Achieve High Reliability and Low-Cost Photovoltaic Solar Support Solutions

For large-scale photovoltaic installations, cold-rolled profiles are a widely used and efficient solution. Whether the design of the photovoltaic support is simple or complex, it can be precisely formed and welded to meet exact specifications. This process ensures structural integrity while maintaining cost-effectiveness. When it comes to materials for photovoltaic supports, there are multiple options available. Close collaboration between cold rolling mills and engineered fastener manufacturers plays a key role in reducing overall project costs. For example, using pre-installed fasteners shifts some of the installation work from the field to the production line. This not only minimizes panel looseness after installation but also reduces labor time and improves efficiency on-site. These pre-assembled fasteners are designed for high performance and ease of use, making them ideal for solar projects. Production Process Cold-rolled forming materials are commonly used in solar trackers and cradle systems. The choice of material depends on the application, with high-strength low-alloy (HSLA) steels and aluminum alloys being the most popular. Some designs require thin sections that still meet strict strength requirements. Both open and closed structures, such as hat-shaped or tunnel-shaped profiles, can be produced through cold rolling. Pre-punched holes of any shape can be added at any stage during the assembly line process. In photovoltaic power plants, bracket lengths are often limited by transportation constraints, with some brackets reaching up to 47 feet. After forming, additional steps like surface finishing, welding, and fastener installation add value to the final product. Cost Considerations Photovoltaic support manufacturers face intense price pressures and increasingly rigorous regulatory standards. Customers expect not only lower component costs but also reduced labor expenses during on-site installation. This is especially important in large-scale PV projects, where manufacturers may need to invest in single-axis mounting systems alongside fixed-tilt solutions to improve installation efficiency. In some cases, bracket designs can even integrate directly into panel assembly systems, enhancing overall productivity. Whether installing single-axis or fixed-tilt brackets, certain mounting fasteners are essential. Some assembly tasks must still be performed on-site, and components are often pre-punched with separate nuts and bolts for easier installation. The number of fasteners required varies greatly depending on the project size. For large-scale power plant projects, the demand for fasteners can be extremely high—up to 70,000 bolts per megawatt in some cases. With projects requiring millions of fasteners, the need for on-site labor becomes significant. To minimize the risk of losing loose fasteners at the construction site, many manufacturers now install fasteners directly during the bracket production process. Field studies have shown that factory-installed fasteners significantly reduce costs compared to on-site installation. In addition to cutting down on labor, this approach also improves quality control. Some projects rely on high wages to hire skilled workers, and temporary staff are often brought in to meet deadlines. However, training these workers quickly can be challenging. For large projects requiring millions of fasteners, using pre-installed, durable fasteners is a smart and practical choice.

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