Flush mount
Rail, cleat and clamp sets that fix panels parallel to metal-sheet roofs, penetrative or non-penetrative.
Flush mount on IBR: cleats on the ribs carry the rail; end and mid clamps hold the modules.
- Anodised as standard
- 10 µm
- Every aluminium part is AL6005-T5, anodised to 10 µm as standard, not mill finish. Fasteners are SUS304 stainless steel.
- Roof pitch
- 0° to 30°
- Above 30°, a project-specific certificate
- Interface spacing
- 1.5 m
- Maximum, under the conditions in each manual
- Wind regions
- A to D
- 32 to 44 m/s, 50-year recurrence
- Warranty
- 20 years
- Aluminium and SUS304 parts, C1 to C4
Where it fits
Installers and EPC contractors fitting arrays on IBR, Klip-Lok and Saflok, corrugated, standing seam and Novotexi 440 sheeting, at roof slopes from 0° to 30°.
IBR
LS-RP-01IBR cleat kit with EPDM seal and four self-tapping screws: fixed (LMS-IBR1-KIT) or adjustable (LMS-IBR2-KIT).
Klip-Lok / Saflok 410 and 700
LS-RP-02Saflok 410/700 cleat (LMS-KL1-KIT) or Saflok mini-rail clamp kit (LMS-KL1-MR-KIT). No roof penetration.
Corrugated
LS-RP-03Corrugated mini-rail kit (LMS-COR-MR-KIT, L80 H77) or corrugated L-bracket kits, portrait or landscape.
Standing seam
LS-RP-04Standing seam multi clamp kit (LMS-SS-KIT). No roof penetration.
Novotexi 440
LS-RP-05Novotexi 440 cleat (LMS-NVT-KIT) or Novotexi 440 mini rail.
What is in the kit
Choose the roof. The model, the drawing, the parts and their codes change with it. Select any part for its material and finish.
| Item | Description | Code |
|---|---|---|
| 1 | LMS-EC30-35-KIT-BP | |
| 2 | LMS-IC30-35-KIT-BP | |
| 3 | LMS-PRO-RAILH | |
| 4 | LMS-IBR1-KIT | |
| 5 | LMS-RN-M8x20-KIT | |
| 6 | LMS-PRO-RAILH-SP-KIT |
Select a part, in the list or in the model, for its code, material and finish.
A representative model for reading the assembly, not a design drawing. PV modules are shown for reference and are not part of the kit. Quantities are set for each project.
Configurations
Three ways the kit is built, one per roof, each with its own manual and limits.
Full rail on IBR cleats
- Roof
- IBR
- Fixing
- Penetrative
- Interface
- IBR cleat with EPDM seal and four self-tapping screwsLMS-IBR1-KIT
- Rail
- PRO Rail H
- Full spacing
- Up to 18° roof tilt
Adjustable cleat LMS-IBR2-KIT sets between 115° and 138°. A mini-rail version (LMS-MRAIL-PRO-KIT) needs no full rail.
Full rail on rib clamps
- Roof
- Klip-Lok / Saflok 410 and 700
- Fixing
- Non-penetrative
- Interface
- Saflok 410/700 cleat, clamped to the ribLMS-KL1-KIT
- Rail
- PRO Rail H
- Full spacing
- Up to 10° roof tilt
Accredited on Saflok 700, Saflok 410 and Lysaght Klip-Lok 305. On any other sheet, an on-site pull-out test is recommended. A mini-rail clamp (LMS-KL1-MR-KIT) and a standing seam clamp (LMS-SS-KIT) are in the same manual.
Full rail on L-brackets
- Roof
- Corrugated
- Fixing
- Penetrative
- Interface
- L-bracket with EPDM corrugated adaptorLMS-LB-COR-KIT-P
- Rail
- PRO Rail 47
- Full spacing
- Up to 10° roof tilt
Portrait (LMS-LB-COR-KIT-P) and landscape (LMS-LB-COR-KIT-L) adaptors. The manual asks you to confirm the interface spacing with Lumasol. A corrugated mini-rail kit (LMS-COR-MR-KIT) is in the catalogue.
More in this family
Klip-Lok full-rail solution
Full rail on Klip-Lok sheeting, with more airflow under the panels.
Hanger bolt and L-bracket full rail
A full-rail landscape system on roof sheeting, for landscape layouts where mini rails are not possible.
Novotexi 440 mini rail
Specifications for these three systems are in the Lumasol product catalogue (PDF, 2.0 MB).
Specification
From the Lumasol installation manual and product catalogue. Each system is designed for its project and ships with a detailed installation guide.
Compare flush mount with the other kit families| Materials | AL6005-T5 aluminium rails, clamps, cleats and mini-rails. SUS304 stainless hardware in splice and clamp kits. |
|---|---|
| Finish | Aluminium anodised to 10 µm. Splice bolts and clamp bonding pins pierce the anodising to bond rails and modules. |
| Design basis | Wind regions A to D (32 to 44 m/s, 50-year recurrence). Guidance up to 20 m installation height; above that, a project-specific engineering certificate.Penetrative system assessed for terrain categories C and D. Non-penetrative system assessed for C, with spacing factors for A, B and D. |
| Roof pitch | 0° to 30°.Full 1.5 m interface spacing up to 18° roof tilt (penetrative) or 10° (non-penetrative). |
| Corrosion class | Anodised aluminium and SUS304 stainless steel: 20 years in C1 to C3 and in C4, not warranted in C5. Screws (1022A, class 3): 20 years in C1 to C3.Reduce interface spacing by 5% in C4; the penetrative manual gives 25% for C5. |
| Interface spacing | Up to 1.5 m.Penetrative: roof height to 20 m, roof tilt to 18°, internal roof zone, terrain C or D, clamp pull-out at least 2.5 kN. Rail overhang up to 40% of the last span. |
| Modules | 30 mm and 35 mm frames; adjustable end clamp for 30 to 45 mm.Penetrative 1.5 m spacing assumes modules up to 2278 × 1134 mm and 30 kg. |
| Fastening | Clamps, splices and M8 rail bolts 16 to 20 N·m.Penetrative cleats: four self-tapping screws with bonded washers at 300 RPM maximum. |
Materials and corrosion by site
- Rails, clamps, cleats and brackets: AL6005-T5 aluminium, anodised to 10 µm.
- Bolts, rail nut bolts and splice hardware: SUS304 stainless steel.
- Penetrative fixings seal with EPDM and bonded washers.
- Splice bolts, clamp bonding pins and earthing clips pierce the anodising, so rails and module frames are bonded electrically.
- Rib clamps can sit directly on most roof sheets; confirm the sheet's compatibility with anodised aluminium with its manufacturer.
| Site class | Aluminium and SUS304 parts | Screws (1022A, class 3) | EPDM and other non-metallic parts | Interface spacing |
|---|---|---|---|---|
| C1 to C3Inland | 20 years | 20 years | 3 years | As designed, up to 1.5 m |
| C4Coastal or industrial | 20 years | Not warranted | 3 years | Reduce by 5% (1.425 m at most) |
| C5Severe | Not warranted | Not warranted | 3 years | Reduce by 25% where the manual gives it (penetrative and L-bracket) |
- Classes to ISO 9223. Warranty from delivery, with the product registered within 30 days of purchase.
- Where a site's class is uncertain, treat it as the higher class and confirm it with Lumasol.
Spacing and design basis
The conditions each manual sets for the full 1.5 m interface spacing. The column for the roof chosen above is marked.
| Condition | IBR cleat (penetrative)Chosen roof | Rib clamp (non-penetrative) | L-bracket (corrugated) |
|---|---|---|---|
| Maximum interface spacing | 1.5 m | 1.5 m | 1.5 m |
| Roof height | Up to 20 m | Up to 20 m | Up to 20 m |
| Roof tilt | Up to 18° | Up to 10° | Up to 10° |
| Roof zone | Internal roof zone | Zone H | Zone H |
| Terrain category | C or D | C. Factors for A (90%), B (95%) and D (106%) | C or D |
| Clamp pull-out | At least 2.5 kN | Accredited sheets, or an on-site pull-out test | At least 2.5 kN |
| Modules | Up to 2278 × 1134 mm and 30 kg | — | — |
| C4 site | Reduce spacing by 5% | Reduce spacing by 5% | Reduce spacing by 5% |
| C5 site | Reduce spacing by 25% | Not given | Reduce spacing by 25% |
| Rail end overhang | Up to 40% of the last span | Up to 40% of the last span | Up to 40% of the last span |
- All three systems suit roof slopes from 0° to 30° and installation heights up to 20 m; above 20 m a project-specific engineering certificate is needed.
- Outside any of these limits the spacing is reduced. Confirm it with Lumasol before installing.
- At 1.5 m spacing, the rail can overhang the last interface by up to 600 mm.
Installation
The sequence from the Lumasol manual, for the IBR configuration. The manual is the reference on site.
Step 1: Plan the layout
- Confirm the wind region, terrain category, ISO 9223 class, roof height (up to 20 m) and slope (0° to 30°).
- Allow at least 18 mm between modules down the slope; set the rails about ½ to ¾ of the module height apart.
- Take the clamping zone from the module manufacturer's manual.
Step 2: Fix the roof interface
- Fix each cleat to the rib with four self-tapping screws with bonded washers: 3/8" hex socket, no more than 300 RPM, screws square to the sheet.
- Tighten until the washer grips for a watertight seal, without over-tightening. Minimum pull-out 2.5 kN per clamp.
- Set the cleats out in a straight line.
Step 3: Fit the rails
- U-channel facing up. Bolt each rail to its roof clamps at 16 to 20 N·m; every rail sits on at least two interfaces.
- Join rails with the splice about ¼ span from a support, never over a support or at mid-span. Splice bolts 16 to 20 N·m; they pierce the anodising to bond the rails.
- Keep the rail end overhang within 40% of the last span.
Step 4: Clamp the modules
- Fix the first module with an end clamp, lightly. Lift it slightly, slide in mid clamps with earthing clips, then place the next module.
- Set the end clamp for 30 or 35 mm frames with its two holes. Earthing clips are single use.
- Tighten every clamp to 16 to 20 N·m once the modules are in their final position.
Step 5: Earth the array
- One grounding lug per rail row, on M8 × 25 bolts at 16 to 20 N·m.
- Earthing cable up to 35 mm², clamped with the M8 × 20 bolt at 8 to 12 N·m.
- Check the resistance between the rail and the conductor.
| Fixing | Codes | Torque |
|---|---|---|
| End and mid clamps | LMS-EC30-35-KIT-BP, LMS-IC30-35-KIT-BP | 16 to 20 N·m |
| Rail to roof clamp, M8 | LMS-IBR1-KIT, LMS-IBR2-KIT, LMS-KL1-KIT | 16 to 20 N·m |
| Rail splice bolts | LMS-PRO-RAILH-SP-KIT | 16 to 20 N·m |
| Grounding lug, M8 × 25 | LMS-EGL-KIT | 16 to 20 N·m |
| Earthing cable bolt, M8 × 20 | LMS-EGL-KIT | 8 to 12 N·m |
Stainless fasteners can gall. Apply force evenly along the thread, use power tools at low speed, and avoid impact drivers.
Tools
- Screwdriver
- Drill bits for M8 bolts
- Torque spanner
- 5 m tape
- Marker pen
- String line
Flush mount or tilt mount
The nearest kit in the range, side by side, from the two manuals.
Tilt mount specifications| Feature | Flush mount | Tilt mount |
|---|---|---|
| Panel angle | Parallel to the roof | 5°, 10° or 20° above the roof, set by the rear leg kit |
| Roofs | IBR, Klip-Lok / Saflok, corrugated, standing seam, Novotexi 440 | IBR and corrugated, Klip-Lok / Saflok, concrete flat roofs, wooden purlins, Novotexi 440 |
| Full 1.5 m spacing | Roof tilt up to 18° (penetrative) or 10° (non-penetrative) | Roof tilt plus panel tilt up to 5°, wind region A or B |
| Roof height for full spacing | Up to 20 m | Up to 15 m |
| Clamp pull-out for full spacing | At least 2.5 kN | At least 3.5 kN |
| Rail | PRO Rail H, or Rail 47 on L-brackets | PRO Rail 47 |
| Choose it when | The roof's own pitch and direction suit the array | The roof is flat or low-pitch and the panels need more angle than it gives |
Technical questions
What roof pitch does the flush system suit?
Roof slopes from 0° to 30°. The full 1.5 m interface spacing applies up to 18° roof tilt for the penetrative system and up to 10° for the non-penetrative system.
When can roof clamps be spaced at 1.5 m?
Penetrative: roof height up to 20 m, roof tilt up to 18°, panels in the internal roof zone, terrain category C or D, clamp pull-out of at least 2.5 kN, and panels no larger than 2278 × 1134 mm and 30 kg. Non-penetrative: roof height up to 20 m, roof tilt up to 10°, and the array in Zone H. Outside these limits the spacing is reduced; confirm it with Lumasol before installing.
How are the penetrative IBR clamps fixed and sealed?
Each clamp is fixed to the roof sheet with four self-tapping screws with bonded washers, tightened until the washer grips to give a watertight seal. Use a 3/8" hex socket bit at no more than 300 RPM. The IBR cleat kits include an EPDM seal. Minimum pull-out is 2.5 kN per clamp.
Which roof sheets is the non-penetrative clamp accredited for?
Saflok 700, Saflok 410 and Lysaght Klip-Lok 305 (standing seam). If the sheet brand and model cannot be identified or is not on that list, Lumasol recommends an on-site pull-out capacity test.
Which panel frames fit?
The standard end and inter clamp kits take 30 mm and 35 mm frames; the end clamp has two holes to switch between them and ships pre-set for 30 mm. The adjustable end clamp kit (LMS-AEC30-45-KIT) covers 30 to 45 mm frames.
What changes on a coastal or industrial site?
Check the site class to ISO 9223. In C4, reduce interface spacing by 5%. The penetrative manual also gives a 25% reduction for C5. Anodised aluminium and SUS304 parts carry 20 years in C1 to C4 but are not warranted in C5; screws are warranted only in C1 to C3.
Projects on this kit
All projects
| Project | Site type | Province or country | System size |
|---|---|---|---|
| Ndwedwe Boxer | Rooftop | KwaZulu-Natal | 246.4 kWp |
| Athlone Shopping Centre | Rooftop | KwaZulu-Natal | 239.4 kWp |
Manuals and documents
- Download Flush mount, penetrative: installation manualPDF, 1.9 MB, May 2026
- Download Flush mount, non-penetrative: installation manualPDF, 2.7 MB, May 2026
- Download Flush mount L-bracket, penetrative fixingPDF, 1.3 MB, May 2026
- Download Lumasol product cataloguePDF, 2.0 MB, May 2026
- Download Lumasol product warrantyPDF, 187 KB, Nov 2025
Quote a flush mount kit
Send the roof or site, the system size and a layout if you have one. The quote request opens with flush mount selected.