Flat Roof Solar Panel Installation and Re-Roof One of the primary considerations when deciding to install solar panels on a flat roof is to determine the age and condition of the existing roof. The cost of removal and replacement of solar panels, to allow for re-roofing, can decrease the overall system savings. A wise solar purchase may include having a re-roof performed a year or so sooner, or to postpone the solar installation for a season. Below is a step by step installation of a solar panel mounting system that is incorporated into the construction a new roof. This process allows for no penetrations to be made in the new roof, and a structural attachment of the racking system. The installation sequence below consists of a 60 panel domestic Hot Water installation, with 10 solar panels on each of 6 buildings. Check out our new solar panel mounts STEP 1. Position the racks on the bare roof to find the correct alignment for placing mounts on top of the rafters.     STEP 2. Align the mounts on top of the rafters, pre drill the rafters with a pilot bit to avoid splitting the rafters, then secure the mounts to the roof with 6" lag bolts. Use a chalk line to keep the mounts in a straight line. The mounts used on this job are 6" long x 1" diameter, powder coated steel, tapped with 3/8" threads.         STEP 3. Finish bolting all of the mounts, typically every 4 feet, depending on rafter centers.       STEP 4. Make sure to cap and pressure test all copper plumbing that will be inaccessible after installation. Apply 10 mill PVC tape where the copper pipes pass through galvanized flashings or use copper flashings, to prevent electrolysis.       STEP 5. The next procedure is to have the roofers install the roof. The mounts are typically "felted in" before the flashings are installed.       STEP 6. Install the first layers of roofing material. The roof installed for this job is bonded by the manufacturer with a 20 year factory warranty. It has 1 layer of felt, 4 layers of roofing materials and a topping of hot asphalt and rocks. A top quality roof.       STEP 7. Have the roofers place and nail down the flashings.     STEP 8. Install the plumbing below while the roofers are working above.       STEP 9. Load the roof with the final layer of rocks. If possible utilize the loading truck to help get the solar panels onto the roof.       STEP 10. As the roofers apply the final layer of hot mop asphalt and rocks, it may be necessary to move the solar panels out of the roofers way. This is easier than than hoisting the solar panels up after the roof is completed.     STEP 11 Place the solar panel racks on top of the mounts. Bolt the racks to the mounts.     STEP 12. Install the solar panels onto the racks.       STEP 13. The web page will continue to be updated.