We feel our design is unique, because of the gentle curve of the support holding up the panels. We have engineered the curve to be strong enough for the loads, while creating a graceful appearance. The materials we use are standard aluminum sections, however the size and thickness are proprietary, in that we have figured out the optimum strength to weight ratio for these sections.What also makes our brackets special is the quality of the TIG welds* done by certified welders on every bracket. If you have ever tried TIG welding you will appreciate how every weld has smooth consistent beads, like you would see on a custom-built bicycle frame. This is accomplished by many years of experience by our welders in a certified fabrication shop. The connection of the horizontal to vertical member at the top is welded all along the joint-a total of 5” of welded connection-overkill for the connection perhaps, but better safe than sorry.
Our brackets are made in Northern California, and qualify for “Buy American” jobs. They are hand welded, not produced by robots. Each is visually inspected for defects before shipping. They are warranted for the lifetime of the solar installation. If any material failure occurs in brackets installed at the proper spacing, the bracket will be replaced free of charge.
* TIG welding is a process where the weld is shielded by Argon gas as the Aluminum filler rod is fed into the arc.
We price each job individually, as there are economies of scale- with bigger jobs the brackets
will cost less/each. The finish color and angle are a factor in pricing. Also if we have the
brackets in stock we will discount them.
It’s important to remember that an awning is considered a roof structure by the building
department. As a roof structure it must be able to resist both the live and dead loads put on it.
The building department requires it to withstand a 20 lb live load, in addition to any snow and
wind loads. The price of the structure will increase your ‘cost per watt’ because you need a
robust structure to handle the loads, similar to if you were building a ground mount structure.
Here is an example: A recent job involving a 30’ portrait awning, with brackets 4’ on center ( 8
brackets) and including the racking on top with top clamps cost $1850. The array had 9
panels at 375 watts each for a total of 3375watts. The cost per watt for the awning support
and racking was @ .55 cents per DC watt.
While this is higher than your ‘normal racking cost, remember that the awning is also shading
windows in the summertime, reducing your electric bill from air conditioning. This double
benefit will likely pay off the more expensive racking costs in very little time. Also if your roof is
facing the wrong direction, the increased production from a south facing awning more than
justifies the expense.
Our structural engineering company has done an extensive computer analysis of the materials, joinery, and geometry of the Bracket. The 16-page document proving the strength of the design for wind conditions up to 140 MPH. and live loads up to 40 Lb’s sq/ft. The engineering is Unstamped.This document can be used by a licensed engineer for your state, to stamp your plans for a building permit submittal. Awnings are considered roof structures by building departments and are subject to the requirements that roof structures fall into. The engineer will have to review the calculations to understand the values of the bolt loading and design the specific connection to your structure. Local loading conditions, such as wind uplift & snow load at the site, must be considered by the on-site engineer.
We provide copies of our engineering with every order. These are the calculations from which our span tables are derived from. If you have a project in development we will provide the calculations to your structural engineering firm for review. However we do not release our engineering to the general public. Often there are some questions that come up, such as limited structure suitable for bolting into. We work with designers & engineers all the time to find solutions to these problems. (Click to see a sample Engineering Document)
With greater than 40 pounds per square foot snow load (portrait) or 50 lbs (landscape), the straight armed bracket must be deployed. Loading exceeds the capacity of the curved support to withstand bending at the spacing indicated on the span tables.
Yes. We drill brackets for frameless panels such as to the exact specifications of the manufacturer. For Lumos panels there is no charge. On other frameless panels there may be a fee for custom drilling. (Click to see Lumos examples)
We do have a bracket that will accommodate the larger 72 cell panels in portrait
orientation. These panels are typically 77-80” long. However these brackets are
larger, and don’t fit on a standard 48” pallet, so shipping is more expensive. They also
need to be made out of heavier material which adds to the cost. If you can get high
efficiency 60 cell panels, that are about 65” long, which can provide up to 400 watts of
power each- this will be your best, most cost efficient option.
Doing 2 panels in landscape is not recommended. You could put extensions on our
brackets to accommodate the racking spacing, however this solution has NO
engineering. It would not be suitable for any snow load!
Yes, as long as the panel is about 40” wide or less and about 65” long or less. However for Landscape applications, the racking runs the long direction of the panel. Certain module manufacturers do not warranty their products for running the racking in this direction. Check with the module manufacturer first.
For small landscape orientation projects, or single panel over a window, consider bottom mounting a module with two brackets each.
The racking must be able to span the distance between brackets. Most racking manufacturer’s have span tables on their websites. Power-Structures likes ProSolar Racking for it’s simplicity and economy. It is a channel that can bolt directly to the Bracket, rather than using L-feet. However all major brands, such as UniRac, IronRidge, SnapNrack are compatible with our system.Our brackets come predrilled for 3/8” bolts to attach racking.It’s also possible to bottom mount modules directly to the brackets. Power-Structures will custom drill holes at specific locations as directed by the customer/ module specs.
For specific attachment methods, the installer must rely on the recommendations of their engineering professional. Particular attention must be paid to using anchors that will not corrode by electrolysis with aluminum.
- Stainless Steel anchors are recommended, and true galvanized steel anchors are acceptable. NOT acceptable are “zinc covered steel” bolts that are commonly sold at hardware stores.
- In Wood Framing the most common bolts used are lag bolts
- In Masonry Construction the engineer may specify expansion or epoxy anchors
- In SIP (Structural Insulated Panels) the anchors would be through bolts in the space between framing members, lags into framing members.
The brackets are predrilled at 3 points along the vertical member. Additional anchors may be required as determined by the on-site structural engineer.
We recommend using a very good exterior polyurethane sealant in and around all penetrations. Some popular brands we have had success with are Sikaflex, Vulcum and PL.On beveled siding, it may be necessary to custom fabricate washers/shims to the bevel angle.On very rough stucco, it may be necessary to remove high spots and or fill in low spots to get the brackets to sit plumb.
Painting the aluminum is not a recommended finish for the brackets. Powder-coating, which is a process of the pigment being electrically attracted and then baked in an oven is a much better, longer lasting finish.
It’s determined by your loading. See span table
In -Stock orders under 12 brackets usually ship in 5 days
Orders over 12: 2-4 weeks
Custom orders: 6-8+ weeks
Yes. We process credit card payments through PayPal. The fee’s will be split and 1.45% will be added to your invoice. If there is time on your job, your order can be paid with a check through the good old US mail, and you’ll save the charges.
Orders under $1000 are paid in full at the time of the order. Orders over $1000 are split in half, with a 50% deposit and 50% paid COD to the trucking company.
