A solar installation is only as strong as its foundations: the roof that anchors it, the mounting system that secures it, and the installers putting it all together.
In a recent interview, Solar Power World spoke with Guy Wellman, Director of Sales at Roof Tech, about the lessons learned from decades of field experience in solar mounting and roof waterproofing. The conversation explores:
- AlphaSeal® flexible flashing and Roof Tech's waterproofing record
- Why real-world testing matters more than laboratory results alone
- The growing demand for repair and reinstall (R&R) projects
- How manufacturers can better support installers through education and long-term expertise
How Field-Proven Waterproofing Improves Long-Term Solar Reliability?
What follows is a conversation every U.S. homeowner and solar installer should read.
Solar Power World: How has AlphaSeal® flexible flashing helped Roof Tech achieve one of the strongest waterproofing track records in the solar industry?
Guy Wellman: AlphaSeal® has been a big part of that track record because it changed the way people think about flashing. A lot of people assume Roof Tech is flashless, but that is not really accurate. We use flexible flashing.
AlphaSeal® is a butyl-based compound and has been part of the same screw-and-AlphaSeal configuration Roof Tech has used for more than 30 years. In that time, we have had zero leaks outside of human error across roughly 30 million penetrations in North America and about 300 million penetrations between Japan and North America. That history is what gives installers confidence.
The system is designed to create a watertight seal at the point of contact. The screw is a double-helix, double-threaded screw, and as it goes through AlphaSeal®, it pulls the material into the void created by the penetration. So, as the hole is being created, the system is also sealing it.
The waterproofing record comes from that combination of the material, the screw design, and the amount of time the system has been proven in the field. In my nearly eight years with the company, whenever we have been contacted about a leak concern, it has always turned out to be something outside the Roof Tech product, like an existing roof issue, a prior leak, or an improperly vented attic space.
Solar Power World: What separates field-proven solar mounting systems from products that only perform well in laboratory testing, and why does long-term reliability matter more than ever today?
Guy Wellman: The crucial difference is time in the field. Lab testing is important, and we absolutely do that. Before our products even go out for third-party testing, they undergo in-house testing at our parent company, Yanegiken. We test for wind, rain, and other conditions and try to recreate what the product will experience on a roof.
A lot of times, someone will say, "We have a mock roof in our office or warehouse, so we can do the training there." That can be useful, but everything usually works well in a controlled setting. There are not many surprises.
But the field is different. Once you are on a real roof, you are dealing with real conditions: different roof types, crews, weather, and jobsite challenges. Those are things you cannot fully recreate in a lab or on a mock roof.
We have conducted outdoor testing since the company's early days, and new products are constantly put through real-world exposure. By the time something reaches the market, we are not just relying on what happened in a controlled environment. We are looking at how the product performs when it is actually exposed to the elements.
That matters more today because installers and homeowners are making decisions that must hold up for decades. These systems are expected to remain on roofs for a long time, and the mounting system must be able to support them.
We have had products on roofs in places like Nova Scotia, where hurricanes have passed through, with zero issues. The same holds in Miami and other parts of Florida, where storms are part of the environment. We have a large number of products installed in those areas, and performance has remained consistent.
Solar Power World: Why are repair and reinstall (R&R) projects rapidly growing, and how can installers reduce labor, hardware waste, and redesign time by reusing existing rails and L-feet during reinstallation?
Guy Wellman: R&R work is growing because solar has been around long enough that many systems are reaching the point where the roof beneath them needs maintenance. Some systems have been installed for 25 or 30 years, and in many cases, the roof was never going to last that long.
Sometimes it is just normal roof aging. Sometimes it is storm damage or hail damage. But once that roof has to be replaced, the solar system has to come off and then go back on. That creates a lot of extra work for installers. They must figure out which racking system is already on the house, who made it, whether that company is still around, whether replacement parts are available, and how to get them.
That is where we see an opportunity to make the process easier. For example, our RT-MINI II can work with anyone's L-foot and rail. Instead of replacing the entire racking system, an installer can reuse the existing rails and hardware, add new feet, and give the homeowner new leak protection.
For the installer, it reduces the amount of research and redesign work required. If the system has a standard L-foot, they know they have a path forward with Roof Tech. For the homeowner, it can reduce costs because they are not told they need to buy an entirely new racking system to put the modules back on the roof.
It also cuts down on waste. If the existing rails are still usable, there is no reason to discard all that hardware. The installer can reuse what is already there, move faster on the job, and still provide new leak protection with a new warranty.
With the RT-MINI II, installers can reattach to existing hardware, and with the RT-PLUS®, a fixed L-foot, we can attach to the existing cradle that connects to the rail. Either way, the goal is to make R&R work faster, cleaner, and less wasteful for both installers and homeowners.
Solar Power World: How can manufacturers better support installers during uncertain economic and policy conditions?
Guy Wellman: The biggest thing manufacturers can do is stay close to installers. That means continuing education, making sure they understand the product, and ensuring it is being installed correctly.
This matters because it only takes one person to explain something incorrectly, and then that incorrect information keeps getting passed down. Manufacturers have to keep revisiting training, keep answering questions, and ensure installers understand both how the product works and where its limits are.
We talk a lot about supporting installers at Roof Tech. Our products can be installed on many different roof types, but that does not mean every situation is the right fit. We will be the first to tell an installer, "You should not install it this way," or "This application is not compatible." That honesty matters, especially when installers are trying to move quickly and manage costs.
During uncertain economic or policy conditions, installers need manufacturers they can rely on for both product availability and guidance. They need to know what will work, what will not work, and how to avoid problems down the road.
For Roof Tech, much of that support comes down to experience. Flexible flashing is becoming more common, especially in the U.S., and more manufacturers are moving in that direction. But many of those products have not been in the field for very long.
We have been doing this for decades across North America and Japan, with a very large number of roof penetrations to our credit. That depth of experience helps us support the installer in a meaningful way; we can share what we have seen in the field, what works, and where they need to be careful. That kind of grounded guidance is exactly what installers need when the market is uncertain.
Conclusion
Throughout this discussion, Guy Wellman emphasized the value of field-tested performance, practical installer support, and solutions designed to address the industry's evolving challenges. From flexible flashing technologies and long-term waterproofing reliability to the increasing demand for repair-ready mounting systems, these insights shape the future of rooftop solar installations and maintenance.
Roof Tech has been developing solar mounting solutions since 1994, with a product history spanning North America and Japan. For installers looking to learn more about waterproofing approach, mounting systems, or R&R-compatible products, additional information is available at https://roof-tech.us/.
