Universal replacement tile: an individual fit

When a photovoltaic system is installed on a tiled roof, each roof hook needs a suitable passage through the covering. A replacement tile provides it: it takes the place of a clay or concrete tile and allows the hook to emerge above the roof. Our universal replacement tile is individually shaped to the existing tiles during installation. This is particularly useful when you work with different tile models or supply customers with varied roofing requirements.

The word “universal” is not enough on its own. The replacement must suit the cover dimensions, tile geometry and intended installation. Here we explain how our approach differs, what information helps you choose and which tasks remain part of planning the PV installation.

Why does a roof hook need a replacement tile?

The roof hook connects the solar mounting structure to the load-bearing roof. In our system, it is screwed into the timber structure. The mounting rail connects above the roof covering. Between those points, the hook must pass through the tiled surface.

A replacement tile creates this transition at the fixing point. It is neither a solar module nor a complete mounting structure. Nor does it replace the structural fixing of the hook. Keeping these functions distinct makes the components easier to choose: the replacement belongs to the roof covering, the hook secures the structure and the rail supports the modules.

Protection against snow and driving rain

The flexible forming pieces and lateral water folds prevent wind-driven snow and driving rain from entering. The expanded-metal-reinforced EPDM pieces are shaped to the tile profile and bonded using their butyl adhesive strips.

The rear reinforcement tab prevents water pockets and unwanted deformation. It transfers the replacement tile’s own weight to the clay or concrete tile underneath.

Materials and storage

Base sheet and reinforcement tab: Aluminium, 0.8 and 1.2 mm respectively. Building material class A1 according to DIN 4102.

Flexible forming pieces: Expanded-metal-reinforced EPDM with butyl adhesive strips. Building material class B2 according to DIN 4102.

Storage and use: Please store in a cool, dry place and aim to use within 12 months. If stored for longer, check before installation that the protective liner can be removed easily.

Alter the tile, use a model-specific replacement or shape the replacement?

There are different ways to create clearance for a hook. Which can be used depends on the mounting system and its manufacturer’s instructions. A model-specific replacement is a valid solution: where it is intended for the existing tile, its shape already matches that model. You do, however, need to select and obtain that particular version.

Example: two customers, two tile models

A merchant receives enquiries for two different roof tile models. With a model-specific replacement, each roof needs the corresponding version. If both tile models fall within the application range of our adaptable replacement, the same basic solution can serve both enquiries. Colour and hook shape are selected for each customer’s needs.

Our article on cutting and grinding roof tiles for PV uses our own examples to explain how this differs from modifying an existing tile. Suitability depends on cover dimensions, profile and installation requirements.

What makes our replacement tile universal?

Our replacement does not reproduce just one fixed tile shape. The installer shapes its flexible, expanded-metal-reinforced EPDM parts at the top and bottom to the profile of the existing clay or concrete tiles. It replaces one tile at the fixing point; neighbouring tiles that were temporarily removed go back in place.

The same basic solution can therefore serve different supported tile profiles. Universal describes this adaptability, not blanket approval for every roof. Our data sheet states suitability for the majority of common roof tile types in Germany, Austria and Switzerland. It does not give a percentage.

Clay and concrete tiles: actual cover dimensions matter

The question is not simply “clay or concrete?”. Fired clay tiles and concrete tiles can have very different profiles, interlocks and overlaps. For the fit, you need the effective dimensions of the existing tile as laid on the roof.

Cover width and length are not necessarily a tile’s outside dimensions. Areas covered by neighbouring tiles do not count towards its effective coverage. If you measure only a removed tile, this distinction needs to be considered. A similar-looking photograph is also not enough for reliable identification.

For our standard version, the data sheet gives a cover width up to 300 mm and a cover length of 300–390 mm. Roof pitch starts at 15°. These criteria apply together; geometry and installation requirements must also match. For larger cover dimensions, the XL version available on request may be considered: up to 330 mm cover width and 391–450 mm cover length, using the same roof hooks.

What does “usually without grinding” mean?

Where our replacement suits the covering, the surrounding tiles usually need no grinding or cutting. The tile at the mounting point is replaced. This can eliminate the task of making a recess and the grinding dust it produces.

“Usually” matters: with rare geometries, the upper part of a tile can be too wide for the intended recess. It then needs adjustment there. A promise that no tile will ever need alteration would therefore be inaccurate. We do not promise the same time saving on every roof either.

Where do the solar installation’s loads go?

Loads from the PV mounting structure pass through the roof hook fixed into timber. The replacement tile does not take the place of this structural connection. Its rear reinforcing tab has a different job: it supports the replacement and can transfer its own weight onto the tile below.

This does not establish an allowable PV load on the lower tile. Suitable fixings, the distribution of fixing points and design for the specific roof remain part of project planning. This also applies to high-snow-load locations. Universal refers to adaptation to the covering, not every possible load.

What is the basic installation sequence?

A few tiles are temporarily removed. The replacement is positioned and its flexible parts shaped according to the guide. The roof hook is screwed into the timber structure, then the other tiles are replaced. Only the tile at the fixing point is permanently replaced.

The illustrated installation stages show these actions in context. The full installation guide governs execution: it covers the adhesive areas, fixings and additional instructions. Its foam wedge is a small optional addition, including for pitches below 25° and protection against wind-driven snow and animals.

Why this matters to merchants and installers

If you supply different tile models as a building materials merchant or wholesaler, an adaptable system can reduce the number of model-specific replacements you need to hold. You do not need a different replacement solely because the supported tile model changes. The effect on your range naturally depends on the roofs and products your customers actually request.

Solar installers, roofers and timber construction firms can also use the same basic method on different suitable roofs. The process stays familiar even when the tile profile changes. Each roof still needs checking; that check is simply no longer the same as finding a separate replacement shape for every supported model.

What is in the set, and what is requested separately?

Our replacement tile comes as a set with the matching roof hook. The hook is also available separately. There are two hook types: perpendicular to the roof plane, or parallel and height-adjustable. The choice depends on the intended connection and installation situation.

Rails, internal rail connectors, four-hole connectors, cross connectors, mid and end clamps, end caps and spacer blocks are separately available accessories. They are not automatically included in the tile set. Every item can be added with its variant and quantity to the same enquiry.

What information helps with your enquiry?

If possible, provide the manufacturer and model of the existing tiles, their actual cover dimensions and the roof pitch. Include any rail or hook connection already planned. If something is uncertain, say so: a complete parts list is not necessary for an initial question.

On our enquiry page, choose products or describe your project first. Merchants can also ask about adding the system to their range. The enquiry is non-binding and does not place an order. It lets us clarify your actual requirements before a general product description is mistaken for confirmation of suitability for a particular roof.