2. Using Steel in Solar
Racking and Mounting

3. Sponsored By:

4. q This webinar will be available afterwards at
www.solarpowerworldonline.com & email
q Q&A at the end of the presentation
q Hashtag for this webinar: #SolarWebinar
Before We Start

5. Moderator
Steven Bushong
Solar Power World
Presenters
David Devine
Wheatland Tube
Sam Jaquette
Patriot Solar
Ray Szkola
Wheatland Tube

6. MECHANICAL TUBE
FOR SOLAR
APPLICATIONS
6

7. What
is
Steel?
Iron
Iron
Ore
Coal
Limestone
Steel
Iron
Scrap
Refined
7

8. Steel
Making
Processes
-­‐
From
Ore
Typical
“Integrated
Mill”
Coal
(Coke)
Iron
Ore
Limestone
Blast
Furnace
Self
Fueling
once
Started.
Campaigns
approx.
7-­‐years
before
reline
Pig
Iron
(4.5%
Carbon)
Recycled
Steel
Scrap
Oxygen
Basic
Oxygen
Furnace
2/3
1/3
Molten
Steel
98%
Fe
0.04-­‐1.5%
C
+
alloys
3000°
ConQnuous
Caster
Steel
Slab
Hot
Strip
Mill
Hot
Band
Thickness
reducQon
of
slab
Finishing
temperatures
control
internal
microstructure
of
steel
hot
band
8

9. Steel
Making
Processes
-­‐
EAF
from
Scrap
Typical
“Mini-­‐Mill”
Recycled
Steel
Scrap
Molten
Steel
98%
Fe
0.04-­‐1.5%
C
+
alloys
3000°
ConQnuous
Caster
Steel
Slab
Hot
Strip
Mill
Hot
Band
Thickness
reducQon
of
slab
Finishing
temperatures
control
internal
microstructure
of
steel
hot
band
Or
Thin
Slab
Caster
Electric
Arc
Furnace
100%
scrap
charge
+
alloy
addiQons
Electrodes
44,000
amps
Approx.
400
kW
per
ton
9

10. “Carbon
Steel”
typically
used
in
solar
include:
Plain
Carbon
Steels
A
steel
may
be
classified
as
a
carbon
steel
if
(1)
the
maximum
content
specified
for
alloying
elements
does
not
exceed
the
following:
manganese—1.65%,
silicon—0.60%,
copper—0.60%;
(2)
the
specified
minimum
for
copper
does
not
exceed
0.40%;
and
(3)
no
minimum
content
is
specified
for
other
elements
added
to
obtain
a
desired
alloying
effect.
HSLA
High-­‐strength
low-­‐alloy
(HSLA)
steels,
or
microalloyed
steels,
are
designed
to
provide
becer
mechanical
properQes
and/or
greater
resistance
to
atmospheric
corrosion
than
convenQonal
carbon
steels.
They
are
designed
to
meet
specific
mechanical
properQes
rather
than
a
chemical
composiQon.
HSLA
steels
are
classified
as
a
separate
steel
category,
which
is
similar
to
as-­‐rolled
mild-­‐carbon
steel
with
enhanced
mechanical
properQes
obtained
by
the
addiQon
of
small
amounts
of
alloys
and,
perhaps,
special
processing
techniques.
Carbon
Steel
10

11. Plain
Carbon
Grades
(Carbon
is
major
Hardening
Component)
Grade
Carbon
Yield Strength
Tensile Strength
Elongation
1008
0.10 max
28,000
48,000
45%
1010
0.08-­‐‑0.13
42,000
52,900
41%
1015
0.13-­‐‑0.18
45,000
60,000
39%
1022
0.17-­‐‑0.23
58,000
68,900
35%
Carbon
Yield Strength
Tensile Strength
Elongation
Weldability
Carbon
Equivalent:
More
Bricle
11
Steel
CharacterisFcs

12. E
(Modulus
of
ElasQcity)
–
“E
envy”
30,000
ksi
Steel
10,000
ksi
Aluminum
Yield
Strength
(typical):
Aluminum
Extrusion
6063
T-­‐6
25,000
psi
Mechanical
Tube
In-­‐line
Galvanize
45,000
to
70,000
psi
(higher
if
needed)
Thermal
expansion
stability:
Steel
(1010)
6.8
x
10-­‐6
in/in
°F
Aluminum
13.0
x
10-­‐6
in/in
°F
Modulus
of
ElasFcity
12

13. Material
Tons
Steel
37,186,872
Paper
25,232,199
Aluminum
2,253,749
Glass
1,533,529
Plastic
1,156,271
North
America's
#1
Recycled
Material
Estimated Tons Recycled By Material Since January 1, 2013
Source: Steel Recycling Institute
13

14. LEED
MR
Credit
2:
ConstrucFon
Waste
Management
Unlike
other
materials,
steel
contains
recycled
material
and
is
also
fully
recyclable.
In
fact,
according
to
the
Steel
Recycling
InsQtute
(SRI),
steel
is
the
world’s
most
recycled
material.
Therefore,
scrap
produced
during
construcQon
is
diverted
from
landfills.
LEED
MR
Credit
4:
Recycled
Content
There
are
two
different
technologies
used
to
make
steel
–
the
Basic
Oxygen
Furnace
method
(BOF)
and
the
Electric
Arc
Furnace
(EAF).
These
processes
use
differing
amounts
of
old
steel
to
make
new
but
neither
should
be
considered
environmentally
superior
to
the
other.
The
annual
average
industry
values
for
the
recycled
content
of
steel
manufactured
in
BOF
and
EAF
furnaces
are
allowed
to
be
used
as
the
recycled
content
of
steel
products.
(www.recycle-­‐steel.org):
Post
Consumer:
19.8%
(BOF)
69.0%
(EAF)
Pre
Consumer:
14.4%
(BOF)
19.5%
(EAF)
If
you
prefer
not
to
submit
an
average
number,
use
the
BOF
percentages
as
a
conservaFve
number.
Steel
products
are
net
contributors
to
the
LEED
recycled
content
points
even
when
using
the
more
conservaFve
percentages
shown
for
BOF
mills.
LEED
MR
Credit
5:
Regional
Materials
We
manufacture
steel
mechanical
products
in
Chicago,
IL;
Wheatland,
PA,
and
Sharon,
PA
LEED
(Leadership
in
Energy
&
Environmental
Design)
14

15. AISC,
AISI,
Cold
Form
Steel
Engineers,
etc.
Understood
by
both
Engineers
and
Code
Officials.
Well
Understood
Design
15

16. Dissimilar
Metals
In the Presence of an Electrolyte
(Pencil)
Third coat of in-line galvanize process presents a thin organic barrier as well
16

17. However,
be
aware
of
Copper
and
Copper
run-­‐off
!!
(also
Tin
coated
grounding
clamps)
“Safe”
“Safe”
“Safe”
Copper
17

18. Easily
adjusted
for
topographic
changes
–
custom
lengths,
wall
thicknesses
to
help
compensate
for
uneven
ground
thereby
disturbing
the
natural
environment
less.
Light
weight
compared
to
structurals
or
formed
shapes
–
tubular
members
offer
the
greatest
strength
to
weight
raQos.
Strong
compared
to
aluminum
–
larger
and/or
more
members
are
typically
required
in
aluminum
to
support
the
same
loads.
(Remember
that
“E-­‐envy”
thing
?).
This
may
result
in
more
parts,
more
labor,
more
Qme
to
erect
aluminum
support
structures
compared
to
in-­‐line
galvanized
steel
tubular
structures.
In-­‐Line
Galvanized
Mechanical
Tubing
18

19. ASTM
SpecificaQons
A513,
A500
(usually
Grade
B,
or
Grade
C)
A500
Note:
Manufacturer
can
cerQfy
higher
min
properQes
Structural
Steel
(beams)
versus
tube
specs
Yield
36,000
psi
min
Tensile
68,0000-­‐80,0000
psi
ElongaQon
21%
(in
2”)
“…and
inspected
in
accordance
with
this
specificaQon
and
any
other
requirements
designated
in
the
purchase
order
or
contract,
and
was
found
to
meet
all
such
requirements.…”
ASTM
SpecificaFons
19

20. Rounds,
Squares,
Rectangles
in
various
sizes
Up
to
5”
round,
and
4”
square
and
thickness
up
to
.220”
Maximum
flexibility
–
not
limited
to
a
single
size/shape
and
can
intermix
tube
size
to
opQmize
designs.
Manufacture
and
DistribuQon
well
established
Wide
Variety
of
Profiles
20

21. 99.99%
High
Grade
Zinc
exterior
coaQng
Triple
coat
/
advanced
coaQng
technology
–
The
synergisQc
effect
that
protects
the
steel
provides
corrosion
protecQon
beyond
individual
coaQng
components
alone.
Steel
tubing
is
manufactured,
coated
with
high
grade
zinc,
and
further
protected
with
a
conversion
coaQng
and
clear
organic
layer.
All
in
one
conQnuous
operaQon.
Secondary
FabricaQon
–
Could
be
provided
by
the
tubing
manufacturer
in
many
cases.
Holes,
bends,
swage,
etc.
completed
in
the
factory
to
save
Qme
and
labor
at
the
job
site.
Minimize
transportaQon
costs
–
Coated
product
is
shipped
directly
from
tube
manufacturer
to
the
job
site.
No
need
for
secondary
coaQng
operaQons,
painQng,
or
other
transportaQon
dependent
corrosion
treatments.
Made
and
Melted
in
America
–
insuring
quality
and
traceability
of
your
materials.
Benefits
of
In-­‐line
Galvanized
Mechanical
Tube
21

22. Cusng,
Bending,
Swage,
Tube
Laser,
Punching,
Drilling,
Coping
–
well
understood
processes
FabricaFon
OpFons
22

23. Welding,
BolQng,
Self
Drilling
Screws,
Nutserts,
Clamps,
Brackets
–
common
hardware,
various
straps
and
fixtures,
(used
in
a
lot
of
industries
such
as
fence,
greenhouse,
playground,
docks,
farm,
equine,
etc.)
–
or
you
can
easily
make
what
you
need.
No
need
for
special
proprietary
hardware
to
fit
special
proprietary
shapes.
Assembly
OpFons
23

24. A
plethora
of
steel
erectors
and
fabricators
can
be
found.
Assembly
methods:
• Field/sQck
built
• Factory/Prefab.
Mechanical
Tubing:
Easily
obtained,
no
tooling
or
special
runs
as
with
custom
profiles.
Changes
to
order
quanQQes
are
easily
dealt
with
among
the
common
sizes.
InstallaFon
Methods
24

25. Who
is
JMC
Steel
Group?
The
JMC
Steel
Group
• Five
operaQng
divisions
• 19
faciliQes
• ConverQng
approx.
2.5
million
tons
of
pipe
and
tube
annually
• Delivering
soluQons
across
the
conQnent
25

26. Broad
Poreolio
of
Products
Structural
–
PosiFon
#1
• Structural
Support
• A500
CerFfied
• Nonres
&
Nonbuilding
ApplicaFons
Piling
–
PosiFon
#1
• Infrastructure
/
FoundaFons
• A252
CerFfied
• Bridges,
Dams
&
Solar
Racks
Fence
–
PosiFon
#2
• Perimeter
Security
• ASTM
CerFfied
• ResidenFal,
Commercial
&
Industrial
Conduit
PosiFon
#1
• Wire
management,
circuit
protecFon
• UL
Listed,
ANSI
Approved
• Non-­‐Res
&
MulF-­‐story
residenFal
Mechanical
–
PosiFon
#2
• A500,
513
CerFfied
• Wide
range
of
sizes
&
customer
lengths
• Solar,
Greenhouses,
Playground
Equip.
Standard
Pipe
–
PosiFon
#1
• Air,
Water,
Gas,
Steam
Transmission
• UL
Listed,
FM
Approved,
MIC
Shield
• Commercial
&
Industrial
ConstrucFon
DOM
–
PosiFon
#2
• Fluid
Power
• API
Listed
• Heavy
Industrial
Equipment
Line
Pipe
&
Casing
• Oil
&
Gas
Transmission
• API
5CT
&
5L

27. Contact
Info
for
your
QuesFons
or
Follow-­‐Up
David
Devine
david.devine@wheatland.com
Phone:
(219)
669-­‐7857
Ray
Szkola
raymond.szkola@wheatland.com
Phone:
(312)
561-­‐0667
Thank
You
27

28. Presenter: Adam Parr
Date: July 30th, 2013
Using Steel In Solar Racking and Mounting

29. Presentation Overview
• Functionality
• Durability
• Availability
• Capacity
• Costs
Why We Use Steel
Steel vs. Aluminum
• Patriot History
• Switching from Aluminum
to Steel
3.4MW Ground Mount Field

30. Multiple Post Options
• Hat Shaped, I-Beam, Helical
Various Sizes, Gauge Thickness
and Lengths
• Posts, Rails, Truss
“I am still waiting for the first project with the following criteria: Perfect Soils, Flat
Terrain, Perfect Weather, Standard Module and String Sizes” – Adam Parr
Why We Use Steel: Functionality
I-Beam Post Hat-Shaped Post

31. Bankability – Long Lasting
• Galvanization
• ASTM Standards
Why We Use Steel: Durability
Galvanized Patriot Racking System
Rail Length
• Span Further
• Increased to 5 panels per
section with 202” rail
• Meets 100 + mph windloads

32. Wide Spread Project Locations
• East & West Coast
• National Suppliers
Quick Lead Times
• 2-4 weeks on some items
“Off The Shelf” Components
• Standard posts and rails
Why We Use Steel: Availability
Patriot rails being shipped to site location

33. Demanding Project Timelines
• High volume in short time frame
• Delivery in 4-6 weeks or less
Inventory Components
• Coils, Post, Rails
• Forecasting
“I am still waiting for that first project that begins on its scheduled time. The solar
construction industry is a hurry-up and wait scenario” –Adam Parr
Patriot Roll-Formed Steel Rail
Why We Use Steel: Capacity

34. Piece Price and Tooling
• High Tooling Cost but Lower
Piece Price
• Significant cost savings on
large projects
• Lowered $/watt by over 25%
by switching to steel rails
Overall Value
• Meets all design criteria
• BOS System
Why We Use Steel: Cost
1.2MW Landfill Project

35. Patriot History
• Satellite and Antenna Industry
• Proven Material – Over 8 Million Steel Structures Deployed Worldwide
1992-2008 2004-2010 2007-2010 2010-present 2010-present

36. Patriot Aluminum Rail
Why We Switched
Added
Hardware
• Less Parts
o Minimal hardware when
rails slide into each
other
• Lower Costs
o Significant reductions to
pass on to customer

37. Module hardware slid in from end
of each row with aluminum rails
Why We Switched: Continued
Added
Hardware
• Easier/Faster Install
o Modules installed using
top clamps instead of
attaching to back of
module
o No longer have to slide
modules on from end of
rails

38. Why We Switched:
Continued
Patriot Steel Rail
Patriot steel rails slide into
each other for minimal
hardware and fast install
Patriot top clamps instead
of previous underside
module bolts

39. Presentation Recap
• Functionality
• Durability
• Availability
• Capacity
• Costs
Why We Use Steel
Steel vs. Aluminum
• Patriot History
• Switching from Aluminum
to Steel 3MW Ground Mount Field

40. Questions?
Solar Power World
Steven Bushong
sbushong@wtwhmedia.com
Phone: 440.234.4531
Twitter: @WTWH_Renewables
Wheatland Tube
David Devine
General Manager - Mechanical
and Fence Products
David.Devine@wheatland.com
Phone: 219.669.7857
Twitter: @WheatlandTube
Patriot Solar
Sam Jaquette
Account Manager
sjaquette@patriotsolargroup.com
Phone: 517.629.9292
Twitter: @PatriotSolar
Wheatland Tube
Ray Szkola
Technical Sales Manager
Raymond.Szkola@wheatland.com
Phone: 312.561.0667
Twitter: @WheatlandTube

41. Thank You
q This webinar will be available at
www.solarpowerworldonline.com & email
q Tweet with hashtag #SolarWebinar
q Connect with
q Twitter: @SolarPowerWrld
q Facebook: …/SolarPowerWorld
q LinkedIn: Solar Power World Group
q Discuss this on EngineeringExchange.com