Achieve High Reliability and Low-Cost Photovoltaic Solar Support Solutions (1)

For large-scale photovoltaic installations, cold-rolled profiles have become a popular and efficient solution. Whether the design of the solar support is simple or complex, it can be precisely formed and welded to meet exact specifications. This method ensures high-quality structures that are both durable and cost-effective. There are numerous material options available for photovoltaic supports, and close collaboration between cold rolling mills and engineered fastener manufacturers helps cut costs in solar projects. For instance, using pre-installed fasteners shifts some of the installation work from the field to the production line, which reduces panel looseness after installation. This not only improves performance but also saves valuable labor time on-site, offering significant benefits for large-scale PV projects. These pre-assembled components are designed for high performance and ease of installation, making them ideal for modern solar systems. Production Process When cold-rolled materials are used in solar trackers or cradle systems, there are many material choices. The most common options include high-strength low-alloy steels (HSLA) and aluminum alloys. Some alloys must be formed into thin sections while maintaining structural strength. Both hat-shaped and tunnel-shaped profiles are widely used, and open or closed structures can be produced through cold rolling. Pre-punched holes of any shape can be added at any position along the assembly line, improving efficiency. In photovoltaic power plants, bracket lengths are often limited by transportation constraints, with some brackets reaching up to 47 feet. Additional steps such as surface finishing, welding, and fastener installation add value to the final product. Cost Considerations Photovoltaic support manufacturers face intense price pressure and increasingly strict quality standards. Customers expect not only lower component costs but also reduced on-site installation labor. This is especially important in large-scale PV projects, where manufacturers may need to invest in single-axis mounting systems in addition to fixed-tilt solutions to improve efficiency. Some bracket designs are even optimized for use in panel assembly systems, further enhancing productivity. Whether installing a single-axis or fixed-angle system, certain mounting fasteners are essential. Some assembly tasks are still performed on-site by construction crews. To simplify the process, components are often pre-punched with nuts and bolts, making installation easier. The number of fasteners required varies greatly depending on project size. Large-scale power plant projects may require tens of thousands of fasteners per megawatt—sometimes as many as 70,000 bolts per MW. With projects involving millions of units, the choice of fasteners directly impacts on-site labor needs. To minimize the risk of losing loose fasteners during installation, many manufacturers now install them directly during the bracket production process. Field inspections have shown that factory-installed fasteners significantly reduce costs compared to on-site assembly. In addition to lowering labor expenses, this approach also improves quality control. Some projects pay premium wages to hire skilled workers, and temporary labor is often brought in to meet deadlines. However, training short-term workers can be challenging. For large projects requiring millions of fasteners, using pre-installed, secure fasteners is a smart and practical decision.

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