Commercial Rooftop Solar Design Explained
Cover Boards and Insulation
The advantages of greater membrane thickness have been demonstrated. However, roof durability is system dependent so we must look beyond the membrane and consider the entire roof assembly. Rooftops with PV arrays are burdened with more trades and increased foot traffic on the roof, and therefore, are more susceptible to degradation and potential leak sources. A logical starting point is to protect high traffic areas with walkway pads.
The addition of a high-compressive-strength cover board below the single-ply roof membrane will also enhance system protection and extend the life expectancy of the roof. Cover boards provide added protection against penetration by objects, including tools dropped by service contractors, wind-borne debris, and hail. Increasing the thickness of the cover board will increase its penetration resistance. The use of high-density polyiso or gypsum cover boards can significantly increase penetration resistance by nearly 250 percent, as shown in Figure 3.
Figure 3: Puncture resistance of varied membrane thicknesses, and with added support of cover boards.
In addition to increased foot traffic, concentrated loads from ballasted PV systems can exceed the compressive strength of the roof system’s membrane and insulation. Specifying a rigid insulation board with high compressive strength, such as an ASTM C1289 Grade 3 polyiso, with a 25psi minimum compressive strength, will distribute loads and help prevent crushing that may occur with lower compressive strength materials.
Design Review
Designers must understand that with the installation of rooftop solar, the roof system becomes a permanent platform for the continuous operation, service, and maintenance of the arrays. As many solar designers may not be intimately familiar with best roofing practices, it is helpful to specify solar layout requirements for rooftop access that align with not only code requirements (i.e., International Fire Code, (IFC) and National Electric Code (NFPA 70)), but with best practices for roof maintenance and safety of rooftop workers. This can include requirements such as prohibiting PV arrays from crossing building expansion joints, and setting PV arrays and rack heights such that the roof membrane seams, drains, and penetrations are accessible for emergency responders and maintenance workers.
Designers and owners also have an opportunity to specify the type of PV attachment, which includes attached, ballasted or adhered. Each option will impact decisions for the roof system design so project teams should take a holistic approach to any value engineering discussions regarding the roof and PV arrays.
As the cost to install PV arrays is significant, specifying an integrity test of the roof membrane prior to installing the solar overburden is a worthwhile investment of time and resources. This could include the incorporation of a metallic primer on the cover board to facilitate electronic leak detection testing, or the installation of a permanent monitoring system, so the owner can continuously monitor for water intrusion, which may be especially useful over critical areas such as uninterruptible power supplies, operating rooms and data storage.
PV Roof System Design: The Real World
While these modifications may have been made in the name of “value engineering,” understanding the risks associated with these deviations from best practices, and the reduced value they bring to long-term performance may lead to informed decisions rather than decisions based solely on dollars.
A significant risk in PV roof system design is that the life expectancy of the PV system exceeds that of the roof system. Replacing a roof with installed PV arrays may be cost-prohibitive. Therefore, aligning the life expectancy of the roof with the PV system makes financial sense, as well as best roofing practice. For instance, the decision to offset the investment of a PV system by extending the life of an aged roof membrane by the use of a maintenance coating may lead to long term complications and expense t when the PV system needs to be dismantled and reinstalled to facilitate a roof recover or replacement. Worst case scenario? The PV system remains in place on a roof that is no longer protecting the building. Instead of just replacing the roof, the owner may have to also deal with structural repairs, water damage, and mold remediation. Removal and replacement of the PV system, as well as damages incurred to the PV system in the process. This often includes leased PV systems or systems that are simply renting space on the rooftop. In addition, some contract clauses leave the building owner with ownership of the PV system at the end of the lease, which means the building owner is responsible for removing and disposing of the PV system from the roof.
In line with the intent of installing a roof system that exceeds the life expectancy of the PV system, refrain from saving a few pennies by installing a 45-mil single-ply membrane. Best practice is to increase roof membrane thickness to match the service life of the PV arrays. A 60-mil thick membrane should be the baseline design. A good design would include an 80-mil thick membrane. A great design would include a high-performance membrane that has enhanced heat and UV resistance. Again, the risk of installing a thinner single-ply membrane could include the cost of replacing the roof before the PV system needs to be replaced. The cost becomes significantly more than just the cost of a roof due to the cost of dismantling and reinstalling the operational PV system.
Mechanically attaching the roof membrane when installing an adhered or ballasted PV system can result in damage to both the roof and PV systems. The normal billowing during high wind events of mechanically attached roofs could cause ballasted PV systems to shift and damage the membrane. This billowing could also create additional stress on the solar arrays and its connections, compromising the long-term performance and life expectancy of both the roof and the PV system.
Eliminating the cover board from the roof system is sometimes the first step in initial cost savings. The cover board is there to enhance the protection of the roof membrane from the overburden, foot traffic, and maintenance activities. This is especially important with ballasted PV systems that move around on the roof during wind events. A common compromise includes the use of 25 psi top layer of polyiso insulation and standard polyiso insulation installed below. While a cover board can extend the life expectancy of the roof, this approach may be reasonable, specifically for attached or adhered PV systems. However, understand that the puncture resistance of this roof system will be dramatically reduced, putting the integrity of the roof at risk every time maintenance personnel steps onto the roof. Oftentimes tools are inadvertently dropped or a shoe forces a loose object into the membrane (like a piece of gravel or dropped screw). Damage from these instances often go unnoticed until water shows up on the inside of the building. Note that the removal of the cover board for ballasted PV systems is not recommended due to the shifting around of the arrays during wind events, and the resulting repetitive impact on the roof.
Loose laying the slip sheet below a ballasted PV system runs the risk of water collecting between the slip sheet and the roof membrane. Trapped moisture that has no means of evaporation or drainage can have negative long-term effects on some membranes. Additionally, slip sheets could blow away if ballasted PV arrays are lifted up during severe wind events. Adhering the slip sheet to the roof protects the membrane and PV arrays from damage.
Roof Systems Guarantees
The importance of matching the life expectancy of the roof and the PV arrays has been discussed. At a minimum, the roof system must be designed such that the roof system guarantee will meet or exceed that of the PV arrays. Roofing guarantees are a valuable tool for the building owner, but they carry important limitations and conditions that must be addressed for successful rooftop PV installation and operation.
From the start, the roofing system must be designed and installed in accordance with the manufacturers published specifications, and PV system details must be accepted by the manufacturer prior to installation to avoid any lessening of coverage of the guarantee.
Manufacturers typically do not guarantee the solar mount system utilized in the solar installation. Therefore, most manufacturers specifically disclaim any liability arising out of or in connection with the integrity, installation or performance of, or damages sustained by or caused by the roof mount or PV systems. This emphasizes the importance of collaboration between the roof system designer and the PV designer.
Solar Shingles?
You may have seen information in the news recently about “solar shingles” and “solar roofing”. We love this concept in that, rather than have your solar investment mounted on top of your roof investment, the solar portion of your roof will actually replace the standard roof. This will effectively reduce the cost of your solar investment because the metal roof will not be installed where the solar is installed.
There are many companies developing and perfecting “solar shingle” technology with whom we are connected. We are seeking the best possible option to bring our customers in terms of solar technology and efficiency and also weathertight integration with our high-quality metal roof systems. Combining solar roofing with metal roofing, and doing it in a way whereby the solar can be updated with future technological advancements is a great way to ensure the ongoing protection and value of your overall roof and solar investment.
Cost-Effective Solar Energy
The current reality is that traditional crystalline photovoltaic panels offer the most cost-effective solar energy production. Their modular nature is very helpful in allowing repairs and replacement. Additionally, while they are durable and built to last 20 or so years, they do eventually need to be replaced, allowing property owners to step up to even more efficient energy production at that time.
Solar Installation on a Classic Metal Roof
Traditional solar panels can be integrated nicely with our metal roofs. With clip-fastened standing seam roofs, the panels can be clamped onto the raised seams so that no or very few actual roof penetrations are necessary. With other types of metal roofs, penetrations of the roof will be necessary but there are many commercially available fastening brackets designed for water tightness that work very well.
Metal roofs are ideal for solar installation. The durability of the metal roof will hold up to roof traffic when the solar array is installed and serviced. The metal roof will also easily last as long as the solar panels themselves. Additionally, cool metal roofs can help to increase the efficiency of solar panels. And, finally, using a metal roof to save energy while producing energy at the same time with solar, is the best of both worlds. Reducing your energy needs with the right roof may reduce the size of the solar array required for your home.
If you consider solar for your home, keep in mind that solar experts generally say their components have a life expectancy of around 20 years. By the end of that time, the production efficiency will have declined and it will be time to update the solar array. However, a quality metal roof will easily last 50 years so it’s important to make sure that replacing the solar will not require replacing the roof.
Plan for Your Future Energy Needs
If you as a homeowner have plans for solar in the future, discuss those plans with your roofing contractor the next time you roof your home. Depending upon the type of roof you choose to have installed, it may be possible for the installer to take steps now that will simplify solar installation in the future.
What Will the Future Bring to Your Roof?
While our current recommendation is to stick to the tried and true traditional photovoltaic panels, we see integrated solar roofing on the horizon. We believe that the coatings on metal roofs themselves will be suitable solar collectors at some point in the future. This truly will be a fully integrated solar roof that makes sense.
Dreaming of Solar or a Solar Roof?
We’d appreciate the opportunity to talk with you about the solar and roof dreams you have for your home, and determine how we can make those dreams a reality for you.
You can learn more about the energy efficiency of a Classic Metal Roof. Our own roofing guru, Todd Miller, is also available to answer your questions on energy efficiency, roof-top energy production on a metal roof, and more.
Buy or Lease? What is the best option for you?
The decision to buy or lease a solar system will depend on your finances, state laws and utility policies.
If you decide to buy a system, you:
- reap the benefits of the electricity produced;
- would be entitled to tax credits or other incentives;
- are responsible for system maintenance;
- can sell the system, if you move.
On the other hand, if you lease a system:
- the solar system company owns it and is responsible for its maintenance.
- You can enjoy cheaper electricity with very low or no upfront costs and monthly payments at agreed rates.
Before signing the lease, ask about your options in the event you decide to sell your property. Zillow has estimated that homes with solar panels sell for 4.1% more compared to homes that are not powered by solar power.[2]
Buying the solar panels directly could unlock additional dollars. First, if you purchase the system there are federal tax incentives through 2023. Your local area may have additional incentives in place to further reduce the cost of the system. Also, there are benefits through Renewable Energy Credits (RECs), that may be sold. The rates received from the RECs vary greatly by state so it is good idea to discuss with your solar provider on what those numbers are. Finally, there is also the electricity generated which will lower some or perhaps all of your electric bill depending on the month. Keep in mind that solar production will be dependent on the season so you should expect more production in the summer and less in the winter. The sum of these savings (tax incentives, RECs, and electricity generation) can be great. In 2016, Consumer Reports estimated that a New Jersey home which purchased a solar roof in cash could result in about 60,000 of savings over 20 years. If the family took out a loan for the entire project, there were still 20,000 in savings over the same 20 year period. [3]
If you lease solar panels, you generally pay the solar company a monthly rate and the solar company continues own the panels and provide maintenance. You can get the benefits of the electricity generation without the upfront cost. However, there are fewer direct financial benefits as customers in the leasing model do not have access to the RECs nor the tax credit and other state financial incentives. With that said, there are still benefits. In this case, Consumer Reports estimated the benefits from leasing to be at 25,000 in savings over 20 years.[4]
Questions to ask your solar provider when getting a proposal.
As with any large purchase, it pays to get multiple quotes. NREL recommends requesting multiple quotes. Remember that there is likely to have been someone else in your neighborhood that has installed solar on their home so check your neighborhood listserv for recommendations. As you obtain quotes from those solar providers, consider this list of questions to ask so that you can get a sense of their work quality and the financial benefit of the system.
- How many systems has the solar provider installed in the past year?
- What is the system size and total installation cost?
- How much electricity will the system generate over the course of a year and what will be the total approximate savings of the system?
- What upgrades does my home need? Would I need a new roof, updated wiring, clearing of trees updated utility interconnection?
- How will I be reimbursed for any excess electricity produced? Does my jurisdiction allow net metering?
- What does the warranty cover and who is responsible for maintenance and cleaning?
- Who is responsible for utility interconnection, permissions, and inspections?
- What happens if I decide to sell my home? What are the conditions for new occupant?
- Who should I contact if my system fails?
- What to do in the event of a blackout?
- If you are considering leasing as a model, consider:
- What is the length of the lease?
- What is the upfront cost and how much do I need to pay over time? The terms may be different depending on the provider so make sure to do the math on how it breaks out.
How to select a solar provider?
Once you have your quotes, it is important that you get the best deal and closely examine the underlying terms and conditions. Look for an installation company that is licensed, has credentials from a certified body, such as the North American Board of Certified Energy Practitioners, and is insured. A good solar provider will offer you a variety of panels and inverters adhering to your aesthetic requirements with appropriate performance warranties. Have them walk you through the options and think about how the panels will look on your home so that you are happy with the result. Keep the warranty in mind. String inverters typically carry a 10-year warranty while micro-inverters can go all the way up to 25 years. Solar panels usually carry a 20-year warranty.
Make sure to compare the average wait time, scheduling, and project completion times for different providers. Lastly, the best provider will be completely transparent about savings, associated assumptions, system monitoring, maintenance and all the estimated costs. The Solar Energy Industry Association’s (SEIA) National Solar Database includes a list of manufacturers and installers across the United States.[5]
Solar Roof Shingles 2023 Cost and Buying Guide
Each product and or company featured here has been independently selected by the writer. You can learn more about our review methodology here. If you make a purchase using the links included, we may earn commission.
Written by Kristina Zagame
Kristina Zagame is a journalist, editor and content writer with expertise in solar and other energy-related topics. Before joining EcoWatch, Kristina was a TV news reporter and producer, covering a wide variety of topics including West Coast wildfires and hurricane relief efforts. Kristina’s reporting has taken her all over the U.S., as well as to Puerto Rico and Chile. Learn About This Person
Reviewed by Karsten Neumeister
Karsten is an editor and energy specialist focused on environmental, social and cultural development. His work has been shared by sources including NPR, the World Economic Forum, Marketwatch and the SEIA, and he is certified in ESG with the CFA Institute. Before joining EcoWatch, Karsten worked in the solar energy sector, studying energy policy, climate tech and environmental education. A lover of music and the outdoors, Karsten might be found rock climbing, canoeing or writing songs when away from the workplace. Learn About This Person
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- Solar Shingles Cost is High Up Front But ROI is Higher
- Cost of Installing a Solar Shingle Roof
- How to Calculate the Cost of Your New Solar Roof Shingles
- Factors That Go Into Solar Roof Shingle Pricing
- Pros and Cons of Installing Solar Roof Shingles
- Lifetime and Durability of Solar Roof Shingles
- Are Solar Shingles Environmentally Friendly?
- Financing Your New Solar Roof Shingles
- Costs of Maintenance and Repairs for Solar Roof Shingles
- Costs of Cleaning Your Solar Shingles
- Are Solar Roof Shingles Worth the Cost?
- FAQs: Solar Shingles vs Solar Panels
Find the best price from solar installers in your area.
Solar Shingles Cost is High Up Front But ROI is Higher
The average cost of solar roof shingles ranges between 25,000 to 60,000. or between 15 to 35 per square foot. for the average U.S. roof size of 1,700 square feet. The total cost will depend on the solar roof tile brand and the roofing contractor you choose for installation.
Compared to traditional solar panels, solar shingles are much more aesthetically pleasing. They look like mini solar panels shaped in the form of traditional roof shingles, allowing homeowners to bypass the bulky appearance of standard photovoltaic (PV) panels.
If you are interested in adding solar panels to your new roof. solar shingles are a much more cost-effective option. With solar shingles, you’ll knock out the cost of a roof replacement and the cost of a renewable energy system with one combined price tag.
SunPower
SunPower designs and installs industry-leading residential solar and storage solutions across all 50 states. With a storied history of innovation dating back to 1985, no other company on this list can match SunPower’s experience and expertise.
SunPower earns its position as the top national installer on our list for a handful of reasons: It installs the most efficient solar technology on the residential market, offers the most expansive service area and backs its installations with a warranty well above the industry standard. All the while, SunPower pioneers sustainability efforts within the industry.
If that weren’t enough, SunPower systems come packaged with products all manufactured in-house by its sister company, Maxeon. This means that your panels, solar cells, inverters, battery and EV chargers are designed to work together and are all covered under the same warranty.
SunPower’s biggest downside? Its high-efficiency panels are considerably more expensive than most of its competitors’ products. However, its powerful panels are workhorses that make up for the initial cost with more backend production (think about this like spending more money for a car that gets more miles per gallon).
Blue Raven Solar
We like Blue Raven Solar because it understands that, for most homeowners, the cost of solar presents the biggest barrier to entry.
For that reason, Blue Raven Solar developed an innovative solar financing plan that offers in-house, flexible, zero-money-down options. The results speak for themselves, as Blue Raven Solar is now one of the fastest-growing solar companies in the nation and was recently acquired by SunPower. Its BluePower Plus plan (exclusive to Blue Raven) mimics the flexible structure of a lease while still providing the greatest benefits of owning your system.
Eligible homeowners enjoy 18 months of solar power before having to pay their first bill. When coupled with the federal solar investment tax credit (ITC), the initial energy savings can offset more than a third of the overall cost of a system before requiring a dollar down.
In contrast, other installers can only offer similar financing through solar leases, PPAs or third-party providers (such as Mosaic or Sunlight). Third-party loan providers can complicate the process, while opting for a loan or PPA will disqualify you from some of solar’s biggest benefits (additional property value, federal solar tax credit and local solar incentives).
Cost of Installing a Solar Shingle Roof
The overall cost for a solar shingle installation ranges between 25,000 to 60,000 for the average U.S. home, which comes out to around 15 to 35 per square foot.
But unlike regular shingles, shingles with solar cells — a type of building-integrated photovoltaic (BIPV) technology — are priced per watt. not per square foot. The cost of a solar shingle ranges between 3.50 and 8.00 per watt depending on the brand.
Most solar companies don’t advertise pricing online, but market research shows the total cost of a solar shingle installation is typically 15%-25% higher compared to a traditional solar panel system installation. The national average solar panel installation costs roughly 24,000, which puts the national average solar shingle installation at around 30,000.
Of course, there are some outliers. For example, a Tesla Solar Roof may cost as much as 70,000 or more for full roof installation, while the budget-friendly SunTegra solar shingles may run closer to 20,000 for the entire roof.
While solar roof shingles cost substantially more than asphalt shingles. you’ll be producing your own electricity, therefore lowering your electric bills (or in some cases completely offsetting) by producing your own clean energy.
“A solar roof is a great and obvious way to reduce energy use and has the added benefit of being environmentally friendly,” said David Snyder, CEO of Nova Home Buyers, LLC.
If you go solar, you’ll also be eligible for solar financial incentives and rebates, like the 30% federal tax credit and net metering credits.
How to Calculate the Cost of Your New Solar Roof Shingles
As discussed, BIPV solar shingles are priced per watt. So to calculate the cost of your solar shingle roof, you’ll need to know how much solar power you need to power your house.
The only way to know the exact cost of your solar roof is to get a professional estimate, but you can calculate it yourself by walking through the follow the following steps:
- Find out how much energy your home consumes (typically found on your energy bills)
- Assess your roof space and the amount of sunlight your home receives
- Figure out the average system size in your area to estimate necessary system size (you can also use our solar calculator to find an estimate)
- Check the wattage of the shingles you intend to purchase
- Divide the required wattage of your system by the solar panel wattage
The average U.S. home needs a solar system that produces 9,000 watts (or 9 kilowatts) to completely offset their utility bills. With the cost of solar shingles ranging between 3.50 and 8.00 per watt, a 9,000-watt solar shingle installation would range from 31,500 to 72,000.
But don’t let those numbers scare you. Remember, your solar shingles don’t need to power your entire home.
Having a roof that produces any amount of clean energy can still significantly reduce your energy bills and your carbon footprint, making it much more impressive than a regular roof made of asphalt.
The Best Roof Materials for Solar Panels – 5 Common Materials
Solar can be installed on just about any roof type. However, there are certain materials on which solar panels can’t — or shouldn’t — be installed. So that begs the question, what’s the best roof material for solar panels?
In this article, we’ll review five different materials to see which one makes the best roof for solar panels.
Best roof materials for solar
Composite shingles
This is the most common, and perhaps best, roof material on which to install solar panels. Because composite shingles are so common, this roof type offers the widest range of options for equipment and installers. This reduces the need for specialized solar equipment and labor, and reduce your overall project costs.
Pictured on the far left in the feature image above, composite shingles — aka asphalt shingles — are made from a fiberglass or cellulose mat. Asphalt and other minerals are then added to the shingle to produce the final product.
Composite shingles are often the most affordable roofing type and come in many colors. Most come with a standard 30-year warranty, although they should only be expected to last 15-25, depending on conditions and care.
If your composite roof is older than 15 years or starting to show major signs of wear, solar installers will likely recommend re-shingling before installing solar panels. Even so, composite shingles are often considered the best material on which to install solar panels.
Tile
Tile roofing is another very common roof type in the Western US that can be found in almost any neighborhood. Tiles, themselves, can be made of different materials, and that is why it is important to accurately determine what materials your tiles are made out of before proceeding.
Roof tile materials include:
- Clay
- Ceramic
- Metal
- Synthetic cedar
- Slate
- Concrete
The material type can impact the cost of your solar project. For example, installing solar panels on clay tiles may be more expensive than installing on concrete tiles.
When a solar panel array is installed on a tile roof, they will need to be attached to brackets that will lift the panels above the roof. The distance that the panels must be raised will be dependent on the material itself, and the cost is also affected based on what material the tiles are.
Most installers, especially in warmer climates, are familiar with and comfortable working on tile roofs. However, it may be harder to find an installer to work on a tile roof in the northern parts of the US where they are less common.
Here’s how a solar system looks on a tile roof:
Metal Standing Seam
Metal roofing with standing seams is one of the best roof material for the installation of solar panels. The standing seams on these roofs make the attachment of the panel array incredibly easy, and with easier installation comes a cheaper cost.
You also do not have to drill any holes into your roof with this roof type. Some of the other benefits of metal roofing are that, by itself, it is already more eco-friendly. They are often made out of recycled materials and are durable enough to last for over 30 years.
Metal roofs with standing seams can allow you to install both thin film and standard PV panels. These roof types also reflect a significant amount of sunlight where it is not being absorbed by the solar panel, which leads to a cooling effect that can increase the efficiency of your system.
Tar and Gravel
For homes that have a flat roof, it is very likely that they will be of the tar and gravel roof type (second from the right in the feature image). Tar and gravel roofs are made out of layers of sheets that are attached with hot tar and roofing felt. There are some other mineral coatings added, as well. Because these are flat rooftops, they may require additional brackets that can be tilted at the 30-degree angle.
This is very simple to do, but it will be more expensive than installing on a tilted roof or with a different material. Nevertheless, tar and gravel is still a very viable roof material for the installation of solar panels.
Wood
The last roof type that you will see commonly throughout neighborhoods are wooden roofs. Wooden roof types can include shingles at an angle or may be completely flat, so the specifics will be dependent on the way the roof is structured.
In any case, a wooden roof is not viable for solar panels because of fire safety concerns. Therefore, wood is not the best material for solar panels.
The best materials for solar panels
Rooftop solar equipment and installers have come a long way in recent years and most roof materials are suitable for solar panels.
With that said, the best roof material is anything that will keep your solar panels secure for their 25-warrantied life or longer. While there may be minor advantages for one material over another, don’t let perfect be the enemy of good. The important thing is to get a system installed so you can start saving money and generating clean energy.
All Things Roof FAQ’s
What is an ideal roof for solar panels?
In most cases a composite asphalt shingle roof, facing south with enough space for placement of your entire system would be the best. Although, in most parts of the country as long as you have space on your roof and you get ample sunlight, solar is viable on most roof types except wood shake.
What is the best roof design for solar?
The answer is pretty straightforward, a large square roof is ideal for a simple solar system install. Roofs with lots of tiers, chimneys, skylights, pipes, and very little extended spaces, create lots of challenges for system design and installation.
What type of roof is not good for solar panels?
We hate to be the bearer of bad news, but if you have a wood roof your options are limited. These roofs will disqualify you from installers, although you still have the option to reroof or look into ground mount solar installations.
What if my roof is old?
If your roof is too old or worn down, it’s best to replace it before installing solar panels. Some installers offer both services, which can bring down the cost by combining the projects.
If your roof is older, but not at the stage of replacement, you can still install the system. However, you’ll likely end up paying for the labor to un-install and re-install the system when you do end up replacing the roof. This cost isn’t typically welcome when you’re already paying for a new roof.