Using Steel in Solar Racking and Mounting

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Before We Start

Moderator

Steven Bushong Solar Power World

Presenters

David Devine Wheatland Tube

Sam Jaquette Patriot Solar

Ray Szkola Wheatland Tube

MECHANICAL TUBE FOR SOLAR

APPLICATIONS 6

What  is  Steel?

Iron  Iron  Ore  Coal    

Limestone  

Steel  Iron  Scrap  

Refined  

7

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

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  

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“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      

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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  

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  

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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

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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)  

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

Well  Understood  Design  

15

Dissimilar  Metals  

In  the  Presence  of  an  Electrolyte (Pencil)

Third coat of in-line galvanize process presents a thin organic barrier as well

16

However,  be  aware  of  Copper  and  Copper  run-­‐off  !!  (also  Tin  coated  grounding  clamps)  

“Safe”

“Safe”

“Safe”

Copper  

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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  

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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  

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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  

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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  

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Cusng,  Bending,  Swage,  Tube  Laser,  Punching,  Drilling,  Coping  –  well  understood  processes  

FabricaFon  OpFons  

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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  

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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  

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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  

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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  

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

Presenter: Adam Parr Date: July 30th, 2013

Using Steel In Solar Racking and Mounting

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

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

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

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

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

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

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

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

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

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

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

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

Thank You

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