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In-Depth Guide to Designing Solar Mounting Structures

Solar panel mounting structures form the backbone of any solar power plant. While solar modules are responsible for generating electricity, it is the mounting structure that ensures long-term safety, efficiency, and reliability.

Therefore, the design and engineering of solar mounting structures go far beyond simply supporting panels. Instead, they involve detailed structural calculations, material selection, and strict adherence to engineering standards to ensure that the plant performs optimally throughout its 25+ year lifecycle.

In this guide, we take a closer look at the technical aspects of designing ground-mounted solar structures and explain why they play a critical role in the success of solar power plants.

1. Structural Analysis and Design Considerations

To begin with, structural analysis forms the foundation of any reliable solar mounting system. Without proper analysis, even high-quality materials can fail under real-world conditions.

1.1 Wind Load and Static Load Analysis

Among all environmental forces, wind load remains one of the most critical design parameters, particularly for open terrains, elevated structures, and high-wind zones.

As wind speeds increase, uplift forces and lateral pressures can cause deformation, fatigue, or even complete structural failure if not properly addressed.

For this reason, wind load calculations must strictly comply with recognized standards:

• IS 875 (Part 3) – Wind load calculations in India
  👉 https://bis.gov.in/standards/is-875-part-3/

• IEC 61215 – Mechanical load testing for PV modules
  👉 https://www.iec.ch/dyn/www/f?p=103:85:0::::FSP_LANG_ID:25

Typically, designers consider the following assumptions:

• Design wind speed: Up to 180 kmph, depending on site conditions

• Panel inclination: 10°–30°

• Terrain category and topography

Subsequently, advanced structural software such as STAAD.Pro is used to perform finite element analysis (FEA). This ensures that stresses, deflections, and stability remain within permissible limits under worst-case loading scenarios.

1.2 Dead Load Calculations

In addition to wind loads, dead loads must be carefully evaluated, as they represent the permanent forces acting on the structure.

Dead loads generally include:

• Solar modules

• Mounting rails and frames

• Purlins, bracings, and fasteners

• Cable trays and electrical accessories

Formula:

For example, a 500 W solar module weighing approximately 25 kg contributes nearly 12.5 kg/m² to the overall structure, depending on layout and spacing.

Hence, accurate dead load calculation is essential to avoid undersized members, excessive deflection, or foundation distress.

1.3 Live Load Considerations

Furthermore, live loads must be accounted for during the design stage. These loads arise primarily during installation, inspection, and maintenance activities.

To address this, designers follow:

• IS 875 (Part 2) – Live load guidelines
  👉 https://bis.gov.in/standards/is-875-part-2/

As a result, the structure remains safe and stable even when technicians are working on or around the solar array.

2. Material Selection for Solar Mounting Structures

Once structural loads are defined, the next critical step is material selection, which directly affects durability, corrosion resistance, and lifecycle cost.

2.1 Structural Members

In most utility-scale and commercial projects, Hot-Dip Galvanized (HDG) steel is the preferred choice due to its strength and long-term performance.

Alternatively, aluminum structures are used in coastal or highly corrosive environments where reduced weight and enhanced corrosion resistance are required.

Relevant coating standards include:

• ASTM A123 – Zinc coating for HDG steel
  👉 https://www.astm.org/a0123_a0123m-17.html

• IS 4759 – Zinc coating specification
  👉 https://bis.gov.in/standards/is-4759/

Typically, a zinc coating thickness of 120–150 microns is recommended to ensure extended service life.

2.2 Fasteners and Anchors

Equally important are fasteners and anchoring systems, as they transfer loads between structural members and foundations.

Best practices include:

• Using stainless steel or galvanized fasteners

• Avoiding mixed metals to prevent galvanic corrosion

• Employing chemical anchors for high-load applications

2.3 Surface Coatings

Moreover, surface coatings play a vital role in corrosion protection:

• Hot-Dip Galvanizing (HDG) provides long-term rust protection

• Galvalume offers superior performance in humid or saline environments
  👉 https://galvalume.com/

Consequently, the right coating system significantly reduces maintenance costs and extends structural life.

3. Types of Solar Panel Mounting Structures

Depending on site conditions and energy goals, different structure types are used.

3.1 Fixed-Tilt Structures

To start with, fixed-tilt structures are:

• Cost-effective

• Simple to install

• Low maintenance

They are particularly suitable for regions with stable solar irradiance, where tilt angles are optimized based on latitude.

3.2 Seasonal Tilt Structures

In contrast, seasonal tilt structures allow angle adjustment for summer and winter.

Although the initial cost is slightly higher, annual energy yield improves, making them attractive for certain applications.

3.3 Solar Tracking Systems

Meanwhile, tracking systems dynamically follow the sun’s path:

• Single-Axis Trackers: Increase yield by 15–25%

• Dual-Axis Trackers: Improve yield by up to 40%

However, due to continuous movement, these systems require robust structural design to handle dynamic loads.

For further reference, guidelines from the National Institute of Solar Energy (NISE) are often consulted.
👉 https://nise.res.in/

4. Foundations and Anchoring Systems

After structural configuration is finalized, foundation design becomes the next priority.

4.1 Common Foundation Types

Depending on soil conditions and site constraints, designers may choose:

• Concrete footings for durability and stability

• Ramming or pile foundations for faster installation

• Ballasted foundations where excavation is restricted

Thus, foundation selection is always site-specific.

4.2 Chemical Anchoring and Grouting

Additionally, chemical anchoring enhances load transfer between bolts and concrete.

• ASTM C881 – Epoxy-based bonding agents
  👉 https://www.astm.org/c0881_c0881m-20.html

As a result, chemical anchors are especially effective in high-wind and seismic zones.

5. Key Technical Parameters in Solar Structure Design

6. Effects of Poorly Designed Solar Structures

If structures are poorly designed, several issues may arise.

6.1 Reduced Efficiency

Incorrect tilt or misalignment leads to lower energy generation.

6.2 Increased Maintenance Costs

Inferior materials accelerate corrosion and failure.

6.3 Safety Risks

Structural instability poses risks to equipment, personnel, and property.

7. Benefits of Well-Designed Solar Mounting Structures

Conversely, well-engineered structures offer:

• Higher efficiency through optimized orientation

• Long service life exceeding 25 years

• Lower O&M costs

• Improved safety, even under extreme conditions

Conclusion

In conclusion, designing solar mounting structures is a highly technical and engineering-driven process that directly influences the safety, efficiency, and longevity of solar power plants.

At ARS Solartech, we focus on site-specific engineering, high-quality materials, and strict compliance with national and international standards. As a result, our solar structures deliver reliable performance, long service life, and maximum return on investment.

Choose ARS Solartech for solar panel mounting structures that truly power your future.