Tesserack Z Released for Shingled Roofs

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As part of this new launch, we are happy to announce that we have qualified our flagship hardware – the Tesserack Z – for use on composite shingled roofs. This particular type of roof is much more prevalent in North America, so we needed a bit of redesign and a lot of testing in order to apply the Z, which has been proven in the field for metal roofs overseas for several years, to the U.S. residential market.

What had to change for composite shingles?

In the final analysis, we decided that the only real difference between the Tesserack Z for metal and for shingled roof is the weather seal. On metal roof, we use a neoprene seal around the bolt holes. On shingled roof, we replace those neoprene seals with a thicker, butyl rubber gasket.

Butyl rubber is widely used for rooftop weather seals overseas and the material is reemerging for solar mounts in the U.S. The advantage of a butyl seal is that you do not need to lift or notch shingles to accommodate a flashing. Of course, you need to be confident that the butyl seal will perform leak free for the life of the installation.

Testing and long term exposure.

We have exposed Tesserack Z mounts with butyl weather proofing gaskets to over 25,000 inches of simulated rainfall with no leaks. As part of that testing, we periodically simulated high wind loads by pushing and pulling on the mounts in an attempt to loosen the seal. In fact, we actually removed the lag bolts from one mount and attempted to lift it off the roof, then bolted it back down and continued testing. The butyl seal adheres so well to the shingle surface, that we could not remove it without damaging the shingle.

Supplier data shows:

  • Use temperature over 100C
  • Over 500% ductility
  • No reduction in properties after 100,000 rapid freeze-thaw cycles
  • No apparent reduction in physical properties after 1000 hours accelerated weather testing.

You can look this interesting note up: butyl tape is used to seal the mounting holes for solar panels on the roof of RV’s. Apparently, constant 60-75 mile per hour winds on the highway are not enough to cause problems with those mounts.

The bottom line is that butyl rubber seals will perform well for the life of the installation when used according to our directions. We will keep testing and report back periodically. For now, check out the Tesserack Z for shingled roof with the butyl rubber gasket!

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