d05 - Mounting and installation VF01

Introduction

The basic construction and the materials for construction are described in guideline b5. This guideline shows the practical aspects and experience from the installation.


Components description. 

Hilti Hanger profile MFT-HP 200 (horizontal profile)
Main support structure for the BIPV modules.

Hilti Profile MFT-L 60 x 40 x 1,8  6m (vertical profile)
Main vertical profile to connect with the brackets on the bearing wall.

Height 60 mm Height 40 mm
Width 21.5 mm Width 60 mm
Length 6 m Length 6 m
Thickness 2 mm Thickness 1.8 mm
Material composition EN AW-6063 T66 Material composition EN AW-6063 T66
Surface finish Flat

Aluminium Self-drill screw S-MD03S 5,5×32 mm
Used to connect the profiles.

Aluminium Self-drill screw S-AD01S 5,5×19 mm
Used to connect the profiles.

Screw diameter 5.5 mm Screw diameter 5.5 mm
Length – L 32 mm Length – L 19 mm
Drilling capacity 2.1 – 6 mm Drilling capacity 1.5 – 4 mm
Thickness range 0.5 – 17 mm Thickness range 1.5 – 10 mm
Washer size 12 mm Washer size 12 mm
Screw  type Hexagon 8 Screw  type Hexagon 8
Corrosion protection Stainless steel A2 Corrosion protection Stainless steel A2
 Washer type  None Washer type Pressed-on

Hilti Bracket MFT-MFI 065 M 11
Bracket that is mounted on the wall (see d5 Mounting and installation) and used to mount the vertical profiles.

Anchor rod HIT-V-R M10x115
Anchoring the bracket to the wall.

Length 65 mm Dril bit diameter 12 mm
Hole diameter – D 11 mm Anchor size M10
Material composition EN AW-6063 T66 Anchor length 115 mm
Height 86 mm Material composition Steel A4 (SS316)
Width 68 mm Environment Outdoor
Insulation material Polypropylene
Thickness insulation material 5 mm

Injectable mortar HIT-HY 270 330/2
Adhesive anchoring system for anchor fastenings in hollow and solid masonry.

Mesh sleeve HIT-SC 16×85

Anchoring element HIT-IC internally-threaded rods,
HIT-SC mesh sleeves,
HIT-S mesh sleeves,
HIT-V threaded rods
Drill bit diameter 16 mm
Environment Indoor, damp conditions, Indoor, dry conditions,
Indoor, ventilated facades, Outdoor
Anchor size 8/10 mm
Mixer types HIT-RE-M Anchor length 85 mm
In-service temperature -40 – 80 °C Material composition Plastic
Approvals / test reports ETA, Fire Environment water
Application Concrete (aerated), Masonry (hollow), Masonry (solid),
Some types of natural stone

 

Framework installation

Wall conditions:

The wall must be even and free of obstacles, such as gutters, thick cable tubes or external pillars that would disrupt its flatness. In opposite case, please see remark , at the end of this document. Given the structure of the wall mentioned above [3cm Plaster – 12cm brick – 5cm DOW(Polystyrene) Insulation – 9cm brick – 3cm Plaster] and for the best force distribution, the mounting of vertical profiles at a distance of 400mm was proposed. The distance between horizontal profiles is determined by the hangers behind the modules, which is 400mm. The drill holes on the wall must be done with the use of a multi-line laser, according to the drawing below.

Installation steps

Installation of the brackets: drill holes in the wall and then inject the chemical mortar HIT-HY 270 330.

Step 1 : Position the bracket on the wall and step 2 : Drill the hole

Use the mesh sleeve HIT-SC 16×85 and a rod HIT-V-R M10x115

Step 3 – Inject the chemical mortar and insert the mesh sleeve and rod. Step 4 – Drill the rod until it reaches the bracket surface, fixing the system

Installation of the vertical profiles: the maximum recommended length of vertical profiles is 3.6 m. By using a cutter, a longitudinal cut must be made along the insulation material, introducing the vertical profile in the created cavity. Attention should be paid to fixed or flexible point of the construction design. A minimum distance of 10 mm should be left between vertical profiles.

Step 6 – Positioning of the vertical profile. For fixed points, the self-drill screw S-MD03S 5,5×32 is used to anchor the vertical profile to the brackets.
Step 7 – Screw the self-drill screw S-MD03S 5,5×32 in the holes aimed at fixed points.
For flexible points, the self-drill screw S-MD03S 5,5×32 is used to anchor the vertical profile to the brackets.

Step 8 – Screw the self-drill screw S-MD03S 5,5×32 in the holes aimed at flexible points.

Installation of horizontal profiles: the installation of the hanger profile MFT-HP 200 is performed anchoring it to the vertical profile by using the self-drill screw S-MD03S 5,5×32 in the exact measured points, in order to respect the correct positioning of the façade modules.

Step 9 – Anchoring of the hanger profile to the vertical profile, using the self-drill screw S-MD03S 5,5×32

Mounting of the PV panels

Start mounting the VF panels, one-by-one on the horizontal profiles and interconnect the electrical cables in strings, according to the electrical diagram.
The VF panels are hanged on the horizontal profiles, by sliding the pre-fixed hooks into the profile. See Picture below. No screws are needed, since the friction between rail-hook provides the necessary fixing.
Fasten all cables on the rails with tire-up, so that no cables are left loose or moving. See pictures below.

Spacers (Optional)

In case there are obstacles on the wall surface, protruding of it and thus disrupting its flatness, such as gutters, thick cable tubes or external pillars, certain spacer elements should be placed between the wall and the mounting pad of the framework.
This case applies in the VF mounting framework of the demo site in Pikermi, due to existence of gutters with thickness 120mm between two continuous wall parts and due to different protrusion of every wall part. This last reason indicates the use of two spacers together in one wall part and one spacer in the other wall part, in order to bring the PV framework in a straight line in front of the entire wall.
The spacers have dimensions of 40 x 40 mm and are shown in the picture below. The length can vary according to the needs for a steady fixing on the base pad or rails.

The left picture shows two spacers and the right picture shows one spacer.

Tools

  • Electricity Generator
  • Electric cutter
  • Mechanical level
  • Screwdrivers
  • Wrench
  • Rule
  • Scaffolding

Safety equipment

  • Protection glasses
  • Safety shoes
  • Gloves
  • Safety helmet
  • Safety belt

 

Text written by HERON, Greece