I am pretty sure it is the freeze-thaw cycle that the blocks are exposed to. I have inspected hundreds of system in the Northeast and this is a recurringproblem. It has to be part of the maintenance protocols or there will be insufficient weight to resist thewind uplift forces.  Chris

On 6/30/2018 6:17 PM, Chris Schaefer wrote:
Kirk,

Had the same thing happen to me on a commercial ballasted system installed back in 2004. Had to be moved around to allow installation of a new roof system. Replaced all the ballast in 2017. I'm located in Western NY, thus the same weather you see. The blocks were on a stainless steel pan of which the array was attached to. I've plenty of ideas as to why they broke down but no real evidence. I expect it to happen again. Does make me wonder about the new ballast systems that still call out for the blocks as ballast. Perhaps poly sand bags?

Christopher

On Wed, Jun 27, 2018 at 4:20 PM, Kirk Herander <vtso...@icloud.com <mailto:vtso...@icloud.com>> wrote:

    All,

    I have a 6 year old ballasted roof system in which about 50% of
    the solid cap blocks(16”L x 8”w x 4”D) are cracked and crumbing,
    some are close to rubble. I assume it was a bad batch, but has
    anyone seen this before? What might be the preventive remedy in
    the future? A coating of some sort?

    *Kirk Herander*

    *Owner|Principal, VT Solar, LLC *

    */Celebrating our 27^th Anniversary 1991-2018/*

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    dba Vermont Solar Engineering

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