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<a href="https://www.gaf.energy/about/" target="_blank" rel="noreferrer noopener">GAF</a>, the largest commercial and residential roofing manufacturer in North America, has long been the roofing of choice for architects, upscale remodelers, and homeowners with an eye for design. The company has been around since 1886 and makes billions of dollars in sales annually.

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Amid increasing consumer interest in renewable energy sources such as solar power, GAF saw an opportunity to innovate and develop a solar roof product that would be easy and affordable to install and—importantly—integrate attractively into building designs. 
<h3>The Problem </h3>
Most existing rack-mounted solar roofing systems also came with painful tradeoffs: 
<ul><li>They were clunky and unattractive, with cheap-looking panels elevated on racks above standard roof singles. </li></ul>
<ul><li>In some areas, chicken wire would have to be installed around the perimeter of the system to discourage unwanted animal “guests” from making themselves at home under the panels. </li></ul>
<ul><li>The systems were complicated, which made them challenging and time-consuming to install—an expense that offset homeowners’ eventual energy savings. </li></ul>
GAF partnered with Delve to develop a new solar roofing solution to solve these issues.

GAF Deco Tech Solar Roof case study for web INLINE1 problem

<h3>Our Approach</h3>
Delve worked closely with the GAF team to design, engineer, and validate a novel, attractive solar roof solution that is easy for standard roofers to install.
Over the course of this multi-year collaboration, Delve delivered:

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<ul><li>Product vision, roadmap, and conceptualization</li></ul><ul></ul>
<ul><li>CAD, prototyping, and production drawings </li></ul>
<ul><li>Strategy and research (including contractor interviews, homeowner surveys, and beta testing) </li></ul>
<ul><li>Prototyping (non-functional user experience models, scaled demonstration prototypes) </li></ul>
<ul><li>Industrial design (renderings for homeowner surveys and consumer research studies) </li></ul>
<ul><li>Mechanical engineering (virtual prototyping and FEA, fully functional and aesthetic prototyping, competitive benchmarking, concept comparisons) </li></ul>
<ul><li>Electrical engineering (inductive coupler proof of concept)</li></ul>

GAF Deco Tech Solar Roof case study for web INLINE2 process

<h3>The Solution</h3>
Recognizing that the biggest cost of a solar roof is its installation, we designed a system that reduces both the time and skill required for installation, resulting in the lowest possible cost per watt for the homeowner. Typical solar roof installation involves adding solar panels above roof shingles, which is relatively difficult. You need to add mounting feet, each of which has four screws—and each screw is a potential leak point. By contrast, DecoTech’s integrated system is easier and faster to install. Much of the assembly can happen on the ground, so installers have fewer tasks to accomplish up on a pitched roof. Eliminating the shingles under the solar panels reduces the overall cost of a re-roof and speeds installation. The flashing techniques used around chimneys and skylights, are familiar to experienced roofers. 
Installation involves stripping off the old roofing material, inserting the DecoTech modules into a proprietary interlocking frame, attaching that in the center of the roof and filling around it with normal shingles. The UL-certified process makes the whole thing watertight, so rain passes over the system without seeping inside, much like it would over a skylight.

Once installed, the GAF DecoTech solar modules blend in much better than a conventional rack-mounted PV approach, delivering high performance while integrating seamlessly and attractively into the homeowner’s roof. 
<ul><li>Best-in-class panels and cutting-edge integrated technology optimize electrical power output. </li></ul>
<ul><li>The low-profile design, monochromatic Deco Black gloss finish, and no exposed wires deliver a sleek, designer look. </li></ul>
<ul><li>Counterflashing and step flashing help protect against moisture and leaks, while also providing excellent resistance against animal infestation. </li></ul>
<ul><li>The metal frame provides strength and stability, giving years of worry-free performance.</li></ul>

GAF Deco Tech Solar Roof case study for web INLINE4 impact

<h3>Market-Moving Results</h3>
The DecoTech system's stylish design and straightforward installation process, accessible even to standard roofers, provided it with a distinct advantage in the market. The product's successful <a href="https://www.greentechmedia.com/articles/read/gaf-solar-roof-tesla-understands-roofing" target="_blank" rel="noreferrer noopener">launch</a> and enduring popularity helped propel GAF into its current position as the world’s largest solar roofing producer.

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GAF collaborated with Delve to design, engineer, and validate a novel, attractive solar roof solution that’s easy for standard roofers to install.

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