Polar Bear® III HD 10 Degree

Installation Manual
Document Number 9910035 Rev B
Sep 2016

System Fire Class Rating: Class A for low slope roofs with Type I & Type II Modules
Mechanical Load Rating: See Appendix B: UL 2703 Grounding

panelclaw.com
 Revision History

Rev ECO # Date Description of Changes Approved By

A C00430 16-FEB-16 INITIAL RELEASE CN
Add Short Ballast Tray Installation,
B C00457 12-SEP-16 changed bonding/grounding wire size to CN
#12 or #10 AWG Cu, Add Appendix F

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 Table of Contents
Revision History ............................................................................................................................................ 2
Table of Contents .......................................................................................................................................... 3
Introduction .................................................................................................................................................. 4
Document Objective ..................................................................................................................................... 4
Safety Overview ............................................................................................................................................ 4
Parts and Hardware ...................................................................................................................................... 5
Required Tools .............................................................................................................................................. 6
Torque Settings ............................................................................................................................................. 6
Installation .................................................................................................................................................... 7
Step 1: Attach Claws to Modules (Prep)................................................................................................. 7
Step 2: Set up Spacer Stick ..................................................................................................................... 7
Step 3: Build Southern Row of Modules ................................................................................................ 8
Step 4: Install Array Row-By-Row ......................................................................................................... 12
Step 5: Electrical Grounding ................................................................................................................. 13
Appendix A: Safety ...................................................................................................................................... 14
Appendix B: UL 2703 Grounding ................................................................................................................. 16
Appendix C: Electrical Grounding (UL 2703 not applicable) ....................................................................... 18
Appendix D: UL 2703 Fire Classification...................................................................................................... 20
Appendix E: Shim Pad Installation .............................................................................................................. 21
Appendix F: Ballast Blocks........................................................................................................................... 22

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 Introduction
Polar Bear® III HD 10 Degree flat roof system comprises of three major components that intuitively
assemble into a flat roof PV mounting system array. The following features improve construction
performance, optimize maintenance and increase power density:
 Just three major components (Support, Ballast Tray and Claw), light-weight and easy to move
 Tight-row spacing for increased power density
 Compatible accessories to simplify wire management and microinverter attachment
 Built-in rubber roof pads to help prevent roof top damage

Document Objective
This installation manual has been put together to assist in the proper steps required to build a
photovoltaic array using Polar Bear III HD 10 Degree.

“THIS INSTALLATION MANUAL DOES NOT COVER SELECTION OF OR INSTALLATION OF ANY MATERIALS
USED TO SEAL A MECHANICAL ATTACHMENT TO THE ROOF. FOR THESE INSTRUCTIONS PLEASE SEE OEM
PROVIDER INSTALLATION MANUALS AND RELATED LITERATURE. A LIST OF OEM PROVIDERS IS SHOWN
BELOW.
THIS INSTALLATION MANUAL DOES NOT COVER SELECTION OF OR INSTALLATION OF FASTENERS
REQUIRED TO FASTEN A MECHANICAL ATTACHMENT TO THE ROOF STRUCTURE ITSELF. FOR THESE
INSTRUCTIONS, PLEASE SEE OEM PROVIDERS INSTALLATION MANUALS AND RELATED LITERATURE. A
LIST OF OEM PROVIDERS IS SHOWN BELOW”

OEM MECHANICAL ATTACHMENT PROVIDERS:

 Anchor Products: www.anchorp.com
 OMG Roofing Products: www.omgroofing.com
 ECOFasten Solar: www.ecofastensolar.com

Safety Overview
Safety is an essential part of every photovoltaic (PV) installation and every construction site. It is
imperative to plan ahead for any safety concerns and hazards to promote safe work practices during
installation. This section does not claim to address or support all safety concerns that may arise during
the installation of PanelClaw mounting systems or any other aspect of the work being performed. Before
beginning work, installers should refer to all local and federal safety, health, and regulatory
requirements to assure compliance. Refer to OSHA Part 1926 and its related Subparts for federal
construction related regulations and standards.

The section in Appendix A: Safety outlines some of the obvious / major hazards that could exist during
the installation of PanelClaw products, and are divided to bring a level of clarity to such hazards. Some
sections do not apply to all PanelClaw product lines and such exclusions are noted within each section.

PRIOR TO INSTALLATION, READ THE SAFETY PROVISIONS ATTACHED IN APPENDIX A: SAFETY AND
REVIEW THE INSTALLATION MANUAL IN ITS ENTIRETY.

An annual corrosion inspection and potential corrective actions are required to maintain product
warranty. Visible surface red rust on galvanized steel components must be locally coated with a
commercially available galvanized paint or coating to maintain product warranty.

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 Parts and Hardware

Major Components

 Supports  Claw  Ballast Trays

Short Ballast Tray

North Support

Support Long Ballast Tray

South Support

Hardware Kits

 Claw Fastener Kit  Ballast Tray Nut Kit  Ballast Tray Bolt Kit

Ballast Mechanical Attachments System Accessories

 Ballast Block  OMG Roofing Products 

(Customer supplied, PowerGrip Shim Pad
See Appendix F: Ballast Blocks) PowerGrip Plus Microinverter Attachment Kit
Optimizer Attachment Kit
EcoFasten® Solar
Anchor Products
U-Anchor 2000
U-Anchor 2400
U-Anchor 2600

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 Parts and Hardware
 Support Support unit with pre-installed integrated recycled rubber pads

 Claw Module clamp with integrated bonding. Used to attach modules to Supports

 Ballast Tray Connects Supports and captures 4”x8”x16” or 2” x8” x16” ballast.

 Claw Fastener Kit

Serrated flange nuts Stainless Steel 18-8
Hex head cap screw Stainless Steel 18-8

 Ballast Tray Nut Kit Serrated flange nuts 1/4-20 Stainless Steel 18-8

 Ballast Tray Bolt Kit Hex head cap screw 1/4-20 x 0.5” Stainless Steel 18-8
Solid cap concrete roof paver, conforms to ASTM C 1491-03 standard and manufactured for
 Ballast Block freeze-thaw resistance where applicable. Block must be specified so that it maintains its weight
over the life of the system.

 Mechanical Attachment
(design dependent)
Designed with OMG Roofing Products (PowerGrip and PowerGrip Plus), EcoFasten® Solar, and
Anchor Products (U-Anchor family) attachment systems as needed.

Required Tools
 3/8” drive torque wrench (settings available up to 10 ft-lbs)
 3/8” deep socket (bolts)
 7/16” deep socket (nuts)
 1/2” deep socket (5/16” bolts/nuts)
 Spacer Stick (supplied) Figure 2 on page 8.
 Battery powered tools may be used as long as they do not exceed torque requirements

Torque Settings
Torque Setting Fastening Operation
4-6 ft-lb (48-72 in-lb) Attaching Ballast Tray to Support
Attaching Claw to Module
8-10 ft-lb (96-120 in-lb)
Attaching Claw to Support

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 Installation
Step 1: Attach Claws to Modules (Prep)
1. Lay module, glass side down, on work surface.
2. Place Claw over appropriate mounting hole while resting Claw flange against outside edge of
module (reference the “ARRAY DIMENSIONS” table in the project drawings if the module has
more than four mounting holes).
3. Insert bolt through Claw and module holes.
Note: Shift the Claw towards the module junction box such that it “bottoms out” against the
bolt. This will ensure that the Claws on the module are always consistently spaced.
4. Reach under the module frame flange and thread nut onto bolt until snug.
5. Press Claw tab against module frame and tighten bolt to 8-10 ft-lb (96-120 in-lb) of torque
(Figure 1).
6. Repeat Steps 2 through 5 for the other Claw.

Tab

Module

Torque to 8-10 ft-lb

(96-120 in-lb)
Note: All the Claws should be the same orientation
relative to the junction box. (Exception: when using
optimizers or due to string requirements)

Figure 1 Claw Placement on Module

Step 2: Set up Spacer Stick

1. Consult the provided Racking Construction Set drawing for the Support spacing between
modules (Spacing L) and Support spacing under modules (Spacing Q) (Figure 2). Dimensions L
and Q are module dependent and vary for each manufacturer.
2. Reference the Q and L dimensions on the Racking Construction Set drawing. Set two spacer stick
brackets to the Q dimension and 2 spacer stick bracket to the L dimension.

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 4x Adjustable Spacer
Stick Bracket

Figure 2 Spacer Stick

Step 3: Build Southern Row of Modules

1. Snap north-south and east-west layout lines (chalk or dry line recommended) for the edge of the
array. Consult the Racking Construction Set drawing for the Support spacing from array edge
(Spacing R).
2. Begin the array at the southeast or southwest corner.
3. Place the three South Supports in approximate locations east-west and use the Spacer Stick
provided to set the Supports in the correct locations. Eastern Support roof pads must be lined

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 up with north-south snap line. Southern Support roof pads must align with the east-west snap
line. (Figure 3).

Support

x3
South Support
Array Perimeter

Figure 3 Starting the Array

4. Carry module (with Claws attached) to south-east (or west) corner.

5. Follow Figure 4 to align Claws over the South Support mounting holes. Insert bolts through Claw
and Support mounting hole. Finger-tighten nuts onto bolts.
6. Lower module onto upper mounting hole of the Support. Move the Support in or out to align
the holes. Insert bolts through Claw and upper mounting hole of the Support.

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 Reference Detail A sheet PC-3 of the
Racking Construction Set drawing for
correct Hole Location

High Side of Module

1 x2 x2
Long end of the Torque to
South Support will 8-10 ft-lb (96-120 in-lb)
stick out past the 2 x4
modules.
Use this hole for all
2 x2 x4 low side connections
1 in all rows except
Installation where the South
is shown Support is used
into Hole 1

Figure 4 Attach Module to Supports

7. Tighten all four mounting bolts to 8-10 ft-lb (96-120 in-lb) of torque.
8. Repeat Steps 6 through 9 for southern row. Be sure to use inter-column spacer to ensure that a
1”spacing is maintained.
9. Follow Figure 5. Place both Short and Long Ballast Trays on the South Supports. Center Long
Ballast Tray between two modules and visually align the Short Ballast Tray with the edge of
module. Shift Short Ballast Tray and find the appropriate Ballast Tray slots to connect two trays.
Either slots or through holes at the end of the Long Ballast Tray may be used.
Notes:
Trays may
overlap
more/less
depending
on the
module used.

2. Visually
align the
Short Ballast
Tray with
1. Center the Long Ballast module edge.
Tray between the two
modules. Notes:
In some instances the slots in the
3. Connect the trays by
Short/Long Ballast Tray will prohibit the
shifting the Short Ballast Tray.
Short Ballast Tray alignment with the
Figure 5 Install Ballast Trays to South Supports module edge. While this mis-alignment is
allowed, it should be minimized.

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 10. Bolt Ballast Trays to the South Supports using two ¼-20 x 0.5” serrated flange bolts to the pre-
installed rivet nuts. Bolt the Short Ballast Tray to the Long Ballast Tray using two ¼-20 x 0.5”
serrated flange bolts and the pre-installed rivet nuts on the Short Ballast Tray. Torque all ¼-20 x
0.5” serrated flange bolts to 4-6 ft-lb (48-72 in-lb). Use the Spacer Stick to keep the Ballast Tray
perpendicular to the Supports while maintaining the spacing between Supports.
11. Repeat Steps 3 through 12 but do not use another Short Ballast Tray until you reach the last
module in the row. Consult Racking Construction Set drawing for proper long and short Ballast
Tray placement.
12. Install required ballast into southern Ballast Trays and bend up the tabs at the ends of the row.
13. Move to the north side of the module and install Ballast Trays on the Supports. Center the Long
Ballast Trays between two modules and hang them on the pre-installed bolts. Use the Spacer
Stick to ensure the low sides of the Supports are properly spaced. Thread a serrated-flange nut
onto each of the pre-installed support bolts and torque to 4-6 ft-lb (48-72 in-lb) (Figure 6).
NOTE: Do not fasten Long Ballast Trays to each other where they overlap.

Do NOT bolt to each other

Figure 6 Attach Long Ballast Trays to Supports

14. Place Short Ballast Tray at either ends of the row and visually align the Short Ballast Tray with
the edge of the module. Shift the Short Ballast Trays to find the appropriate slots. Either the
slots or through holes of the Long Ballast Tray may be used to connect the Short and Long
Ballast trays. Install the Short Ballast Trays using two ¼-20 x 0.5” serrated flange bolts and the
pre-installed rivet nuts to attach the Long and Short Ballast Trays together. Install a serrated
flange nut onto each support bolt (Figure 7). Nuts and bolts must be torqued to 4-6 ft-lb (48-72
in-lb).
15. Install required ballast into the ballast trays and bend up the tabs at the ends of the row.

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 Hardware is required where
Long Ballast Trays and Short
Ballast Trays overlap

Figure 7 Attach Short Ballast Trays

Step 4: Install Array Row-By-Row

1. Place two Supports for each module at their approximate final resting location. If the row being
built is the last row in the array, use North Supports.
2. Connect module Claws to lower mounting holes on the Support of the previous row. Finger-
tighten bolts.
3. Tilt module down and adjust the placement of the previously spaced Supports to connect
module Claw to the high side of the Support. Finger-tighten nuts and bolts. Be sure to align the
outer support pads with north-south snap line.
4. Tighten all four mounting hardware to 8-10 ft-lb (96-120 in-lb) of torque.
5. Repeat Steps 1 through 4 for remainder of the row.
6. Install Long Ballast Trays, Short Ballast Trays and ballast blocks as done in the previous row.
7. Complete the array by constructing row-by-row until the north array edge. The north row in the
array utilizes North Supports to secure the high side of the module. If the project requires north
double capacity ballast, Ballast Trays are installed in both the inclined position and flat position
of the North Supports in a similar fashion to the south array construction. See Figure 8.

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 Notes:
Ballast Trays are also installed in flat
position of the supports if the project
requires north double capacity ballast.

Figure 8 North Double Capacity Ballast Tray Installation

Step 5: Electrical Grounding

Please consult with national and local building code(s) for complete grounding requirements for your
installation. The Polar Bear grounding method conforms to UL 2703 and is certified by UL for use with
approved photovoltaic modules listed under UL 1703. Installers can quickly and easily establish UL-
certified electric bonds between all connected array components, including modules and mounting
system components, without the use of additional grounding devices, e.g. ground lugs and copper wire.
At least one ground lug must be used to ground all strings within a physical sub-array provided the fuse
rating for each string does not exceed 30 amps. Installers may opt to use multiple lugs per sub-array for
redundancy. When grounding devices are installed according with the approved methodology and
capacity below, the connections described above meet all the requirements outlined in NEC 690.43.

Grounding Instructions
For modules that are certified to UL 1703, please follow the instructions below in Appendix B: UL 2703
Grounding. Additional information regarding UL 2703 and the specific modules included in PanelClaw’s
UL listing can be found in the “PB3 HD UL Overview and Module Listing” document (available at
www.panelclaw.com).

For uncertified and unapproved modules, please follow the grounding instructions below in Appendix C:
Electrical Grounding (UL 2703 not applicable).

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 Appendix A: Safety
The subsections below outline some of the obvious / major hazards that could exist during the
installation of PanelClaw products, and are divided to bring a level of clarity to such hazards. Some
sections do not apply to all PanelClaw product lines and such exclusions are noted within each section.

Electrical Hazards: PanelClaw products are purely mechanical and do not contain any electrically live
parts. When a photovoltaic module is exposed to sunlight it is electrically live and cannot be turned off.
As soon as modules are installed using a PanelClaw system, an electrical shock hazard is present. All
personnel on site should coordinate to ensure that such electrical hazards are clearly communicated. It
is advised, at a minimum, that all personnel utilize caution and proper Personal Protective Equipment as
outlined in that section. Only electrically qualified personnel should perform PV module installation.
Refer to OSHA Part 1926 Subpart K – Electrical and NFPA 70E for additional information.

Fall Hazards: This section only applies to Polar Bear® products installed on locations six feet or higher
above grade. Proper fall protection should be in place at all work sites. There are many fall protection
solutions readily available to help reduce exposure to fall hazards. These may include personal fall arrest
systems, safety nets, guardrails, and flagged setbacks from all roof edges as outlined in OSHA Part 1926
Subpart M – Fall Protection.

Trip Hazards: All PanelClaw arrays have elevated components that are installed above grade or above a
roof surface. Such hazards should be identified and caution should be taken to avoid tripping over such
components. Refer to the Fall Hazards section specifically if working with the Polar Bear product line.
Make sure to pick up and not drag your feet when working on site, and always pay attention to your
path of movement to note any obstructions that could create a trip hazard.

Lifting Hazards: The PanelClaw installation process involves lifting of heavy items that could lead to
personal injury and damage to property. All personnel should be trained in the proper procedures for
manually lifting. Evaluate an object’s size and weight prior to lifting, and follow these general guidelines
for lifting:

1. Assess the lift and know the object weight.

2. Bend at the knees and get a good grip.
3. Keep back straight and lift straight up with legs without twisting. It is important to lift with the
legs and not the back.
4. If an object is too large or heavy, ask for help and do not attempt to lift by yourself.
In the case that mechanical assistance (e.g. crane, forklift, etc.)is required to complete the lifting
operations, all machine operators of such devices should be licensed and trained.

Material Handling: All PanelClaw parts and components are made of aluminum and steel alloys and
utilize stainless steel assembly hardware. These materials are considered non-toxic and require no
special handling procedures. Metal components may have sharp edges, so be sure to handle with care
and utilize proper personal protection equipment, especially gloves, during handling. Refer to OSHA Part
1926 Subpart H – Materials Handling, Storage, Use, and Disposal for additional information.

Personal Protective Equipment (PPE): All personnel should utilize and implement proper PPE per OSHA
requirements. Refer to OSHA requirements for proper use and implementation of PPE. The following

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 items are suggested as a minimum to avoid injury based on the installation procedure outlined in this
manual:

1. Appropriate work clothing

2. Electrically insulated hard hat
3. Protective eyewear
4. EH rated safety boots
5. Gloves
6. High-visibility safety vest
7. Hearing protection

If any PPE appears to be defective, stop the use of such equipment immediately, and ensure it is
replaced before work continues. Refer to OSHA Part 1926 Subpart E – Personal Protective and Life
Saving Equipment for additional information.

Hand and Power Tools: Access to all hand and power tools should be regulated and controlled at all
times on site to prevent improper use and related injuries. When not in use, all equipment should be
stored in a secured location. Only personnel who have been properly trained in the safe operation of
any potentially dangerous tool should be allowed access. All required tools to perform the installation of
PanelClaw racking are outlined in the installation procedure. All tools should be inspected daily and
before use by the operator. If any tool appears to be defective, stop the use of such equipment
immediately, and ensure it is replaced before work continues. Electrical power tools should follow
proper lock-out tag-out procedures per OSHA requirements. Refer to OSHA Part 1926 Subpart I – Tools –
Hand and Power for additional information.

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 Appendix B: UL 2703 Grounding
The Polar Bear III HD 10 Degree flat roof system may be used to ground and/or mount a PV module
complying with UL1703 only when the specific module has been evaluated for grounding and/or
mounting in compliance with the included instructions. For a list of modules which have been evaluated
see PanelClaw’s “PB3 HD UL Overview and Module Listing” (available at www.panelclaw.com).

A periodic re-inspection of the system shall be performed for loose components, loose fasteners, and
any corrosion. If found, they should be immediately replaced or remedied in accordance with the
system installation instructions.

System Ground Path

The system ground path follows through the Tyco Lug, Ballast Tray, Support, Claw and into the module
frame (Figure 9). The module frame’s anodization is broken via the through-bolt connection at the
module mounting holes, which is secured with a serrated flange nut. The bonding continues through the
module frame to the adjacent Claws as shown below.
Bonding path from Lug to System Typical: North-South Module to Module Bonding Path
Ground Path
through Support

To DC
Grounding Ground Lug
Path Tyco #2106831

Ground Path through

Ballast Tray

Typical: East-West Module to Module Bonding Path

Figure 9 System Ground Path with UL2703 Listed Module

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 Grounding Instructions:
PanelClaw components within the array are required to be electrically bonded to other DC grounding
paths via the use of either a #12 or #10 AWG Cu bonding jumpers and a UL 467 listed Tyco solid wire
grounding assembly, part number 2106831, manufactured by Tyco Electronics Corporation. The
conductor size should be selected in accordance with NEC 690.45 and NEC 250.122.

To ground the array, first determine the groupings of strings whose power output wiring is grounded
together at an equipotential grounding conductor location. This could be all the strings within a physical
sub-array, or all the strings grouped by a single combiner box. Once the groupings of strings at
equipotential have been determined, a Tyco solid wire grounding assembly must be attached to one
Ballast Tray within each group of strings. PanelClaw’s Polar Bear Ballast Trays have a hole to which this
grounding device/lug can be attached (see Figure 10). In an array that requires multiple bonding
jumpers to satisfy the equipotential requirements, each bonding jumper should be located and installed
on a Support within the group of strings which will be grounded by that jumper.

Note: Every independent array section must include at least one grounding device/lug.

To attach the Tyco grounding device/lug to the Ballast Tray, the mounting hex washer and threaded post
end should be installed to the specified hole in the Ballast Tray and torqued to 25 in-lb. Once the
grounding device/lug has been attached to the Ballast Tray, a copper bonding jumper from an
acceptable DC grounded location outside of the array must be installed to the wire slot end and torqued
to 45 in-lb. For additional instruction regarding the installation of the Tyco solid wire grounding
assembly, please refer to the Tyco Electronics instructions sheet (document number 408-10262) via
their website www.te.com.

Figure 10 Ground Lug Attachment Location

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 Appendix C: Electrical Grounding (UL 2703 not applicable)
The Polar Bear III HD 10 Degree flat roof system must be electrically bonded to the other DC grounding
paths.

System Ground Path

The system ground path follows through the module to the Tyco Lug into the Ballast Tray via a solid #12
or #10 AWG Cu bonding jumper. The conductor size should be selected in accordance with NEC 690.45
and NEC 250.122. The Ballast Tray is bonded to the Support, and Claw. (See Figure 11).
Bonding path from Lug to System (TYP)

Ground Lug
Tyco #2106831

To DC
Grounding Path

Figure 11 System Ground Path

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 Grounding Instructions:
PanelClaw components within the array are required to be electrically bonded to other DC grounding
paths via the use of either a #12 or #10 AWG Cu bonding jumpers and a UL 467 listed Tyco solid wire
grounding assembly, part number 2106831, manufactured by Tyco Electronics Corporation. The
conductor size should be selected in accordance with NEC 690.45 and NEC 250.122.

To ground the array, a Tyco solid wire grounding assembly, part number 2106831, manufactured by
Tyco Electronics Corporation, must be installed on each Ballast Tray. As you run the copper wire
necessary to ground each module (not provided), ensure the same copper wire is run through every
Tyco solid wire grounding assembly and secured per Tyco Electronics Corporation, LLC specifications
(www.te.com).

To attach the Tyco grounding device/lug to the Ballast Tray, the mounting hex washer and threaded post
end should be installed to the specified hole in the Ballast Tray and torqued to 2.08 ft-lb (25in-lb) (see
Figure 12). Once the grounding device/lug has been attached to the Ballast Tray, a copper bonding
jumper from an acceptable DC grounded location outside of the array must be installed to the wire slot
end and torqued to 3.75ft-lb (45in-lb). For additional instruction regarding the installation of the Tyco
solid wire grounding assembly, please refer to the Tyco Electronics instructions sheet (document
number 408-10262) via their website www.te.com.

Figure 12 Ground Lug Attachment Location

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 Appendix D: UL 2703 Fire Classification
The system has a Fire Class A rating for low slope roofs with Type I and Type II modules when the
following requirements are met:
 System is installed over a fire resistant roof covering rated for the application (UL2703, 26.3B)
 Roof slope is less than 2”/ft

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 Appendix E: Shim Pad Installation

Installation
Follow Figure 13, place the Shim Pads underneath the support pads and compress firmly.
Stack the Shim Pads as needed to get the suitable height, a maximum of 2 Shim Pads can be stacked.
Notes: Shim Pads installation is not required on all three pads, select the appropriate locations and
stack suitable numbers of Shim Pads.

Attach the Shim Pads to the support pads.

Stack the Shim Pads as needed. Max stack height of 2

Shim Pads

The flat edge of the pads should face each other when
installing Shim Pads on a tight row spacing Support

Figure 13 Shim Pads Installation

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 Appendix F: Ballast Blocks
PanelClaw does not provide the ballast blocks required to construct the system in accordance with
PanelClaw’s Racking Construction Set drawings. However, PanelClaw maintains a list of potential block
suppliers across the country and this list is available upon request.

BALLAST BLOCKS FOR ANY BALLASTED ROOFTOP SYSTEM MUST BE MANUFACTURED TO RESIST FREEZE-
THAW AS REQUIRED BY LOCAL CONDITIONS AND TO MAINTAIN THEIR WEIGHT OVER THE LIFE OF THE
SYSTEM. IT IS STRONGLY RECOMMENDED THAT INSTALLERS WEIGH SEVERAL BLOCKS ON-SITE TO
ENSURE BLOCK WEIGHTS MATCH THE WEIGHT OF THE BLOCKS SPECIFIED IN PANELCLAW’S RACKING
CONSTRUCTION SET DRAWINGS. BLOCK WEIGHT VARIANCES LISTED IN THE CHART BELOW ARE
ACCEPTABLE.
Ballast Block Description Nominal Weight Allowable Weight Variance
kg [lb] (+ or -) Kg [lb]
BLOCK, CONCRETE, 2"X 8"X 16" 6.6 [14.6] 0.45 [1.00]
BLOCK, CONCRETE, 3"X 8"X 16" 10.7 [23.6] 0.57 [1.25]
BLOCK, CONCRETE, 4"X 8"X 16" 14.8 [32.6] 0.68 [1.50]

BLOCKS WITH A WEIGHT VARIANCE GREATER THAN WHAT IS SHOWN IN THE CHART ABOVE MUST NOT
BE USED.
FAILURE TO FOLLOW THESE PRACTICES MAY RESULT IN SYSTEM PERFORMANCE BELOW DESIGN
CRITERIA AND/OR MAY CAUSE STRUCTURAL DAMAGE TO THE BUILDING AND/OR ARRAY.

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