together with the height above sea level, the height of the building itself and the roof shape. Frequently a project specific analysis needs to be undertaken to get local approval for the installation of a PV plant. Snow load may also need to be considered, the base for this is a snow zone map as pro- Wind zone map for germany Up to 120 meters above sea level Wind zones: 1-4 Snow zones: 1-3 Up to 510 meters above sea level Wind zones: 1+2 Snow zones: 1-3 Up to 710 meters above sea level Wind zones: 1+2 Snow zones: 1+2 Centrosolar CENPAC Above the 3 specified regions duced in regions where this is a requirement. Restrictions may also apply dependent on the on PV panel type and the roof build-up. Finally hail has also to be taken into account, which is again dependent on the location. Shading and pollution Shading from chimneys, vent pipes and other plant or equipment on the roof can lead to substantial power generation losses compared to the initial calculations. Shading on a single panel can affect the performance of a whole system if it is connected in series. It is also important to have a look at the closer environment; small trees can grow fast and within a few years cause significant shading. There are specialized optical analysis instruments available which can calculate the annual development of shading in a specific location, together with its potential influence on the PV energy production. Pollution in or from industrial areas can be a reason for unwanted dirt pick-up on lightcoloured surfaces. This is not helpful in situations where the light reflective membrane is designed to contribute to the energy generation process. There is no method available for the prediction of the soiling rate to inspect and evaluate existing nearby roofs is usually the best solution. 7

8 Financial Considerations Case A) Investment in a PV Installation and a New Roof Earn the Maximum Return from Your Roof Investment When investment in a PV installation is considered then this is always about the long term. Depending on if the PV plant will be installed on a new roof, or on an existing roof, the processes are slightly different and the consequences concerning the financial aspects are high. This is shown in the graph below, which lists all of the investments and returns during the anticipated life of the PV plant. Choosing a cost-optimized system of PV installation and Roof waterproofing membrane ensures a long-lasting PV cash machine. The slight degradation of the PV panels performance over time is dependent on the PV technology selected; usually the panel producers will guarantee an output of >80 % after 20 or 25 years. Our experienced partner companies will monitor the installation and conduct regular maintenance in order to maximise output and avoid any expensive surprises. Financial returns are more and more important, so consider only PV systems which are supported by the Power Companies. Depending on the country, Feed-in-Tariffs (FiT) can be paid for up to 20 or 25 years, although in some countries grid parity will soon be reached and the most attractive FiT may disappear. However, even after this time, the PV plant will still produce energy that can continue to be sold or consumed. A single source of responsibility for your new roof and PV system is the best approach. Reliable partners for a secure investment at a fixed cost are the key for success. Return on Investment Income according to FiT* / self consumption Operation + Maintenance Income on Extended Operation (no more FiT) Optimized Investment in Roofing / Waterproofing Optimized Investment in Solar PV Installation Return on Investment * Feed-in-Tariff (duration depending on country) Years of operation Investments 8

9 Case B) Investment in a PV Installation on an Existing Roof If the PV plant is to be installed on an existing roof, then the build-up and waterproofing system needs to be assessed to ensure that it can remain for another 20+ years without major deterioration. This is to avoid the unpleasant situation of the Roof membrane needing to be replaced during the lifetime of the PV installation. The consequence of this would be the temporary removal of the PV installation, a certain period without energy generation, new waterproofing application and finally the re-installation of the PV panels with their mounting system. All this extra work has a tremendous influence on the Return on Investment. The graph below illustrates how the cash flow looks in a situation where the roof has to be replaced in year 12. The difference in the financial output at the end of life for the PV installation is mainly based on the cost of dismantling and re-installing the PV plant, plus the loss of energy generation within the period of re-roofing. There are some BAPV (Building Applied PV) solutions which can more easily be temporarily taken from the roof, e.g. ballasted ones. However this gets much more difficult when the mounting structures are mechanically fixed to the sub-structure by penetrating screw fasteners. MIPV (Membrane Integrated PV) is the worst case in this situation because dismantling and re-use of the bonded laminates is not possible, at least with single-layer installation. Therefore the roof waterproofing system and the build-up also need to be taken into account when evaluating a PV investment. Return on Investment Income according to FiT* / self consumption Operation + Maintenance Income on Extended Operation (no more FiT) Investment in Roofing / Waterproofing Investment in Solar PV Installation Return on Investment * Feed-in-Tariff (duration depending on country) Dismantling and Re-Installation of PV Plant D ROI Years of operation Investments 9

10 PV Selection Guide: Mounting Systems and Installation Roof Load Capacity What are the main decision factors in the selection of the best type of PV installation? After having checked the roof build-up with the responsible structural engineer and the meteorological location according to local standards, the load capacity for a PV system installation on the roof is known. It is then important to check the fixing possibilities for the PV installation on the specific roof in question. The additional wind loads can be very high and these need to be kept under control by either ballasting or fixing the PV system to the roof structure. Ballasting is a heavy weight option, especially with tilted panels, because without additional aero dynamic measures they will catch the wind. On the other hand attachment with screws to the metal, wooden or concrete structure creates penetrations which are not always desirable. BAPV: Building Applied PV BAPV installations always include a mounting structure on the roof. This can be a metal profile (rack system) or a plastic (pod) system. Fixing to the roof is usually made with screws into the substructure, but penetration of the waterproofing membrane is the main disadvantage of this approach. Ballasting is the other option which does not harm the membrane, but requires a higher roof loading capacity and a higher level of thermal insulation compression strength. In recent years more and more aerodynamic mounting structures have been developed and introduced to the market. Some of these do not need to be ballasted and are therefore even suitable for use on lightweight steel deck structures with limited extra load capacity for a PV plant. Another trend is to bond or weld the mounts directly to the Roof waterproofing membrane. Many different parameters need to be considered in developing the design of a PV installation. A tilted BIPV solution does not necessarily harvest the highest amount of energy throughout the whole year on a specific roof. Tilted panels can also create some shading, a minimum aisle width between the rows of panels therefore has to be ensured. Large tilt angles and wide aisles can be less efficient than a low-tilt installation, which is not the optimum but has a reduced loss of panel area and achieves superior overall output. Shaded PV Panels Metal mounting system Sika SolarMount system Ballasted plastic pod system Centrosolar 10

11 Important Considerations for Mounting Systems The PV panel and installed system incentives have drastically reduced during the last few years in some countries. The cost of the mounting systems within the overall system costs is therefore under a lot of pressure. The easier the mounting system is to install therefore, the better are the chances of success. The optimization of the whole system logistic chain is therefore required in addition to a reduction in installation time. The complete electrical installation needs to be undertaken carefully to avoid damage due to future water ingress and to prevent any fire risk. Fixing the Mounting structure to the Roofing membrane is key for long term durability: Secure positioning, no sliding of the mounting on the roof 100 % compatible materials in an integrated system to avoid long term damage No mechanical stress imparted to the membrane due to differential thermal expansion coefficients BIPV: Building Integrated PV Photovoltaic systems built into the roof or walls (the façade) of a building are called: Building Integrated PV, or BIPV. A sub-category is MIPV which stands for: Membrane Integrated PV, in which Membrane refers to the roof waterproofing membrane. BIPV is therefore part of the building envelope and often defined as needing to provide secondary functions other than just PV. For example this could be the primary waterproofing function, or the PV cells can be semi-transparent and integrated into skylights or other areas. Next to roof load and aesthetics BIPV installations are often selected due to the fact that in many countries there are better feed-in tariffs for semi or fully integrated Photovoltaic systems. MIPV: Membrane Integrated PV The roof load of MIPV systems can be just fractions of BIPV systems. Their aesthetic impact on a buildings appearance is also minimal, as they are usually not visible thanks to their integration into the Roof membrane. MIPV applications require flexible PV panels or laminates, because Roof membranes are obviously not rigid and can also be deformed in use by wind uplift forces etc. Durability aspects are the main challenge when it comes to MIPV due to the need for thin, light-weight and flexible polymer films to produce the laminates, including their encapsulation. Roof installation in parallel (semi-integrated) Membrane integrated PV 11

12 PV Selection Guide: Cell Technology Efficiency and Output per Area A PV or solar cell is the semiconductor device that converts sunlight into electricity. They need protection from exposure to the environment, such as by encapsulation. What are the decision factors for the selection of the right PV cell technology for a project? In situations with limited available roof space for the PV system: then the cell type leading to the highest annual output is always preferred If there is ample roof space available: then the PV system with the lowest cost and maintenance requirements can be more suitable Crystalline PV Cells Facts Crystalline cells have the longest track record of PV cells and are very reliable and durable. There are 2 main types of crystalline cells poly-crystalline and mono-crystalline They are produced by sawing larger blocks into thin structures, known as wafers The consumption of active PV material when compared to thin-film systems is much higher due to their thicker layers Poly-crystalline cells Mono-crystalline cells Main characteristics They have a characteristic speckled blue appearance. The efficiency of poly-crystalline cells is Usually slightly lower than for mono-crystalline cells. Their appearance is matt and blackish in colour. Special developments with back contacts allow the highest performance. Bi-facial cells can generate energy at both the front and rear sides, thanks to reflectance from the substrate. Relative cell efficiency High High Area required per unit output Small Small Dependency on operating temperature High (the cooler the better) High (the cooler the better) Performance at low light Conditions Medium Medium Sensitivity to moisture Low Low Panel type available Rigid Rigid Other Cell Technologies are in the Development Phase in many Laboratories (including Organic Cells and Dye-sensitised Cells). 12

13 Flexcell Durability, Market Experience Crystalline cells and PV panels made with them are the PV products with the longest track record. This experience now covers more than 20 years and some of the earliest installations are still operating successfully. Durability is therefore an important additional factor which has to be taken into account when selecting a PV system. This fact is more and more important when it comes to the financing of a PV installation. A guaranteed financial return is often limited to a small number of PV products from a few producers with long experience and rigorous quality management systems. Thin-film PV Cells Facts The Cells are produced by the deposition of photovoltaic active semiconductor layers onto flexible or rigid substrates. Typical substrates are temperature resistant and can be steel, glass or polymeric sheets. Substrates can be rigid or flexible. Some of the active layers are very moisture sensitive. Reliable and proven encapsulation is therefore crucial to achieve the required durability. They are flexible concerning shape (surfaces don t need to be even) and transparency (e.g. for façade application). CdTe cells CIGS cells Silicon based cells A cadmium telluride film is deposited onto a glass panel. Overall production experience is above 5 years A Copper-Indium-Gallium Selenide layer of is deposited onto a glass sheet or high temperature resistant polymer film. Their high sensitivity to moisture requires perfect encapsulation. Amorphous silicon (a-si) layers can be deposited at low temperatures, which allows the use of standard polymers. Tandem cells have an additional micro-crystalline absorber layer to increase their efficiency by about 20 %. Medium Medium Low to medium Medium Medium Medium to large Low Medium Low Medium Medium High Medium High Low Rigid Rigid, flexible Rigid, flexible Most of these are not yet commercially available for Roofs and therefore are not shown in the illustrations above. 13

14 PV Selection Guide: Panel Technology PRAMAC Mounting Solutions and Ventilation A PV panel or laminate is the installation ready assembly of individual cells, including their encapsulation for protection against environmental influences. The first decision is related to the Installation i.e.: can a rigid panel be used, or is the roof limited to a low-weight flexible laminate? The range for the roof load for a traditional BAPV installation is from ca. 15 up to 100 kg/m 2 whereas a MIPV solution is only about 5 kg/m 2. The second decision is the selection of the cell type. This is dependent on the mounting situation and possibilities. A tilted BAPV installation usually offers the possibility of natural ventilation for the panel, which is mandatory for the efficient use of crystalline panels. If this is not possible, then a thin-film wafer based panel, especially silicone or tandem, may be the best choice. A) Centrosolar Rigid PV Cell technology Crystalline A) Bifacial Cells B) CdTe C) Panel efficiency (commercial Panels) High (13 20 %) High (15 18 %) Medium (ca. 11 %) Market experience High (>20 Years) Low (< 5 Years) Medium (> 5 Years) Panel weight per area High (12 15 kg/m 2 ) High (ca. 18 kg/m 2 ) High (ca. 17 kg/m 2 ) B) Panasonic Encapsulation Front: glass, back: polymer (or glass), edge sealed Front and back: glass, edge sealed Front and back glass, edge sealed Natural ventilation recommended? Yes Yes No Installation possibilities On any metal or polymeric mounting Special racks with minimized shading loss BAPV or BIPV Framed or unframed panels? Both Framed Unframed C) First Solar FS Series 3 14

15 United Solar Weight and Appearance There are roofs with an available load capacity that is simply not enough to allow the installation of a BAPV solution, even an aerodynamic lightweight version. The use of membrane integrated laminates can be the only possible solution in such situations. Additional wind loads are not induced by this type of installation. Nevertheless it needs to be confirmed that the movement of the whole membrane build-up by wind uplift cannot harm the PV laminates and their fixing system long term. In sensitive situations MIPV systems provide the great advantage that no panels are visible from a distance, even on a low building. A) Q-Cells Rigid PV Flexible Laminates CIGS A) a-si / a-si/μc-si (Tandem) B) Silicon / CIGS C) Medium (10 12 %) Low to Medium (a-si ca. 7 %) (Tandem ca. 8.5 %) Low to Medium (Silicon ca. 5 8 %) (CIGS ca. 10 %) Medium (> 5 Years) High (a-si >15 Years) (Tandem ca. 5 Years) Low to High (CIGS ca. 2 Years) (Silicon > 10 Years) High (16 19 kg/m 2 ) High (16 19 kg/m 2 ) Low (ca. 2 4 kg/m 2 ) B) MASDAR PV GmbH Front and back: glass, edge sealed Front and back: glass, edge sealed Front and back: polymer films No No No BAPV or BIPV BAPV or BIPV MIPV by bonding or laminating Both Unframed, often on back rails No frame, adhesive bonded to the substrate C) Global Solar Energy 15

16 The Sika Solar Parks: Practical Long-Term PV Experience Stuttgart (DE) Aim of the Sika Solar Parks Sika is proud to have several of our own Solar Parks in operation. All are comparative installations for different PV systems installed on single-ply and liquid applied membrane covered flat roofs. Building owners, investors, architects, engineers, roofing contractors, PV installers, students and solar energy enthusiasts all appreciate the chance to investigate different possibilities on a real scale. Sika uses these facilities to test our products and our partners systems and to demonstrate our competence to all interested parties, who can get first-hand experience of different PV installations and their behaviour in real-life conditions. Most of the installations are connected to the local grid and so also take profit from available local feed-in-tariffs for clean PV energy. Stuttgart (DE) The installation in Stuttgart is the oldest Sika Solar Park; the first phase was built at the end of 2008 with 5 PV systems. A large extension took place at the end of 2010 and during Since the end of 2011 out of 11 PV systems installed all together, one is a façade system. The number of formal visitors is rising every year and currently stands at more than 500. The first Sika Solar Day was held at this site in 2009 and this has become an annual event, which attracts many focused visitors. After presentations on the PV technologies and installations by the system suppliers, the visitors can physically inspect the Sika Solar Park themselves. Thanks to the latest inverter and online monitoring technologies, it is also possible to conduct any desired data comparisons of the installed PV arrays. An annual report on this is compiled by Sika Germany, which presents the actual status of the Solar Park, the key values and also many other observations and developments over time. Monthly PV Panel Efficiency Analysis Annual Energy Output Comparisons 12,0% 10,0% 8,0% 6,0% 4,0% 2,0% 0,0% Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez in kwh Jan Feb Mrz Apr Mai Jun Jul Aug Sep Okt Nov Dez

17 Stuttgart (DE) Sarnen (CH) The Solar Park in Sarnen consists of 2 roofs with 6 PV systems installed. Due to this location being close to the Swiss Alps it is a demanding environment with plenty of snow in winter time. It is a centre for experience with highly reflective membranes and bi-facial PV panels. The evaluation of different mounting structures for rigid PV panels and bonded flexible PV laminates to membranes are the other main tasks at Sarnen. Canton, MA (US) Sika Sarnafil, in the USA, has the largest Sika Solar Park when it comes to installed power generation. The Solar Park provides customers with a clear demonstration of two diffe rent photovoltaic technologies in a real environment. Each solar array has its own inverter which allows us to determine the net energy production of each system independently. Shanghai (CN) Large parts of Asia have a very demanding climate for PV materials and their installation. Therefore an important role of the Solar Park in Shanghai is to look at PV system durability in all aspects and details. A further focus in Shanghai is to compare crystalline PV panels on different mounting systems. Monitoring with on-line access is standard on Sika Solar Parks Further Sika Solar Parks are in the Development Phase. 17

18 Sika Roofing Solutions for Exposed Roofs Roof structures without ballast or wearing layers on the waterproofing membrane are known as Exposed Roofs. They are ideal for lightweight roof structures with large spans as well as for complex roof structures and geometries, including domes for example. Light weight roof build-ups Possibility of light / bright coloured surfaces for improved sun and heat reflection, plus reducing the heat island effect Almost unlimited design possibilities with different membrane colours, profiles and roof graphics, etc. Some examples of mechanically fastened Sika solutions for typical exposed roof requirements Steel decks Requirements FPO membrane with extended guarantee Fast and easy installation High chemical resistance of the waterproofing membrane Good fire behaviour of the thermal insulation Concrete decks Requirements PVC-membrane with lacquered surface and extended guarantee Fast and easy installation Special colours and design (décor profiles) Sika has a wide range of exposed Roofing systems, all of them designed to provide high performance, long lasting and sustainable roof waterproofing. They easily withstand all common environmental influences: UV light exposure Heat and cold Air born pollution and dust Wind uplift forces Rain, hail, snow and all other common exposures Sika system FPO membrane Sarnafil TS 77, mechanically fixed with Sarnafast SF 4.8 mm and Sarnafast Washer KT Mineral wool or PIR insulation Vapour control layer Sarnavap 1000 E Steel deck Sika system PVC membrane Sarnafil S 327, mechanically fixed with Sarnafast SB 6.3 mm and Sarnafast Washer KTL Mineral wool or PIR insulation Vapour control layer Sarnavap 3000 M Concrete deck 18

19 Some examples of adhered Sika solutions for typical exposed roof requirements An example of a liquid applied membrane solution Concrete decks Requirements Fully adhered, felt-backed FPO membrane with extended guarantee Highest aesthetic appearance No penetration of the roof deck (when all roof build-up components are adhered) Special colours and design possibilities (including décor profiles) Concrete decks Requirements Self-adhered PVC membrane No VOC s or liquid adhesives on site Easy and fast installation Instant adhesion, convenient for application on steep roof slopes No penetration of the roof deck Standard guarantee Non-insulated waterproofing Requirements Non-insulated roof waterproofing with Sika MTC technology Seamless waterproofing No penetration of the roof deck Extended guarantee Increased fire resistance No water underflow Sika system FPO membrane Sarnafil TG 76 Felt fully adhered to the insulation with Sarnacol 2142 S PIR, EPS/XPS insulation bonded to the vapor control layer with Sarnacol 2162 or mechanically fastened to the substrate Self adhesive vapor control layer Sarnavap 5000E SA or bitumen Primer 600, where required Concrete deck Sika system Self-adhered PVC membrane Sarnafil G 410 EL FSA PIR insulation bonded to vapour control layer with Sarnacol 2162 Self adhesive vapour control layer Sarnavap 5000E SA or bitumen Primer 600, where required Concrete deck Sika system 2 Top coats of Sikalastic -621 TC Reinforcement with Sikalastic Reemat Premium Base coat Sikalastic -601 BC Sika Concrete Primer where required Concrete deck 19

20 Sika Roofing Solutions for Ballasted Roofs Gravel ballasted Roofs In gravel ballasted roofing systems, the waterproofing membrane is covered and ballasted against wind uplift and other influences with a layer of gravel. Conventional gravel ballasted roofs have been established in most markets for many years and are suitable for flat roofs and load bearing structures. With the Sikaplan / Sarnafil and Sikalastic product ranges, Sika can provide both single ply and liquid applied membranes for these roofing systems according to the client s specific requirements. Gravel ballasted roofs have many benefits and frequently make a very economic roofing system with: Fast and easy installation No penetration of the roof deck Some examples of Sika solutions for typical gravel ballasted roofs Warm roofs Requirements FPO-membrane with extended guarantee on PIR/EPS/XPS insulation Fast and easy installation High chemical resistance of the waterproofing membrane Extended guarantee Inverted roofs Requirements Inverted roof waterproofing with Sika MTC technology Seamless waterproofing Standard guarantee No water underflow For most applications it is possible to find the optimized Sika solution based on one of the following systems: Sikaplan and Sarnafil single-ply membranes Sikalastic liquid applied membranes SikaRoof MTC systems (liquid applied membranes and coatings) Sika system Gravel min. 50 mm and 80 kg/m 2 FPO membrane Sarnafil TG 66 PIR/EPS/XPS Vapour control layer Sarnavap 3000 M Concrete deck Sika system SikaRoof MTC Ballast Gravel min mm and 80 kg/m 2 Filter layer S-Felt VS XPS insulation Top coat of Sikalastic 622 TR Reinforcement fleece Sikalastic Reemat Premium Base coat Sikalastic -602 BR Sika Concrete Primer where required Concrete deck 20

21 Green Roofs In so called Green Roofs soil, or another suitable plant growing medium, is placed and planted with the selected vegetation over the waterproofing membrane. Green roofs can therefore make a significant contribution and provide practical solutions in the quest for sustainability, increased biodiversity and quality of life. Green Roofs are classified as Extensive or Intensive. Extensive green roofs have a shallow growing medium with small plants Intensive green roofs have a thicker soil layer with additional drainage, designed for planting larger plants, bushes and small trees, thus creating actual roof gardens. Some examples of Sika solutions for typical green / utility roofs Extensive green roofs Requirements PVC-membrane with lacquered surface and extended guarantee Extensive green roof with low maintenance Utility roofs: pedestrian traffic Requirements Inverted build up with Sika MTC Pedestrian terraces Standard guarantee Seamless waterproofing No water underflow Inverted roof build-up Utility Roofs On utility roof decks the top layer is also designed as a wearing surface for pedestrian and / or vehicular traffic. Utility roof decks can help to: Create more utilized space and bring additional value to the building. Generate an increased return on investment by using the roof for a car park, restaurant area, or any other viable purpose or facility. Utility roof decks share many features with gravel and green roof ballasted systems: The membrane is protected against any aggressive environmental exposure and mechanical damage. The natural non-combustible properties of the paved wearing surface contribute significantly to the fire resistance of the whole roof. Sika system Soil with plants (min. 80 mm thick and 80 kg/m 2 ) Drainage layer Sarnavert Aquadrain 550 PVC membrane Sarnafil G 476 / G 410 Separation layer S-Glass Fleece 120 PIR/EPS/XPS insulation Vapour control layer Sarnavap 3000 M Concrete deck Sika system SikaRoof MTC Ballast Pavers on chipping bed 30 mm Filter layer S-Felt VS 140 XPS insulation Top coat of Sikalastic -622TR Reinforcement Sikalastic Reemat Premium Base coat Sikalastic -602 BR Sika Concrete Primer, where required Concrete deck 21

22 Sika s Roofing Experience and Possibilities Incident light to front side Incident light to back side Highly reflective Sika membrane Single Ply Membranes Sika is one of the most experienced single ply membrane producers with a track record of more than 50 years. Our production incorporates the latest, most efficient and proven technologies. PVC membranes are manufactured on extrusion and coating, calendar and spread coating production lines. FPO Polyolefin membranes are manufactured on extrusion and coating production lines, which were specially designed and optimised for FPO membrane production by our own engineers. Mechanically Fastened Systems Mechanically fastened systems are ideal for large, lightweight metal decked structures on buildings such as retail stores, distribution and logistics centres, warehouses, supermarkets and workshops etc. FPO membranes Brand name: Sarnafil Track record for over 20 years High chemical resistance Fast installation independent of the weather SR colour range for PV systems which can take advantage of surface reflectance, as with Cool Roofs PVC membranes Brand names: Sarnafil, Sikaplan Established technology with long track record Easy to repair Possibility of customized design solutions (colours, profiles, and roof graphics) Highly flexible, easy to handle on site Good vapour permeability Flame free installation Recyclable Installations with Sarnafil / Sikaplan Sarnafil T polyolefin membranes are resistant to bitumen and can be applied directly on to old existing bitumen roof waterproofing systems The fastest installation speed is always achieved using mechanical fastenings Sarnafil / Sikaplan membranes for mechanical fastening have special polyester reinforcement to resist the highest wind loadings Installation is almost non-weather dependent 22

23 Adhered Systems Adhesive attachment of the exposed Sikaplan or Sarnafil roofing mem brane is an option for nearly any roof. These provide an ideal solution for public and residential buildings, including schools, offices, hotels, hospitals, apartments, sports centres etc.; plus they are especially suitable on all types of refurbishment projects. Liquid Applied Membrane Systems Liquid applied roof membranes are an increasingly important focus for Sika. Innovation has allowed us to develop and customize new products based on advanced MTC technologies, especially for flat roof applications. These systems are ideal for exposed roofs with large numbers of penetrations and complex detailing. Product lines are based on 1-component and 2-component Polyurethanes A further product line includes coatings based on aqueous Acrylic dispersions and Sika s CET technology Installations with Sarnafil / Sikaplan High aesthetic appearance Freedom of design and suitability for complex roof shapes No penetration of the roof deck is required Very low noise emissions during installation Easy refurbishment of existing bitumen roofs MTC 1-C PU systems (Moisture triggered 1-component Polyurethane) Brand name: SikaRoof MTC systems Systems are rain and moisture tolerant almost immediately after application Easy and fast detailing with unique reinforcement Seamless waterproofing No water underflow, due to the full bond of the waterproofing to the substrate High fire resistance, self-extinguishing characteristics when cured 2-C PU membranes (Elastic, crack-bridging, rapid-curing 2-component Polyurethane) Brand name: Sikalastic For use as waterproofing membranes for concrete structures and on non-trafficked concrete deck areas, with an additional top coat for UV-protection Excellent crack-bridging properties Highly elastic waterproofing membranes Standard curing and simple application by trowel or roller Fast curing application with 2-part hot spray equipment 23

24 Sika s Range of Accessories for Roofing Walkways and Separation Layers Walkways These are used in exposed roofing systems to provide pedestrian access mainly to plant and equipment or other maintenance purposes. Walkway pads Sarnafil PVC Walkway pads Sarnafil T Sikaplan Walkway membrane Protection, Separation and Levelling Layers Separation layers are placed between noncompatible components in the roof buildup. Protection layers are used to protect the waterproofing membrane from different kinds of damage. Levelling mats are used to smooth out rough or uneven substrates before the membrane is laid. Protection and separation layer felts S-Felt A 300, T 300, GK 400, M 500, S 800 Protection layer sheets Sarnafil TG63, Sarnafil G445, Sikaplan SBV Separation layer fleece S-Glass Fleece 120 Prefabricated Sections Sikaplan and Sarnafil prefabricated sections are made out of the same polyvinylchloride (PVC) or polyolefin (FPO) and are designed exclusively as components of the Sika Roofing system. Easy and rapid installation Neat and reliable details Good resistance to weather, UV-radiation and stress cracking Guarantee system compatibility Secure welding to the roof membranes Décor Profiles and Batten Profiles Extruded profiles using the same high quality of materials used for our membranes; these provide additional styling and design possibilities. Particularly for sloped, highly visible roofs, décor profiles are used to break up large areas, emphasize forms and to give roofs a unique appearance. Use Décor and Batten Profiles to imitate the appearance of metal roofs Traditional lead batten copper and modern standing seam roof profiles can all be realistically reproduced Décor Profiles are available in a wide range of colours 24

25 Thermal Insulation The Sika Roofing range incorporates the most efficient types of thermal insulation available on the market and includes materials suitable for adhered roofing applications. PIR/PUR Thermal insulation boards produced from rigid PU foam with an isocianurate catalyst. This is a universal and efficient solution and is the most suitable insulation type for adhered systems. SarnaTherm PIR Sikatherm Sarnapur EPS Thermal insulation boards produced from expanded polystyrene granules. This is also one of the most efficient solutions for thermal insulation. Sika provides a range of suitable EPS boards for adhered systems. SarnaTherm EPS S-Therm EPS Application Tools Efficient and reliable installation is ensured by state-of-the-art technology in tools and equipment. Sika provides specially designed application tools to ensure optimal ease of use and installation quality. Spray Tool for the Sarnacol T 770 solvent free hot-melt adhesive used for bonding upstands with Sarnafil T membranes Nylon rollers for adhesive application Dispenser Cart for controlled and continuous application of strips of adhesive Heat Gun for executing details or to reactivate evaporated adhesive Automatic welding machines Hand-held welding machines Cleaners, Sealants, Surface Preparation Agents All the ancillary products for detailing, cleaning, seam sealing, seam preparation and more are specially designed for use in roofing. The right tools, these should always be available on site to ensure good workmanship. Contact adhesives and hot-melt adhesives for flashings Seam cleaners and general purpose cleaners Seam preparation agents Sealants for details at connections, penetrations and terminations Substrate primers 25

26 PV and Roofing Guarantee Experienced Roofing Supplier Experienced Roof Installers Experienced Solar Suppliers Experienced General Contractors Experienced Solar Installers Preconditions for a PV System and Roofing Guarantee What is required to apply for a complete guarantee package? Planning of the PV installation needs to be made by an experienced Solar System designer Installation of both the Sika membranes and the PV system components must be carried out by an experienced Roof and Solar Installer Experienced installation of the Sika SolarRoof PV components A project specific inspection and maintenance scheme needs to be established What Makes the Difference? Investment Planning Financing Installation Single source of responsibility Choose higher PV / roof membrane quality for optimized solar output Guaranteed fixed costs for the investment Support on financing (Experienced partners) Customized solutions (for New build and Refurbishment) Return on Investment Operation Maintenance Future Options 25 years guaranteed solar output of > 80% 20 years operation to beyond the FiT period Regular inspection to minimize maintenance Monitoring by a certified partner company Defined end-of-life, e.g. controlled recycling 26

27 Sika Support for Your PV Project Sika Partner Concept The information in the previous pages of this PV Technology brochure illustrates that the professional design and execution of a PV installation is a very complex task. Nevertheless this is the key to a durable PV installation and a secure solar investment. As the leading manufacturer of roof waterproofing membranes and systems, Sika therefore teamed up with local specialists (*) who are: Experienced Roof Installers Experienced General Contractors Experienced Solar Suppliers Experienced Solar Installers This allows our customers to have success with safe and reliable operation. Service and Maintenance as well as on-line Monitoring, is another part of this success. The duration of any guarantee is dependent on the PV system selected and the level of support required from our partner companies. The table below outlines some of the wide range of services and solutions from these partner companies. It follows the 5 logical steps in the process for the Whole Life Cycle of a PV installation and beyond. (*) Please contact your local Sika Roofing organization for details 1 Commitment 2 Development 3 Installation 4 Operation 5 Future Options Select Sika as your Competent Roofing Partner Obtain PV and Roof Information according to our Checklist Technical Review and Evaluation Customised Solution Selection Obtain Required Approval Arrange Finance Complete Roof Refurbishment / Installation Complete Solar Installation Qualified Grid Connection Acceptance for Power Generation and Supply Ensure Regular Inspection and Maintenance Constant Output Monitoring Extended Operation to beyond the FIT Period Remove and Liquidate Recycling Rebuild / Refurbish 27

28 Sika Full Range Solutions for Construction Concrete Production Waterproofing Flooring Sika ViscoCrete Sika Retarder Sika SikaAer Sikaplan, Sikalastic Sika & Tricosal Water stops Sika Injection Systems Sikafloor SikaBond Corrosion and Fire Protection Concrete Repair and Protection Structural Strengthening SikaCor Sika Unitherm Sika MonoTop Sikagard Sikadur Sika CarboDur SikaWrap Sikadur Joint Sealing Grouting Roofing Sikaflex Sikasil Sikadur SikaGrout Sarnafil Sikaplan SikaRoof MTC Also Available from Sika Sika Services AG Business Unit Contractors Industriestrasse Sarnen / Switzerland Phone Fax Our most current General Sales Conditions shall apply. Please consult the Product Data Sheet prior to any use and processing. Sika Services AG / BU Contractors / CMS / / ID: 24305