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The picture above is a 7.1 kW roof mounted system using homemade racking made of fibreglass pultrusions. Wood systems are possible as well, but usually these would only be considered for barns or outbuildings, as they don't appear as polished in appearance. For the installation pictured above, the heart of the system are pultrusions channels that were bought for a pittance from a window supplier that no longer needed them, and the homeowner (an Engineer and a friend) innovative designed a way to use them as a roof mount racking system. The fibreglass pultrusions provide the E - W rails, two per panel and the panels are attached by the built in mounting holes and some locally made brackets which cost less than $100. The white rail is the long E - W rail, and the black one is a spacer to keep the rail of the roof, so that the rain drainage is not impeded by the rail. I was present and helped in a minor way on the day that these were installed, and took a lot of photographs. From the ground you would not be able to tell that this was done with fibreglass rails, except for the colour this looks very similar to an aluminium extruded rail mounting system.
This installation is located near Arnprior, and a guided tour of this installation might be possible to arrange, at the owner's convenience. This installation was done by a crew of contractors who had never installed any solar system before, and under the owner's direction it took one day to mount the rails onto the roof, and by mid afternoon on the 2nd day when this picture was taken the last panel had been attached and wired up. When the appearance is not critical, and the installation is not on a residence's roof, then pressure treated 2x4 can be used as a basis of creating a mounting to fit on a corrugated roof.
Then a series of horizontal (E - W) 2x4 are run the width of the installation and mounted on top of the N - S lengths of PT wood. The horizontal 2x4 are predrilled and stainless steel bolt, washers and nuts are inserted, to create a stud facing upward on which to attach the panels, using the same type of bracket used for the fibreglass rails.
It is not a great idea for the pressure treated lumber to contact the galvanized corrugated roofing either, as galvanic action could accelerate corrosion.
The N - S 2x4 could be replaced by a series of Hanger bolts, such as Unirac's part number 310025. You can improvise an EPDM washer by using a stainless steel fender washer, and cutting out a round or square portion of a sheet of EDPM material.
The trickiest part of using lag bolts or hanger bolts on a corrugated roof is when the hole must go on the sloped side of the corrugation instead of the top or bottom.
When the rafter is under the trapezoid, then something different is required to do the attaching. From the ground level this looks similar to any other roof mounted solar panel installation. Thus in the solar industry they are bolted to the bottom on the panel, but fastened in place from above.

The brackets provides support to two adjacent panels, from the one stud that you can see in the picture below. This attaches to the roof by the lag bolt, very similar to the L feet used by most rail systems. Buying this new directly from the manufacturer offers no saving over the extruded aluminium rails that are made specifically for this purpose.
Usually all the tools required are already in your possession, or can be borrowed from your brother in law. If a E - W 2x4 was mounted directly on top of the corrugation, this would tend to block rain and snow sliding off the roof. To prevent this a layer of insulating material such as ice and roof shield is placed under the lower 2x4, insulating it from the galvanized surface and solving the concern. This has the desirable characteristics of having a machine thread for nearly all of its length, and an extra flange nut to force an EPDM washer against the top of the corrugation. You can use a leatherworker's style hollow punch cutter to cut out the hole size that you need. If the barn is built of beams or posts, this is not a problem, just shift the fastener's hole left or right a bit from the center of the beam. Then the panel fastening is similar to a wood based home made ground mounted racking system. In this case a suitable spacer is required, so that a horizontal (E - W) pressure treated 2x4 does not contact the top of any of the trapezoids.
He bought all that the supplier had on hand, and used it to do three roof faces with the same system. The aluminium brackets provide both a means of permitting expansion and contraction of the panels to occur with low stress, and also provide the grounding bonding between adjacent panels. The stud sticking up is used to anchor the panel to the rail, two panels are attached to one stud. Tour your local scrap yards, and look for a similar type of product that you can adapt for this purpose. Care must be taken not to crush the corrugated metal roofing by over tightening the lag bolts. In this case bottom access for tightening fasteners would be very difficult, and the brackets provide a top fastening system for convenient installation.
Butyl mastic tape can be used to help create a watertight seal where the lag bolt goes through the metal roofing.
This would be used to support the E - W 2x4 and it would not contact the corrugations, eliminating the concern about PT lumber interacting with the galvanized coating of the steel roof, and also removing the concern about crushing the corrugations.

The EPDM washer is pressed against the top of the corrugation by the lower flange nut, and if the hanger bolt is not inserted sufficiently, or the corrugation is too low, then a spacer would be slipped over the hanger bolt to ensure the lower flange nut presses the EDPM washer onto the corrugation. You can more conveniently buy stainless steel bonded EPDM sealing washers in bulk from Cook Fasteners in Mississauga.
When the rafter is 2" wide, or less if 2x4 trusses are used, there is not enough width to shift the fastener. A short length of imitation wood decking that is actually a type of plastic could serve as this spacer. An important characteristic is that the fibreglass rails are a reasonably close match to the wood in its coefficient of expansion. They also provide for a top mounting, where the panel is preassembled with four brackets on the ground, and then on the roof the panel assembly is lowered onto four studs and then a self-locking nut + washers is attached from above. A stainless steel fender washer or spacer could also be used to prevent PT lumber from contacting the galvanized metal roof surface. When the hanger bolt goes into the trough of the corrugation, then a spacer will certainly be required.
In this case blocking below the roofing's metal surface may be called for, or a bolt to anchor into the purlin.
This plastic is designed to be UV and water resistant, but a concern remains with its coefficient of expansion. A pultrusion is similar in concept to aluminium products that are extruded through a die to determine their shape.
Stainless Steel is the metal least affected by the ACQ preservative in today's preserved wood.
This hangar bolt is also a recommended way to install commercial aluminium rails such as SolarMount to the roof, together with an L foot.
This is used with a long enough stainless steel lag bolt top passed trough the 2x4, spacer, roof purlins or sheathing, and then have 3" of thread to anchor into the rafters. Other product brand of hangar bolt may be fully threaded all the way to the lag bolt thread, in which case this would not need a spacer, but just an extra nut.

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