Generic Archives

Accessories Used in Solar Panel Mounting System

March 4, 2024

by Jaya with No Comment Generic

I. Introduction to Solar Panel Mounting Accessories

Solar panel mounting accessories are essential components of any solar panel mounting system. These accessories help securely install solar panels on rooftops, ground mounts or other surfaces.

Some key solar panel mounting accessories include:

Solar base plate – Provides a sturdy foundation for the solar panel structure.
Solar degree clamps – Allow adjusting the solar panel angle to optimize sunlight exposure.
End Z clamps – Attach solar panels securely to the mounting rails.
Middle U clamps – Hold solar panels together on mounting rails for stability.
Power snaps – Anti-theft clips to prevent solar panel theft.
Nuts and bolts – Fasten all components of the solar structure together.
Fastener chemicals – Bond mounting bolts to the installation surface for strength.

Accessory	Purpose
Solar base plate	Foundation
Solar degree clamp	Angle adjustment
End Z clamp	Panel attachment
Middle U clamp	Stability
Power snap	Security
Nut/Bolt	Structure
Fastener chemical	Strength

These solar panel mounting accessories are made from durable materials like steel and aluminum. They can withstand tough outdoor conditions for long periods.

Using the right mounting accessories improves the safety, performance and lifespan of any solar panel installation. They provide the structural integrity needed to keep solar panels fixed securely under different wind, weather and environmental conditions.

Investing in good quality mounting accessories like spring nut-bolts, SS Allen bolts and structural fastener chemicals ensures your solar power system will function optimally for many years.

II. Solar Base Plate for Foundation

The solar base plate provides a sturdy foundation for the entire solar panel mounting structure. It is installed directly on the roof, ground or any other mounting surface.

The base plate bears the weight of solar panels, racks and other components. It must be made of durable materials like:

Base plates are available in different sizes like:

41mm x 41mm
80mm x 40mm

Larger solar panel installations require bigger base plates for greater load bearing capacity.

The key functions of a solar base plate are:

Anchor the mounting structure securely to the installation surface.
Resist corrosion and environmental damage.
Support the weight of solar panels, racks, wires etc.
Withstand high winds without failing.

A proper foundation is crucial for safety and performance of the solar power system. High quality base plates ensure:

Long term mounting structure stability.
Optimized energy output.
Reduced risk of collapse or damage.

Invest in sturdy and appropriately sized solar base plates for your installation. Proper selection and installation of base plates will maximize the lifespan of your solar panel mounting system.

III. Solar Degree Clamps for Angle Adjustment

Solar degree clamps allow for seasonal tilt angle adjustment of the solar panels to optimize energy production.

These clamps are installed between the solar panel frames and the mounting rails. They have adjustable knobs that can tilt the panels at different angles.

Degree clamps are available in different sizes like:

41mm x 41mm
80mm x 40mm
High quality solar degree clamps are made of materials like:
Anodized aluminum
Stainless steel

Key features of degree clamps include:

Adjustability range of at least 45 degrees tilt.
Corrosion resistant construction.
Easy to install knob bolts.
Compatibility with panel frame sizes.

Proper tilt angle as per sun’s position ensures:

Maximum sunlight exposure on the solar panels throughout the year.
Optimized power output.
Enhanced return on investment.

Solar degree clamps must be robust enough to hold the panels steadily at the right angles. Investing in properly sized, good quality clamps will maximize energy production from your photovoltaic system.

Annual seasonal adjustment of panel angles using degree clamps improves solar electricity generation and economic viability of the installation.

IV. End Z Clamps to Attach Panels

End Z clamps are used to securely attach the solar panels to the mounting rails of the structure.

These clamps have a unique Z-shape design that tightly grips the edge of the solar panel frame on one side and the mounting rail on the other.

Key features of high quality end Z clamps include:

Sturdy aluminum or galvanized steel construction.
Weather resistant build.
Pre-drilled holes for easy installation.
Long lasting finish to prevent corrosion.

End clamps are available in various sizes to match different solar panel frame dimensions.

Benefits of using end Z clamps:

Provide very secure attachment of panels without gaps or loosening.
Allow for quick and easy panel installation.
Suitable for long term outdoor use.
Reusable if panels need rearranged.

Proper panel attachment is crucial for:

Optimized solar energy production.
Withstanding wind, rain and other weather events.
Preventing panel theft.
Ensuring long term safety and function.

Invest in good quality end Z clamps designed specifically for your solar panels. Correct installation using the right clamps will maximize the stability and lifespan of your photovoltaic system.

V. Middle U Clamps

Middle U clamps are installed between two adjacent solar panels on the mounting rail for optimum stability.

These U clamps have a curved, rounded shape that securely grips the edges of two panels equally.

Key features of high quality middle U clamps are:

Durable aluminum or galvanized steel construction.
Corrosion resistant finish.
Available in various sizes to fit panel frames.
Pre-drilled holes for quick installation.

Benefits of using middle U clamps:

Prevent panels from sliding down or drifting apart.
Provide excellent structural support.
Suitable for all types of solar panel mounting structures.
Reusable if panel positions need adjusted.

Proper stability of the solar panels ensures:

Optimized energy production over time.
Ability to withstand weather events like storms, snow etc.
Long term safety and function of the system.
Reduced maintenance costs.

Invest in appropriately sized, high quality middle U clamps designed for your specific solar panels. Correct installation of these clamps will maximize the structural integrity and lifespan of your photovoltaic system.

Key features of power snaps:

Made of durable UV-resistant plastic.
Available in different sizes to fit rail dimensions.
Require no tools for installation.
Reusable as needed.

Benefits of power snaps:

Deters potential solar panel theft.
Provides extra peace of mind and security.
Suitable for all types of panel mounting structures.
Quick and easy to install.

VII. Nuts and Bolts for Structure

Nuts and bolts are used extensively in solar panel mounting to assemble the structural framework.

Common types include:

Spring nuts – Allow easy insert of bolts into drilled holes.
SS Allen bolts – Tighten panels and components securely.
Stud bolts – Attach items like junction boxes.

Benefits of using the right nuts and bolts:

Strong assembly of the entire mounting structure.
Ability to withstand weather elements like rain, wind.
Long term integrity and stability.
Reusability during the maintenance.

High quality hardware is essential for:

Optimized energy production over decades.
Reduced risk of structural failures.
Lower maintenance time and costs.

Choosing appropriately sized nuts and bolts made of durable materials ensures a sound framework for your solar panels. Periodic inspection and proper re-tightening preserves the stability and lifespan of the installation. Investing in good quality mounting hardware is vital for a robust and long-lasting solar power system.

VIII. Fastener Chemicals for Extra Strength

Fastener chemicals provide additional strength and stability for roof-mounted solar installations.

These adhesives are used with bolts and screws to securely bond the mounting structure to the roof surface.

The typical application process involves:

Drilling a hole in the roof material.
Injecting the chemical into the hole.
Inserting a bolt and allowing the adhesive to set fully.

Benefits of using fastener chemicals:

Create an exceptionally strong and waterproof bond.
Allow secure attachment to tile, metal and other roof types.
Compensate for weaker roof materials.
Resist weathering and deterioration over time.

Proper structural strength enables the solar system to:

Withstand extreme winds, rain and other weather events.
Avoid leaks, cracks and damage to the roof.
Maintain optimal mounting integrity for decades.

Proper installation by trained professionals ensures maximum structural reinforcement and lifespan for your roof-mounted solar system.

Anodized Aluminum: Is it the Ideal Solar Panel Frame Material?

February 19, 2024

by Jaya with No Comment Generic

I. Understanding Anodized Aluminum

Anodized aluminum is an aluminum alloy that undergoes a process called anodization, in which an oxide layer forms on the surface of the metal.

Key properties of anodized aluminum include

Corrosion resistance
Strength
Durability
Light weight

The anodization process:

Thickens the natural oxide layer on the aluminum surface
Creates a transparent, hard and protective finish

The resulting surface resists:

Corrosion
Wear
Weathering
Scratching

Benefits of the anodized layer:

Corrosion resistance
Protects against oxidation, rust, staining
Surface hardness
More scratch and abrasion resistant
Durability
Withstands weathering and harsh conditions
Aesthetic versatility
Available in a range of finishes and colors

Anodizing is an electrochemical process that creates a protective oxide layer on the surface of aluminium. This coating is highly durable, resistant to weathering, and provides excellent insulation. Anodized coatings are often used on aluminium solar mounting structures. AA10 is the common industry standard of anodized coating which is 10 microns thick.

Common applications for anodized aluminum:

Application	Benefits Provided
Building exteriors	Corrosion protection, strength
Electronics	Light weight, thermal performance
Solar panel frames	Corrosion resistance, strength-to-weight ratio

The anodized aluminum layer can be thinner or thicker depending on the required characteristics:

Hard-coat anodizing produces thicker oxide for wear resistance
Architectural anodizing provides corrosion protection and aesthetic options

Anodization transforms aluminum into a tougher, more durable and weather-resistant material while retaining its light weight. This makes it well-suited to applications like solar panel frames that demand corrosion resistance, strength and durability in outdoor environments. The thermal conductive properties also aid solar panel thermal performance.

II. Advantages of Anodized Aluminum Frames

Anodized aluminum frames offer several key strengths that make them an exceptional choice for solar panel installations:

Corrosion Resistance

The anodized surface strongly resists corrosion, oxidation, and rust
Ideal for outdoor use in high humidity, coastal, industrial and other harsh environments
Requires very little long-term maintenance

Strength-to-Weight Ratio

Frames are lightweight yet highly durable
High strength-to-weight ratio enables stable structures without added weight
Easier transportation, handling and installation
Suitable for elevated and pole-mounted solar arrays

Aesthetic Versatility

Available in a diverse range of architectural finishes and colors
Can mimic styles like wood grain or granite
Blends into natural scenery or matches building exteriors
More aesthetically appealing than industrial-looking steel frames

Thermal Performance

Excellent heat dissipation properties
Prevents solar panels from overheating
Enhances efficiency and prolongs operational lifespans
Ideal for solar installations in hot climates

Anodized aluminum frames combine optimal corrosion resistance, strength, durability and flexibility in design to meet the demanding structural and environmental needs of solar panel systems. The exceptional thermal performance also enhances efficiency. This blend of technical and aesthetic qualities makes anodized aluminum an outstanding solar panel frame material for varied installations.

Click Here to Learn More

III. Applications

Anodized aluminum frames are extensively used in diverse solar panel installations:

Residential, Commercial and Industrial

Rooftop solar panels for homes, factories, offices
Ground or pole mounted arrays
Thermal properties aid efficiency

Carports and Building-Integrated

Vehicle and parking shade structures
Building facades, walls, rooftops
Aesthetic finishes blend seamlessly

Ground Mount and Tracking

Free standing arrays on ground bases
Solar trackers following sun movement
Resilience to outdoor exposure

Off-Grid Installations

Remote cabins and rural areas
Recreational vehicles and trailers
Resistant to vibration and shock

Sustainability

Recyclability makes suitable for green building

The lightweight yet durable anodized aluminum provides both structural integrity and design flexibility for solar panels across small scale residential to large commercial installations in diverse settings. It remains one of the most versatile and reliable solar infrastructure materials.

Let me know if you need any changes or elaboration on the highlighted applications. I aimed for brevity while including relevant keyword targets.

Learn More

IV. Sustainability

Anodized aluminum stands out as an eco-friendly metal used for solar panel frames due to:

Recyclability and Reduced Waste

Fully recyclable at end of product lifecycle
Recycling requires little energy
Reduces landfill waste
Conserves bauxite ore resources
Reusable without quality loss

Energy-Efficient Manufacturing

Anodizing process consumes less energy
Lower carbon footprint than other metals
Process powered by renewable electricity

Anodized aluminum is aligned with solar energy’s sustainability goals. Key properties like:

Corrosion resistance
Strength and durability
Thermal conductivity

Enhance lifespan, cutting replacement needs.

The combined qualities make anodized aluminum a standout green material for solar farm infrastructure. Its closed-loop recyclability and energy-efficient production supports renewable energy’s mission to reduce environmental impact.

V. Comparison to Other Frame Materials

Anodized aluminum stands out from other typical frame materials:

Galvanized Steel

Heavier than aluminum
Prone to rust and corrosion
Higher maintenance costs
Narrow aesthetic options

Stainless Steel

More expensive
Heavier than aluminum
Limited decorative varieties

Composite Materials

Durability issues in outdoor settings
Can delaminate over time
Shorter lifespan than aluminum
Not easily recyclable

Anodized Aluminum Advantages

Lightweight strength
Resilience to extreme weather
Excellent life cycle durability
Ability to harmonize visually
Sustainable properties

As a metal, anodized aluminum offers an optimal balance of strength, corrosion resistance, and recyclability – enabling more durable and eco-friendly solar panel infrastructure. Combined with flexibility in colors and textures, it remains a premium framing choice.

VI. Conclusion

Anodized aluminum stands as a top-tier solar panel framework option when key deciding factors around resilience, sustainability and aesthetics are considered.

Key properties like corrosion and abrasion resistance lend well to long-term use within hot, humid or coastal environments – while an efficient strength-to-weight ratio provides structurally sound support regardless of mounting variables across diverse solar farm, commercial building and residential settings on ground, rooftop or elevated installations.

Sustainability merits also rate highly – with superior recyclability, energy-efficient manufacturing processes and lifecycle durability that minimizes replacement needs – thus aligning well with renewable energy ideals.

Additionally, ability to colour and finish in a plethora of architectural styles empowers more seamless visual integration within different landscapes.

Compared against steel, composites and other customary building metals on vital metrics ranging from weather resilience to eco-friendliness – anodized aluminum garners excellent marks as a specialized solar panel framework, earning its classification as an optimal top choice for critical infrastructure across an array of solar energy project needs.

8 Major Benefits of Solar Carports

February 12, 2024

by Jaya with No Comment Generic

I. Solar Carport Efficiently Use Space

Our solar carports system are an innovative solution that utilizes existing spaces efficiently to generate clean energy. By installing solar panel canopy structures over parking lots and other areas that are already being used, solar carports are able to produce renewable power without taking up additional land.

Some key ways that solar carports leverage space efficiently include:

Using unused real estate: Solar carports are mounted over spaces that are often underutilized.
Parking lots
Driveways
Patios
Sidewalks
Maximizing horizontal spaces: The wide, flat canopy structures of solar carports are perfect for covering spaces used for parking and storage.
Making double use of necessary structures: Solar carports shelter vehicles, equipment, and people from the elements while also collecting energy from the sun.

Benefits	Details
No lost land usage	Solar carports added over existing infrastructure don’t require using up green spaces or acquiring additional land
Increased productivity	The shaded spaces under solar carports allow assets like vehicles to operate more efficiently
Dual-use infrastructure	Solar carports do “double duty” by generating renewable power in spaces that serve other primary purposes like parking

The next time you walk through a parking garage or outdoor lot, consider the potential to install solar canopies or carports. By embracing the available but overlooked real estate, businesses and towns can generate clean energy efficiently through solar technology that maximizes existing space usage.

II. Solar Carports Reduce Costs

Our installing process of solar carports delivers major cost savings in two key areas:

Energy Expenses

Solar panels generate clean electricity, offsetting power that would otherwise need to be purchased from the grid
Businesses can save thousands per year on electricity bills with an appropriately-sized solar carport system
Solar carports can power adjacent buildings, electric vehicle charging stations, outdoor lighting, and other facilities

Infrastructure Costs

Solar carports serve dual purposes, eliminating the need for separate structure investments just for power generation
Building a solar carport over an existing parking lot costs less than adding a rooftop solar array
Multi-capability design reduces need for other weather/UV protection measures

Additional financial benefits stem from:

Lower maintenance needs than ground mount solar or traditional rooftop systems
Increased productivity from shaded working/storage areas protected from elements
Enhanced property value from improved generating capacity and modernized facilities

Cost Savings Area	Solar Carport Advantage
Energy expenses	Clean solar energy offsets grid purchases
Infrastructure costs	Dual-use structures reduce additional builds
Maintenance	Easy ground-level access minimizes upkeep
Productivity	Weather protection increases asset efficiency
Property value	Modern energy infrastructure improves sites

With lower overheads and generation capabilities that pay for themselves over time, solar carports enable substantial cost reductions. And as electricity rates rise, solar carports will provide increasing levels of savings each year.

III. Solar Carports are Customizable

One of the key advantages of solar carports is their high degree of flexibility and customization potential. Installers can tailor solar carport solutions to meet the specific needs of the property.

Customization capabilities include:

Size: Carports can be small or cover expansive lots, with solar panels scaled appropriately
Layout: Flow with angled parking spots or irregular shapes using creative structural designs
Solar orientation: Panels can be tilted at ideal angles to maximize sun exposure and power generation
Aesthetic options: Choose colors/finishes to match branding or surroundings
Additional features: Integrate lighting, charging stations, storage, signage displays into the carport structure

This modular flexibility empowers property managers to create solar systems tailored to their sites. For example:

Retail stores can match carport colors to their brand palette
Fleet yards can install high-capacity carports to power maintenance facilities
Agricultural facilities can orient solar panels for optimum energy generation across seasons

Customization Factor	Carport Capabilities
Size	Small or large coverage areas
Layout	Flow across properties efficiently
Solar orientation	Optimize panel angle for conditions
Aesthetics	Match color schemes and branding
Features	Add lighting, charging, displays

The adaptable nature of solar carports enables properties to establish renewable energy infrastructure that blends seamlessly with the space. Custom solar carport solutions meet generation needs while fitting aesthetically into the existing environment.

IV. Solar Carports are Easy to Maintain

One major advantage of solar carports compared to rooftop solar arrays is that they are much easier to access and maintain. Key factors that simplify upkeep include:

Convenient Access

Installers can reach panels and electrical components from ground level
No need for ladders, scaffolding or roof access
Streamlined inspections, cleaning, repairs

Weather Protection

Raised canopy structure channels rain, snow melt away
Prevents to build up of leaves, ice, and other debris
Prolongs equipment life by shielding from UV and temperature swings

Simplified Connection

Wiring neatly converges to single interconnection point
No complex routing through walls and ceilings
Easy grid integration with net metering

Enhanced Safety

Grounded access minimizes fall and electrocution risks
Clearly visible electrical conduits per code
Stable structures engineered for wind/seismic events

Benefit	Advantage
Accessibility	Straightforward ground-level component access
Weather protection	Channels precipitation away, shields equipment
Simplified wiring	Converges to single interconnection area
Safety	Reduced risks for installers and inspectors

The ability to easily reach, assess, maintain, and protect all aspects of solar carports ensures reliable clean power generation over their lifespan. Streamlined upkeep translates into lower operational costs.

Click Here to Learn More

V. Solar Carports Provide Protection

Solar carports safeguard vehicles, equipment, and inventory from exposure while also generating clean energy. Key elements of protection include:

Weather Shielding

Roof structure deflects rain, snow, hail
Prevents exterior damage, internal water incursion
Reduces weather-related repairs/clean up

Temperature Control

Shade cools interior temperatures by over 50°F
Prevents overheating that strains mechanical parts
Extends component life by limiting temperature swings

UV Ray Blocking

Reduces interior fading, cracking, discoloration
Shields electronics from solar disruption
Protects tires, seals, plastic components

Shelter from Debris

Captures falling leaves, airborne dust
Reduces abrasion, exterior dulling
Helps maintain asset appearance

Solar carports deliver essential weather protetion to improve durability and lifespan. Shielded assets will look better, require fewer repairs, and maintain optimal working order for longer under a solar canopy.

VI. Solar Carports Generate Clean Energy

Installing solar carports empowers properties to establish renewable energy independence using sun power. Key clean energy benefits include:

Lower Environmental Impact

Solar carports produce zero direct emissions
Reduce reliance on fossil fuels for electricity needs
Support corporate sustainability commitments

Energy Bill Savings

Lower or eliminate power purchases from utility
Insulate against rising electricity rates
Payback financing options often available

Grid Support

Excess power generation can be sold back to grid
Stabilize shared infrastructure during high demand
Enable establishment of micro grids

Enhanced Public Image

Highly visible sign of commitment to sustainability
Strengthen community relationships
Attract forward-thinking customers/partners

Transitioning a portion of power usage to solar carports helps properties minimize environmental impact in an economical way. And their visibility promotes an innovative, eco-conscious public image.

VII. Solar Carports Benefit Businesses

Installing solar carports Structura offers many tangible benefits for companies across sectors:

Cost Reduction

Lower facility energy bills
Leverage available parking/storage areas
Minimize additional weatherproofing spends

Productivity Gains

Protect inventory and equipment from elements
Prevent overheating of sensitive materials
Create comfortable outdoor working conditions

Sustainability Profile

Highlight green commitment to customers
Achieve environmental impact goals
Qualify for related tax/rebate incentives

Grid Independence

Establish micro grid from carpot output
Reduce vulnerability to utility outages
Store excess power in batteries for backup

Customer Experience

Provide shaded parking for visitors
Offer EV charging under carport awnings
Create space for outdoor dining/retail

Forward-thinking companies can leverage solar carports in many ways – from cost and resilience to brand image. The benefits for business operations and the bottom line are substantial.

VIII. Solar Carports Support Communities

Installing solar carports delivers benefits that resonate across neighbourhoods and towns:

Clean Decentralized Power

Reduce reliance on distant fossil fuel plants
Establish locally-generated clean energy
Increase community energy independence

Grid Infrastructure Resilience

Distribute solar widely across parking lots
Avoid centralized power failures from single points
Maintain access to electricity during outages

Civic Collaboration

Shared public carports in municipal lots
Joint projects between local stakeholders
Bring together constituencies around sustainability

Economic Development

Savings for businesses passed to consumers
New jobs created in solar installation/maintenance
Environmental leadership attracts talent relocation

Improved Quality of Life

Cleaner air from reduced emissions
Accessible community EV charging
Vibrant public spaces with carports as social infrastructure

Forward-looking towns are smart to embrace solar carports – they deliver environmental performance, resiliency, and quality of life benefits that serve the whole community.

Solar Mounting Structure Construction Methods

February 12, 2024

by Jaya with No Comment Generic

I. Selecting Solar Mounting Structures

Carefully selecting solar mounting structures is crucial in maintaining solar panel performance and system longevity. This process involves geological surveys, soil condition analysis, fixed tilt and tracker design considerations, and recommendations from advanced modelling tools.

Foundation Requirements

Our geological surveys must be performed to determine the optimal type of foundation for the solar mounting system, assessing:

Factors	Recommendations
Soil acidity	Apply protective coating if needed
N values	Indicative of soil strength
Groundwater	Prevent corrosion
Soil conditions	Detailed analysis

Plant Design Considerations

The mounting structures must account for the planned plant design:

Fixed tilt: Angled at optimal degree for site location
Trackers: Follow sun throughout the day, best suited for flat sites

Analyse topography to account for complex terrain:

Foundation pile lengths
Model shadowing
Streamline parts and installation

Automated Recommendations

Leverage advanced modelling software like Rated Power to automate:

Plant layout optimization
Component selection for environmental conditions
Cost, performance and profitability projections

These tools provide data-driven recommendations to optimize mounting structure selection based on the project goals and constraints.

Their projections help determine required:

Pole diameter and depth
Fastenings rated for extreme weather
Reinforcements to prevent collapse

Carefully weighing these considerations enables selection of cost-effective, durable solar mounting systems able to withstand decades of operation.

Click Here to Learn More

II. Mounting Structure Types

The soil conditions and operational environment dictate the optimal mounting structure. Main options:

Ballast Mounts

Pre-cast concrete block
Rest on compacted soil
Residential rooftop installations
Avoid need to drill/excavate

Helical Piles

Driven into soil conditions
Withstand uplift forces
Resist expansion and strong winds
Provide load-bearing capacity

Pole Mounts

Steel poles with concrete anchors
Simpler than ballast mounts
Multi-pole systems
Single row of panels
Ease large project adjustments

Ground Screws

Soil conditions:
Compacted
Heavy clay
Rocky surface
Minimal earthwork and engineering

Factor	Considerations
Steep terrain	Screws have limited gradient suitability
Granular soils	Provide less stability

Read More

Concrete Foundations

Ideal for:
Brownfield sites
Capped landfills
Wetland sites
Minimally invasive mounting

Careful analysis of the site geological surveys and planned solar farm size determines optimal structure types.

Learn More

III. Structure Installation

Once the mounting structure type is selected, proper installation is key to ensuring solar farm performance and longevity.

Location Planning

Survey site topology
Mark locations for:
Mounting structure base
Foundation piles

Considerations:

Access for construction equipment
Optimizing spacing and tilt angles
Minimizing shading

Foundation Installation

Method depends on structure type:

Ballast
Level ground
Position blocks
Bolt to frames
Piles:
Drive into ground
Depth based on soil, loads
Attach to structure
Screws:
Mechanically screw in
Add torque as needed
Concrete:
Cast foundation
Cure properly
Attach racks

For small sites, hand tools can be used. Larger solar farms require:

Excavation equipment
Pile driving machinery
Cement pouring

Other Considerations

Schedule installs around rain to allow proper curing
Check for shift/corrosion periodically
Assess after extreme weather events

Proper base structure installation ensures the solar farm can withstand environmental conditions for the project lifetime.

IV. Failure Modes

Improperly designed or installed mounting structures can fail, causing solar farm damage or collapse.

Design Failures

Inadequate design is a common failure mode:

Incorrect tilt angle
Reduces energy generation
Accelerates weathering
Insufficient corrosion planning
Shortens lifespan
Risks collapse
Not accounting for environmental conditions
Wind, snow, rain loads
Seismic factors
Lightning strikes

Use advanced modelling tools during design to predict and address these factors.

Installation Failures

Faulty foundation installation causes most failures:

Improper pile depth
Loosens over time
Insufficient anchor
Inadequate curing
Weakens concrete
Cracks under load
Poor leveling
Twists structure
Unbalances loads

Conduct pull-out testing after install to validate integrity.

Impact

Panel damage from detached arrays
Destabilized ground
Risks landslides
Further equipment damage
Lost energy generation
While repairs conducted
If decommissioned

Preventing mounting structure failure is crucial for utility-scale solar farm optimization. Adequate design and installation is key.

V. Advanced Modelling

We specialized solar design software leverages advanced algorithms to streamline and optimize mounting structure selection.

Key Features

3D site modelling
Analyse terrain
Identify ideal layout
Automated engineering
Foundation sizing
Pull-out calculations
Structural analysis
Machine learning
Data from prior projects
Improves recommendations
Custom reporting
Details selections
Installation guidelines

Automated Deliverables

Extract key project outputs:

Bill of materials
Parts, quantities, costs
Permit drawings
Submit directly
Installation plans
Equipment needs
Construction schedule

Continuously optimize as design evolves:

Adjust for equipment purchases
Update code compliance
Reruns in seconds

Why automate?

Eliminates error-prone manual work
Provides data-backed recommendations
Saves significant time and costs
Enables design of high-performing mounting solution

Leveraging advanced tools ensures selection of ideal, cost-effective mounting systems for each unique solar site.

VI. Next Steps

Properly designing and implementing solar mounting structures is critical for project success. Key recommended next steps:

Detailed Site Analysis

Perform in-depth site surveys assessing:

Soil conditions
Composition
Load capacities
Topography
Height variations
Obstacles
Accessibility
Construction equipment
Maintenance needs

This data informs ideal mounting structure planning.

Design Optimization

Leverage advanced algorithms to automate optimizing for:

Energy generation projections
Land usage efficiency
LCOE minimization
Custom objectives

These tools run iterative simulations to determine optimal:

Tilt angles
Foundation sizing
Pole configuration
Tracking capabilities

Streamlining mounting structure design enables maximized ROI.

Demo Request

See a live demo of data-driven mounting structure optimization in action:

Custom 3D site modelling
Foundation design
Automated BOM generation
Performance/cost projection

Understand capabilities before committing, to ensure solution adequacy for specific project needs.

Implementation Planning

With optimized mounting structure selection completed, detailed implementation planning is next:

Permitting
Grid interconnection
Foundation and structure installation
Panel mounting
Inspection

Proper construction is vital for protecting long-term solar farm durability against extreme weather and maximizing energy generation.

We provide careful planning and leveraging modern solar design tools enables streamlined mounting structure implementations for productive, profitable solar projects.

EPDM Rubber for Solar Panel Mounting Structure

February 5, 2024

by Jaya with No Comment Generic

EPDM Rubber for Solar Panel Mounting Structure

Introduction to EPDM Rubber

EPDM (ethylene propylene diene monomer) is a type of synthetic rubber that offers excellent performance properties that make it well-suited for use in solar panel mounting applications. EPDM stands out from other rubbers due to its:

Durability
Weather resistance
Flexibility across a wide temperature range
Chemical resistance

These characteristics allow EPDM rubber to withstand outdoor environments for many years without degradation.

EPDM contains three main components:

Ethylene
Propylene
Diene

The diene facilitates sulfur vulcanization which enables crosslinking and gives EPDM its useful properties.

Key Properties

Temperature resistance: From -50°C to +150°C
UV radiation resistance
Ozone resistance

Due to its saturated polymer backbone, EPDM vastly outperforms unsaturated rubbers in terms of resisting heat, light, and environmental damage over time.

Property	Value
Thermal expansion	160 μm/(m·K)
Max temperature	150°C
Min temperature	-50°C

Solar Panel Mounting Applications

In solar panel mounts, EPDM is used primarily for:

Roof penetrations
Prevents water leaks
Protects electrical connections
Gasket material
Cushions and secures panels
Absorbs vibration

Its water resistance and weather resistance makes EPDM the ideal sealant and protector for roof-mounted systems in rainy climates.

With proper EPDM accessories like rubber pads and adjustable clamps, solar installers can securely mount frameless solar modules without risk of cracking thin film PV panels.

Overall, EPDM rubber offers an optimal balance of critical performance properties to safely and reliably mount photovoltaic arrays exposed to harsh outdoor conditions

II. EPDM Properties and Benefits

EPDM rubber stands out from other rubber materials due to its exceptional weather resistance, durability, flexibility, chemical resistance and water resistance. These properties make it ideal for outdoor applications like solar panel mounting:

Weather Resistance

Withstands UV radiation, ozone and weathering
Saturated polymer backbone resists damage
Maintains properties after years outdoors

Durability

High temperature resistant up to 150°C
Retains strength and shape
Low temperature performance down to -40°C

Flexibility

Remains flexible in extreme cold and heat
Conforms to various shapes
Absorbs vibration and shock

Chemical Resistance

Resilient against acids, alkalis
Withstands many harsh organic solvents

Water Resistance

Waterproof and moisture-proof
Prevents leaks, flooding and corrosion
Protects electrical systems

These capabilities make EPDM ideal for:

Roof penetrations
Gasket material to secure panels
Protecting outdoor electrical connections

With its balance of critical properties, EPDM rubber is the preferred material to safely install frameless solar modules and mount PV arrays in harsh climates.

III. EPDM Applications

With its excellent weather resistance, durability and flexibility, EPDM rubber is widely used in outdoor applications that require reliable water and air sealing properties.

Key applications include:

Solar Panel Mounting

Roof Penetrations
Flashings, collars and seals
Prevents interior leaks
Gasket Material
Secures panels to mounts
Absorbs vibration
Protects components

Roofing Materials

Rubber Roofing Panels
Durable and waterproof
Resists mold and rot
Harnesses solar power

Accessories

Rubber Pads
Cushion clamps
Protect thin film PV panels
Module Clamp Rubber Strips
Secures frameless solar modules
Prevents glass cracking

Adjustable Clamps

Safely secures uneven and curved surfaces
Thermal expansion accommodation
Compatible with 5-10 mm panels

Outdoor Enclosures

Protects electrical boxes and gear
Seals out moisture, dirt and debris
Withstands weathering and UV rays

With EPDM’s balanced material properties, it serves critical sealing, mounting and protection functions across countless outdoor applications.

IV. EPDM in Outdoor Environments

EPDM’s exceptional resistance to heat, sunlight and environmental degradation makes it an ideal rubber material for permanent outdoor installation.

Temperature Resistance

Withstands high temperatures up to 150°C
Retains flexibility at low temperatures down to -50°C
Handles extreme weather fluctuations

UV Resistance

Specialized polymer backbone resists UV radiation
Prevents material degradation
Provides decades of exposure resistance

Ozone Resistance

Additives block ozone degradation
Prevents cracking and hardening
Extends service life

Weathering Resistance

Stands up to years of rain, sun and snow
Retains a like-new appearance
No visible signs of aging

Service Lifespan

Properly formulated EPDM lasts for decades
Far exceeds the capability of other rubbers
Reduces the need for replacement

These capabilities make EPDM the preferred choice for:

Roof seals
Solar panel mounts
Outdoor gaskets and seals
Protecting components in harsh environments

EPDM rubber delivers reliable, long-lasting performance in even the most punishing outdoor installation environments.

V. EPDM in Solar Panel Mounting

EPDM’s exceptional durability and weather resistance makes it an ideal material for solar panel mounting applications.

Key Uses

Roof Penetrations
Flashings and seals
Prevent leaks
Gasket Material
Cushion and secure panels
Absorb vibration

Solar Mounting Accessories

Rubber Pads
Protect thin film PV panels
Cushion adjustable clamps
Module Clamp Rubber Strips
Secure frameless solar modules
Prevent glass cracking

Benefits

Waterproof and moisture-proof
Accommodates expansion and contraction
Electrically insulating
Resilient shock absorption

Adjustable Clamps

Secure uneven and curved surfaces
Compatible with 5-10 mm panels
EPDM pads protect glass

Frameless Mounting

Secure mounting without frames
Rubber pads prevent damage
Clamp securely without slipping

With its durability and sealing capability, EPDM rubber makes an ideal accessory material for safely and reliably mounting solar arrays on rooftops and carports while protecting them from weather events and mechanical stresses.

Click Here to Learn More

VI. EPDM Accessories

EPDM’s flexibility and durability make it an ideal material for accessories used to safely mount solar panels. Key accessories include:

Rubber Pads

Cushion and protect panels
Place inside clamps
Prevent glass damage
Available thicknesses:
5mm
10mm
15mm

Module Clamp Strips

Created from extruded EPDM strips
Protect frameless panel edges
Offer cushioning and grip
Lengths:
8cm
12cm
15cm

Adjustable Clamps

Flashed aluminum clamps
EPDM rubber inserts
Secure uneven shapes
Grip 5-10mm panels

Flashing Seals

Seals roof penetrations
Split EPDM boot design
Prevents leaks
Reusable and adjustable

Specialty Gaskets

Seals electrical boxes
Moisture and dust protection
Custom shapes available

With its sealing properties and flexibility, EPDM enables solar installers to safely secure panels and protect components from weather and mechanical damage.

Conclusion

EPDM rubber offers an unmatched balance of properties that make it the ideal material for solar mounting applications. Key advantages include:

Weather resistance – Withstands decades of UV, ozone, rain, snow and temperature extremes
Durability – Retains properties after years of outdoor stress
Flexibility – Remains flexible across a wide temp range
Waterproof – Prevents leaks and flooding
Chemical resistance – Withstands environmental pollutants
Solar Mounting Uses:
Roof penetrations – Flashings, seals and gaskets
Gasket material – Secures panels, absorbs vibration
Rubber pads – Inside adjustable clamps to protect glass
Module clamp strips – Secures frameless solar modules

Out of all available rubber materials, properly formulated EPDM delivers the best assurance for long-term performance and reliability in the harshest outdoor environments.

With UV stabilizers and antioxidants, modern EPDM formulations resist degradation from heat, light and ozone for decades. Paired with adjustable clamps and compression seals, solar installers can securely mount PV arrays in all climates knowing the rubber gaskets will continue providing protection against the elements throughout the system lifetime.

EPDM rubber stands above other materials as the ideal choice for safely securing roof-mounted solar panel installations.

Solar Mini Rails, Cheaper Solution for Your Metal Roof

February 3, 2024

by Jaya with No Comment Generic

mini rail system

8 Ways to Slash Solar Project Construction Costs Efficiency

January 30, 2024

by Jaya with No Comment Generic

I. Select the Right Land

Choosing the right piece of land is a critical first step to lower solar construction costs. The land has certain requirements and criteria that must be met before building a solar project on it, covering factors like:

Topography and terrain
Electrical infrastructure access
Wildlife impact

The land should ideally be:

Reasonably cleared and level
Within 1-3 miles of a substation
Within 1 mile of a three-phase power line

It’s important not to rush into leasing land only based on an attractive price. Being selective about your future solar site may cost more upfront and involve competition with other solar developers, but the wrong land could raise financial implications later on.

For example:

Contaminated lands bring liability and regulatory issues
Prolonged construction time and higher costs

Conducting site evaluations with a geotechnical investigation plan helps mitigate risk:

Site Condition Evaluations	Importance
Slope stability analysis	Ensures proper foundation design
Sediment control testing	Informs storm water management system
Subgrade examinations	Verifies adequate ground bearing pressure

Being selective about your solar land site may cost more upfront, but saves money in the long run by preventing avoidable construction issues. Analyse the size, shape, and terrain to determine if the land meets critical criteria. Don’t rush into a land lease solely based on an attractive price.

Click Here to Learn More

II. Let the Land Inform Design

Once you have secured the right land, conduct thorough site evaluations to inform the solar project design. This helps reduce unexpected issues arising during construction that add costs. Key steps include:

Geotechnical Investigations

Perform detailed geotechnical studies of the site including:

Slope stability analysis
Soil corrosivity measurements
Identifying soil bearing pressure and capacities

This data helps determine:

Proper foundation dimensions
Appropriate ground preparation
Necessary sediment erosion controls

Having accurate geotechnical inputs prevents under-engineering foundations that fail or over-building that wastes money.

Racking and Mounting Design

The site’s soil and terrain conditions should also guide designing the solar racking system:

Account for slope, load capacities and wind shear
Ensure proper anchor sizing and embedment depths

Carefully matched racking avoids unnecessary costs from:

Insufficiently anchored structures failing in high loads
Oversized racking increasing materials, construction and land use

Storm Water Management Evaluation

Assess site topography and hydrology
Model potential erosion volumes
Design effective grading and sediment control measures

Preventing runoff and erosion problems during construction protects water quality and avoids costly mitigation.

In sum, informed solar design optimized for the site’s unique properties saves money during builds and over asset life cycles.

III. Choose Reliable Equipment

Selecting durable, high-performing equipment suited for the solar project can help efficiently meet construction targets and budgets. Best practices include:

Vendor Evaluation

Thoroughly assess potential vendors and suppliers on:

Product quality and durability
Warranties and maintenance terms
Past performance meeting specifications

This reduces unexpected costs from fixes or change orders.

Specification Setting

Clearly define project performance requirements and operating conditions including:

Weather resilience testing (wind, humidity, temperatures)
Critical load capacities and safety factors
Compliance with all applicable standards

Equipment unable to meet specifications can slow progress or require replacements.

Testing and Inspection

Validate equipment condition and capabilities through:

Performance verification testing
Quality control inspections at factories and upon delivery
Operational trial runs before full deployment

This prevents integrating defective components into builds.

Preventative Maintenance

Follow all manufacturer recommended upkeep like:

Component lubrication and cleaning
Tightening loose connections
Tuning and calibration

Proactively caring for equipment prevents breakdowns or failures that are more disruptive to fix during active construction.

Choosing robust, durable equipment tailored to the project’s specific demands increases construction efficiency and asset longevity while lowering lifetime equipment costs.

IV. Simplify Racking Installation

Streamlining the solar racking installation process through thoughtful design and planning cuts costs by maximizing efficiency. Useful techniques include:

Adjustable Components

Specify racking with some flexibility to accommodate variability in site conditions like:

Slope grade changes
Subtle foundation shifts
Minor anchor position adjustments

This avoids expensive time delays from disassembly or holes requiring re-drilling.

Installation Work Plans

Create detailed work plans mapping the sequential process including:

Equipment and tool requirements
Labour needs and assignments
Anticipated production rates

Thorough plans allow coordinating teams and deliveries for smooth flows, preventing downtime from missing items.

Streamlined Hardware

Prioritize racking using simplified components like:

Universal clamps fitting multiple module types
Single bolt designs
Integrated ground bonds

Simpler assemblies with fewer unique parts quicken overall mounting.

Specialized Equipment

Leverage purpose-built tools for efficiency gains on repetitive tasks like:

Auto-dispensing auger rigs for drilling pile foundations
Custom jigs ensuring consistent positioning
Lifting aids for positioning sections

The right equipment prevents injury and enhances productivity.

Careful coordination, adjustable parts allowing adaption, and streamlined installations prevent complications that sap field productivity – saving costs with efficient solar racking assembly.

V. Control Construction Budget

Carefully managing the construction budget helps avoid cost overruns that erode project returns. Best practices include:

Early Cost Estimation

Develop initial budgets during early planning using expected:

Equipment, material, and labour expenses
Permitting, grid connection, and inspection fees
Site preparation and installation costs
Lease payments

Regularly update these projections with real quotes as specifics firm up.

Risk Assessment

Proactively evaluate uncertainties that may impact costs like:

Inclement weather delays
Potential supply chain disruptions
Changes in material pricing
Community complaints

Identify mitigations to contain budgets despite issues.

Contingency Funds

Incorporate 5-10% contingencies within budget estimates for the inevitable unplanned events on large builds. This prevents scrambling to fund surprises.

Value Engineering

Continuously identity ways to trim costs like:

Sourcing substitute materials
Simplifying designs
Using more efficient construction techniques

Savings from value engineering provide additional buffers.

Change Control

Carefully evaluate any project changes for cost/benefit before approval to prevent scope creep.

Ongoing cost oversight, planning for uncertainties, and continuous optimization prevents overspending, keeping solar projects economically viable.

VI. Account for Soft Costs

“Soft costs” like permitting, financing, and labour add up. Strategies to control these expenses include:

Streamlined Permitting

Research local solar ordinances in detail
Prepare thorough permit packages
Use expediters to ease process

Understanding requirements and properly completed submissions prevent delays from application issues.

Efficient Procurement

Comparison shop equipment and materials
Leverage online supply marketplaces
Optimize logistics like shipping modes

Casting a wide net surfaces best pricing and responsiveness.

Labour Optimization

Cross-train workers on multiple tasks
Use crews balancing experience levels
Incentivize on-time delivery

Flexible, motivated crews prevent downtime and inefficiencies.

Strategic Sourcing

Buy cables, connectors in bulk
Seek winter off-season discounts
Favour modular components

Order consolidation and tactical timing reduce supply chain expenses.

While some soft costs are fixed, focus on streamlining variable expenses.

Cost Containment Strategies

Area	Savings Approach
Permitting	Submit complete packages
Procurement	Leverage marketplaces
Labour	Reward on-time work
Sourcing	Buy at scale in off-seasons

Get ahead of soft costs early in planning to protect project profitability.

VII. Assemble Experienced Team

The right solar project team is crucial for on-time, on-budget delivery. Best practices for assembly include:

Diverse Expertise

Staff key roles with experts in areas like:

Solar design engineering
Procurement and supply chain
Project planning and controls
Grid integration and commissioning

This breadth covers the multifaceted competencies vital for success.

Proven Track Records

Validate capabilities by examining:

Years in industry
Projects successfully delivered
Client references
Safety and performance metrics

This reduces risk of underperforming personnel sinking progress.

Aligned Incentives

Structure contracts promoting shared project success through:

Bonuses for schedule and budget achievement
Penalties for missteps
Profit sharing

Incentive alignment prevents finger pointing during crunch times.

Scalable Resourcing

Ensure capacity to flex expert personnel levels up and down as activity fluctuates during project phases. This cost-effectively right-sizes labour.

Responsiveness Training

Conduct emergency response simulations preparing crews to smoothly handle incidents like storms or injuries if they arise with minimal safety and cost impacts.

Investing in the right expertise, experience, motivation and responsiveness in a solar build team pays dividends through maximized efficiency and risk reduction over the project lifecycle.

VIII. Prepare Contingency Funds

Despite best-laid plans, unexpected events during solar construction add costs. Maintaining contingency funds mitigates overruns threatening project viability. Best practices include:

Historical Spending Analysis

Examine past projects to estimate emergency cost frequencies in areas like:

Permitting delays
Weather downtime
Equipment failures
Materials pricing changes

These insights quantify contingency targets.

Probability Impact Matrices

Map identified risk events by likelihood and potential cost severity to prioritize responses and gauge required reserves.

Risk	High Likelihood	Low Likelihood
High Cost	Permit denials	Foundation redesigns
Low Cost	Inspections	Minor repairs

Ongoing Reassessment

Re-evaluate required contingency amounts and probability estimates at major milestones as uncertainties resolve over the project timeline.

Contingency Tracking

Implement formal change control processes ensuring contingency funds only applied to eligible unforeseen costs rather than scope expansions.

Proactively earmarking reserves for the inevitable unknowns, continually refining estimates, and tightly controlling drawdowns ensures access to emergency funding without tapping capital required for planned activities. Sized correctly, contingencies become insurance policies enabling construction progress despite surprises.

Aluminium Channels

January 27, 2024

by Jaya with No Comment Generic

I. Introduction to Aluminium Channels for Solar Mounting Sytems

Aluminium channels refer to extruded aluminium profiles that have an inward facing radius suitable for mounting applications. Aluminium is a lightweight, strong, and durable metal that makes an ideal material for solar mounting components like rails, brackets, and panel frames.

Benefits of Aluminium Channels

Some key advantages of using aluminium channels for solar mounts include:

Corrosion resistant – Aluminium forms an oxide layer when exposed to air that protects against corrosion. This makes it very weather and rust resistant.
Lightweight – With only 1/3 the density of steel, aluminium minimizes weight loads on rooftops and structures.
Strength – Despite being lightweight, certain aluminium alloys like 6063 and 6061 provide excellent strength for structural applications.
Customizable – Aluminium can be easily machined and extruded into customized mounting components.

Property	Aluminium	Steel
Weight	Low	High
Strength	High	Higher
Corrosion Resistance	High	Low
Customization	High	Low

Click Here to Learn More

Types of Solar Mounting Systems

Common solar mounting systems that utilize aluminium channels include:

Roof Mounts – Aluminium rail systems to mount solar panels along rooftops.
Ground Mounts – Framed aluminium structures to mount panels on the ground.
Solar Farms – Large scale ground systems to mount panels across acres of land.
Carports – Aluminium structured carport frames that have integrated solar panel mounting.

These mounting methods typically include aluminium component likes rails, flashing, brackets, posts as well as hardware like bolts, clips, and connectors.

Aluminium offers an exceptional material for solar mounting hardware due to its versatile properties. Proper selection of durable and corrosion resistant alloys along with suitable structural design allows aluminium channels and components to reliably mount and frame solar modules for decades.

Learn More

II. Aluminium Grades and Alloys

There are numerous aluminium alloys available, but some stand out for applications in solar mounting systems due to their specific material properties.

Common Alloy Grades

The most common alloy grades used for solar mounting components are:

6063 – This grade offers good corrosion resistance, weld ability, and finishing capability. It is easy to extrude into complex shapes.
6061 – With excellent strength and corrosion resistance, this grade is suitable for structural mounting framing.
7075 – Where very high strength is needed, this grade can be used despite difficulty welding and machining.

Alloy	Properties	Uses
6063	Corrosion resistant, easily extruded and machined	Solar rails, decorative trims
6061	High strength, easily welded and machined	Structural brackets, supports
7075	Very high strength, difficult to weld and machine	Heavy loadbearing components

Alloy Properties and Strength

The silicon and magnesium content in 6063 and 6061 alloys provide good corrosion resistance and weld ability.
Addition of zinc, copper, and small amounts of other metals give 7075 alloy exceptional strength.
Heat treating and tempering alloys also enhances their strength considerably.
6063 T6 and 6061 T6 tempers provide a good blend of strength, machinability, and corrosion resistance needed for most solar mounting applications.

III. Extrusion Process

Aluminium parts like channels, angles, and tubes for solar mounting systems are primarily made using the extrusion process.

Extrusion Methods

There are two main methods:

Direct extrusion – Material is pushed through a die using a ram.
Indirect extrusion – Material pulled through a die using a stem.

Direct extrusion is more common for larger aluminium sections like solar frame components.

Dies and Moulds

The shape and dimensions of the extruded aluminium profile is defined by the steel die design. Common dies exist for standard rails and channels.

Complex profiles can require custom die fabrication. Proper die heating up to 500°C is needed for smooth extrusion flow.

Billet Preparation

Aluminium billets provide the raw material.
Billets are heated up to 900°C to soften the aluminium for smooth extrusion.
Proper lubrication prevents sticking inside the chamber.

Extrusion Variable	Typical Value
Ram Pressure	15,000 tons
Billet Temperature	750°C to 930°C
Extrusion Speed	5 to 50 ft/min

This allows very customizable aluminium grades and profiles to be created for solar mounting components using the extrusion process.

IV. Mounting System Hardware

Aluminium channel extrusions and fabricated components make up solar mounting system hardware like rails, brackets, frames, and more.

Rails and Brackets

Common aluminium mounting hardware includes:

Rails – Channels that span rafters or posts to mount panels either in portrait or landscape orientation.
Brackets – Angle brackets to mount rails to rooftops and poles or act as panel support legs.
Flashing – Bent aluminium sheets to seal roof penetrations.

These components often use 6063 grade for good corrosion resistance and ease for fabrication.

Panel Racking and Frames

Panel racking refers to the entire support structure:

Framed racking uses joined aluminium profiles as vertical posts and horizontal cross beams.
Rail systems have minimal underlying structure.

Panel frames made of aluminium channels help rigidize panels.

Hardware	Description
Rails	Horizontal channel supports
Brackets	Angled brackets for attachment
Frames	Border channels around panel

Roof and Ground Mounts

Panel orientation hardware differs:

Roof mounts use tilt legs and clamped connections.
Ground mounts rely on fixed pole foundations.

Proper selection of durable aluminium hardware ensures long system lifespans.

V. Finishes and Coatings

Aluminium can be given different finishes and coatings to improve aesthetics, protection, and performance.

Anodizing

Anodizing is an electrolytic process that converts the surface to aluminium oxide for enhanced corrosion resistance.

Hard anodizing creates a thicker protective layer but poor wear resistance.
Soft anodizing offers better abrasion resistance.

Anodizing also allows dying the surface in colours like black for an attractive finish.

Powder Coating

Powder coated finishes are commonly applied through:

Surface preparation
Powder application through spraying
Baking to cure the powder

Advantages include:

Highly abrasion resistant
Can produce metallic colour finishes
Environmentally cleaner process

Pre-treatments

Chemical pre-treatments like chromate conversion help cleaning and metal preparation to improve coating adhesion.

Finish/Coating	Application Method	Use
Anodizing	Electrochemical	Corrosion protection
Powder Coating	Spray then bake	Colour finish
Pre-treatment	Chemical cleaning	Improve coating bond

Properly finished aluminium can maintain excellent performance and appearance for solar hardware when exposed to harsh outdoor environments.

VI. Design Considerations

Properly designing aluminium mounting hardware requires accounting for several factors:

Weight Ratios

The extruded profiles must provide adequate strength while minimizing weight.

Higher alloy grades enable thinner walls and less material.
But machinability and ductility decrease with stronger alloys.

Wind and Weather

The mounting components must resist:

High wind forces
Snow/ice loads
Temperature swings
Generally wet conditions

Corrosion resistant alloys and coatings are critical.

Vibration Dampening

Uncontrolled vibrations can slowly loosen connections and fasteners over time through metal fatigue.

Structural stiffness tuning using shapes like tubes or ribs help attenuate harmonic vibrations.
Bushings and grommets in mounting hardware also dampen vibrations.

Careful engineering ensures aluminium solar mounting hardware reliability over their ~25 year expected lifespan.

VII. Advantages Over to Other Materials

Aluminium has many benefits compared to other materials for solar mounting construction.

Strength and Durability

Aluminium alloys provide very good strength while resisting corrosion.
Steel is strong but much heavier and prone to rusting.
Polymers are lighter but weaker and degrade under UV exposure.

Aluminium’s durability ensures continued structural stability over decades in harsh outdoor environments.

Cost Efficiency

Extruding aluminium is relatively affordable:

It is a high volume, continuous production process.
Tooling and setup costs are low compared to other processes that require moulds or custom fabrication.
Recycling aluminium requires little reprocessing.

These factors mean finished aluminium components are very cost competitive.

Customization Ability

The extrusion process allows creation of specialized and complex cross-sectional profiles:

Custom dies can make unique asymmetric shapes.
Strength can be tuned using different alloys and tempers.
Post-production fabrication allows further part optimization.

This flexibility allows aluminium solutions to be customized around application requirements.

Learn how durable and lightweight aluminium channels, extruded rails, and mounting hardware enable customized solar PV mounting systems.

Seasonal Tilt Solar Mounting Systems

January 27, 2024

by Jaya with No Comment Generic

I. Introduction

Seasonal tilt solar mounting systems refer to adjustable structures that allow for changing the orientation of solar panels to optimize energy production as seasons change throughout the year.

Key features of these systems include:

Manual adjustable joints and mechanisms to easily alter the tilt angle of the solar panels. This allows for:
Increased power generation during peak sunlight seasons. Seasonally adjusted panels can capture 5-10% more energy than fixed tilt systems.
The ability to position panels to maximize sunlight exposure depending on location and time of year.
Durable materials including galvanized steel, aluminium alloys, and stainless steel to withstand weather conditions over 25+ year lifespans.
Corrosion resistant treatments like anodizing and galvanization to protect system integrity.
Simple structures with less accessories and components, enabling:
Low installation costs
Reduced maintenance and operations expenses

Type	Ground Mount
Colour	Natural or Customized
Treatment	Anodized, Galvanized
Structural Materials	Aluminum Alloy, Galvanized Steel, Stainless Steel

By changing orientation 2-3 times per year, seasonal tilt mounting maximizes solar collection during peak seasons. Manual adjustability makes modification straightforward based on location and time of year. Durable, corrosion-resistant materials also minimize maintenance costs over decades of service.

II. Durable and Corrosion Resistant Materials

Seasonal tilt solar mounting systems are designed for durability to withstand decades of outdoor exposure to various weather conditions. Key material considerations include:

Corrosion Resistance

Corrosion can compromise structural integrity over years of service. Therefore, systems utilize:

Galvanized steel: Galvanization applies a protective zinc coating to steel. This guards against rust for 25+ year lifespans.
Anodized aluminium: Anodization electrically treats aluminium alloy to reinforce corrosion resistance.
Stainless steel: Stainless steel alloys like 304 and 316 feature chromium to prevent surface oxidation from weather exposure or rust.

Simple Structure

Simpler designs result in:

Fewer components needed for installation.
Lower potential points of failure or wear compared to more complex structures.
This maintains system reliability over decades of operation.
Low Installation Costs
Minimized parts along with straightforward manual assembly directly reduce initial installation costs.
Easy Maintenance
Basic robust builds allow easy visual inspection.
Manual seasonal adjustments do not require expensive specialized equipment or expertise.

Combined with inherent durability, lifespan maintenance costs stay low.

By focusing on fundamentals of durable, maintenance-free structural design, seasonal tilt mounting systems deliver reliable service for 20-30 years. This allows for outstanding return on investment over the system lifetime.

Click Here to Learn More

III. Location and Hemisphere Factors

To optimize the energy generation, seasonal tilt solar mounting systems must adjust panel angles based on location and time of year. The key factors related to geography are:

Hemisphere

The hemisphere where the system is installed determines peak sunlight seasons:

Northern hemisphere – Peak production in summer
Southern hemisphere – Peak production in winter

This impacts ideal tilt strategies.

Country/Region

More specifically, the country and region indicate:

Latitude – Affects sun angle path
Climate patterns – Rainy or dry seasons affect solar availability

Sunlight Exposure

Tilt adjustments maximize sunlight exposure during peak seasons:

Winter – Tilt to maximize lower winter sun angles
Summer – Account for higher summer sun paths

Angles that capture the most sun during peak seasons will generate the greatest additional energy.

Ideal Tilt Angles

Formulas can dial in optimal orientation based on location:

Summer – (Latitude * 0.93) – 21°
Winter – (Latitude * 0.875) + 19.2°

Sensitivity Analysis around these starting points can further maximize yearly yield if seasonal cloud cover data is available.

Properly accounting for site geography informs data-driven tilt strategies that maximize solar utilization potential for seasonal mounting systems. This allows substantial gains in solar energy production on an annual basis.

Seasonal Tilt Adjustments

To maximize power generation, seasonal tilt solar mounting systems must alter their orientation multiple times per year to match the sun’s shifting path across seasons. There are two main approaches:

Half-Yearly Adjustments

Tilt angle can be changed twice a year based on spring/fall equinox dates:

Northern Hemisphere:
Summer tilt – March 20th
Winter tilt – September 22nd
Southern Hemisphere
Summer tilt – September 20th
Winter tilt – March 21st

This better aligns with seasons versus calendar dates.

Quarterly Adjustments

For more precision, adjust tilt 4 times per year aligned to solstices and equinoxes:

Season	Northern Hemisphere	Southern Hemisphere
Summer	June 20th	December 21st
Autumn	September 22nd	March 20th
Winter	December 21st	June 20th
Spring	March 20th	September 23rd

Benefits

Increased energy collection during “shoulder” seasons
Reduced machine downtime for adjustments
Gradual angle changes better track sun’s daily course

Considerations

Additional manual labour required
Possible downtime during adjustments

Data Analysis

Historical on-site solar data can reveal optimal dates and degree days for adjustments. Sensitivity analysis identifies energy gains from extra tilts.

Automated Systems

For large installations, automated actuators can systematically alter tilt. But this adds complexity and capital costs.

Fine-tuning mount orientation to follow the sun’s seasonal movement provides outsized electricity generation gains for minimal incremental effort using seasonal tilt solar mounting systems.

Galvanized and Hot Dip Galvanized Coatings

January 19, 2024

by Jaya with No Comment Generic

I. Introduction

Galvanized and hot dip galvanized coatings are commonly used for corrosion protection of solar mounting structures. The choice between galvanized solar mounting frames and hot dip galvanized solar rails depends on factors like cost, longevity, and ease of application.

The key differences between galvanized and hot dip galvanized coatings for solar mounting structures:

Type of zinc coating
Surface preparation requirements
Resulting surface texture and finish
Corrosion resistance performance

A summary of the differences is provided in the table below:

Criteria	Galvanized Coating	Hot Dip Galvanized Coating
Process	Electroplating, thermal spray	Hot dip immersion in molten zinc bath
Surface preparation	Degreasing, pickling	Degreasing, pickling, fluxing
Coating texture	Smooth, sharp finish	Rough finish
Corrosion protection	Moderate	Excellent

Galvanized coatings are applied by methods like:

Electroplating
Thermal spray of molten zinc
Mechanical plating

These provide a smooth, uniform finish on solar mounting components like frames, brackets, and fasteners.

Structura will provide a Hot dip galvanizing involves dipping prepared steel components in a bath of molten zinc to form zinc-iron alloy layers. This provides excellent corrosion resistance but results in a rough texture.

By understanding the key differences, solar project developers can select the optimal corrosion protection method for their specific solar mounting requirements.

Click Here For More Detail

II. Galvanized Coatings for Solar Mounting Structures

Galvanized coatings are commonly applied to solar mounting components like:

Solar module frames
Solar array brackets
Solar structure bolts

Galvanized coatings provide moderate corrosion protection with a smooth finish.

The main galvanizing processes are:

Electroplating – Uses electric current to deposit zinc onto solar components
Thermal spray – Sprays molten zinc onto solar panel parts
Mechanical plating – Deposits zinc through mechanical energy

Benefits:

Lower cost
Uniform smooth finish
Good for steel solar anchors and mounting posts

Limitations:

Less corrosion protection than hot dip galvanizing
Not suitable for high corrosion environments

Overall, galvanized coatings are cost-effective for solar structures not exposed to extreme weather conditions. The smooth finish also allows efficient installation of solar modules.

III. Hot Dip Galvanized Coatings for Solar Arrays

Hot dip galvanizing is commonly used to protect large solar array structures and components like:

Solar array rails
Solar panel clamps
Solar tracking braces

The hot dip galvanizing process involves:

Surface preparation – Degreasing, pickling, and fluxing
Dipping in molten zinc bath to form zinc-iron alloy layer
Inspection of coating quality

Benefits:

Excellent corrosion resistance
Withstands extreme weather environments
Long service life for solar mounting hardware

Limitations:

Rough surface finish
Higher cost than galvanizing

Hot dip galvanized coatings provide maximum corrosion protection for large solar arrays and mounts installed in coastal, industrial, and severe climate environments. The service life can exceed 25 years.

IV. Surface Preparation of Solar Mounting Components

Proper surface preparation is essential prior to applying galvanized or hot dip galvanized coatings on solar mounting hardware. The main preparation steps include:

Degreasing – Removes oil, grease and dirt from surfaces like:
Solar module frames
Solar tracking drive arms
Solar clamp bolts
Pickling – Uses acid solution to remove iron oxide and mill scale from:
Solar structure I-beams
Solar foundation anchor bolts
Fluxing (for hot dip galvanizing) – Applies protective flux coating to prevent oxidation of steels like:
Solar torque tube shafts
Solar array roller pins

Effective surface preparation allows maximum adhesion and corrosion protection from the galvanized or hot dip galvanized coatings.

It is crucial to remove all traces of oil, grease, rust, scale and other contaminants from the steel surface through thorough cleaning, pickling, and fluxing steps.

This ensures optimal zinc coverage and corrosion resistance for the solar mounting hardware over decades of service.

V. Corrosion Protection with Zinc Layers

The key purpose of galvanized and hot dip galvanized coatings is to provide corrosion protection for steel solar mounting components.

The zinc coating protects the underlying steel in two ways:

Barrier protection – The zinc coating forms a physical barrier preventing corrosion agents like oxygen, moisture and chloride ions from reaching the steel.
Cathodic protection – If the zinc coating gets scratched, the zinc sacrifices itself and corrodes first instead of the underlying steel. This is due to the electrochemical properties of zinc.

During hot dip galvanizing, iron on the steel surface reacts with the molten zinc bath to form protective zinc-iron alloy layers.

Prior pickling to remove iron oxide and mill scale allows better contact between the steel and molten zinc to form uniform alloy layers.

The resulting zinc coating provides excellent corrosion resistance for steel solar mounting hardware, even in harsh outdoor environments with high humidity, salt spray or industrial pollutants.

Proper surface preparation and quality hot dip galvanizing processes optimize the protective zinc layer thickness and life span.

VI. Finishing and Inspection of Solar Mounts

The final steps for galvanized and hot dip galvanized solar mounting components involve:

Finishing to achieve the desired surface texture
Inspection to ensure coating quality
Galvanized coatings have a smooth, sharp finish suitable for:
Solar array frames
Solar tracker gears
Solar PV module clamps

The smooth finish allows easy cleaning and maintenance.

Hot dip galvanizing produces a rough surface finish. The zinc-iron alloy layers form crystals that grow outward as spiky dendrites.

This rough texture provides optimal adhesion for paints and sealants when applied on:

Solar torque tubes
Solar support strut channels
Solar tracker rails

Thorough inspection verifies coating thickness, integrity and uniformity.

The visual contrast between galvanized and hot dip galvanized finishes provides a quick way to identify the corrosion protection method used on solar mounting components.

Proper finishing and inspection ensures long-lasting weather resistance and durability.

VII. Conclusion

Both galvanized and hot dip galvanized coatings offer effective corrosion protection for steel solar mounting structures.

Galvanized coatings provide good weather resistance at lower cost for solar components like:

Frames
Brackets
Fasteners

Hot dip galvanizing is the optimal choice for heavily loaded structural solar mounts and arrays in harsh environments, including:

Coastal areas
Industrial zones
Deserts

Proper surface preparation, zinc coating method, quality control and finish are crucial to achieve the desired longevity and return on investment.

By selecting the appropriate galvanizing method for the solar application and environment, developers can minimize maintenance costs while maximizing power output over decades.

Regular inspection of zinc coatings enables proactive maintenance to avoid any coating damage or corrosion issues.

Overall, both galvanized and hot dip galvanized treatments provide reliable, low-maintenance corrosion protection for a wide range of solar power projects.