Zhejiang Haina Solar Tech Solar System
Home » News » Photovoltaic Knowledge » The Key To Enhancing Solar Mounting System Efficiency

The Key To Enhancing Solar Mounting System Efficiency

Views: 0     Author: Site Editor     Publish Time: 2025-10-10      Origin: Site

facebook sharing button
twitter sharing button
line sharing button
wechat sharing button
linkedin sharing button
pinterest sharing button
whatsapp sharing button
sharethis sharing button
The Key To Enhancing Solar Mounting System Efficiency

PV Bracket Selection, Application, and Maintenance Guide: The Key to Enhancing PV System Efficiency

In a photovoltaic (PV) power plant system, PV brackets do not directly generate electricity, but they serve as the "invisible backbone" that determines the stability, power generation efficiency, and service life of PV modules. They must not only bear the weight of PV modules but also withstand the impacts of complex outdoor environments such as wind, snow, strong winds, and temperature differences. Meanwhile, they maximize solar energy absorption by optimizing the installation angle. This article provides a comprehensive analysis of practical knowledge about PV brackets, covering their core types, suitable scenarios, selection techniques, and maintenance tips, helping you choose and use PV brackets correctly to ensure long-term stable and efficient operation of your PV system.

I. Core Types of PV Brackets: How to Choose Materials and Structures? Avoid Mistakes After Understanding These 3 Types

Performance differences among PV brackets mainly stem from their materials and structural designs. Different types are suitable for different scenarios; choosing the wrong type may lead to module displacement, reduced power generation efficiency, or even safety hazards. Currently, there are three mainstream types of PV brackets on the market, each with clear application boundaries:

1. Classification by Material: Aluminum Alloy, Carbon Steel, Stainless Steel – Balancing Cost and Weather Resistance

(1) Aluminum Alloy PV Brackets (First Choice for Rooftop Distributed Systems)

  • Core Features: Made of 6063-T5 aluminum alloy, lightweight (approximately 2.7g/cm³), corrosion-resistant (surface anodized, salt spray resistance ≥1000 hours), and easy to process (customizable special-shaped structures);

  • Core Advantages: No complex anti-corrosion treatment required, easy to install (only 2-3 people needed to install a single set of brackets), low load requirement on the roof (load ≤15kg per square meter), suitable for distributed scenarios such as flat roofs and sloped roofs;

  • Notes: Mechanical strength is slightly lower than that of carbon steel (tensile strength ≥260MPa); not recommended for high-load scenarios in large ground-mounted power plants or areas with strong winds (wind speed ≥30m/s).

(2) Carbon Steel PV Brackets (Mainstay for Large Ground-Mounted Power Plants)

  • Core Features: Made of Q235B carbon steel, hot-dip galvanized surface (zinc layer thickness ≥85μm), high mechanical strength (tensile strength ≥375MPa), and strong load-bearing capacity (a single bracket can bear ≥200kg);

  • Core Advantages: Cost is only 60%-70% of aluminum alloy brackets, suitable for large-span, high-load scenarios such as large ground-mounted PV power plants and agri-PV complementary power plants, and can withstand pressure from snow thickness ≤50cm;

  • Notes: Regular inspection of the galvanized layer is required (once every 2-3 years) to prevent rust in humid environments (additional anti-corrosion coating is recommended for coastal areas).

(3) Stainless Steel PV Brackets (Exclusive for Special Corrosion-Resistant Scenarios)

  • Core Features: Made of 304 or 316 stainless steel, salt spray and acid-alkali resistant (316 material has salt spray resistance ≥2000 hours), no risk of coating peeling;

  • Core Advantages: Suitable for highly corrosive environments such as coastal tidal flats and areas around chemical plants, with a service life of over 30 years (5-8 years longer than aluminum alloy brackets);

  • Application Scenarios: Fish-PV complementary power plants and coastal distributed power plants. The disadvantage is high cost (approximately 2.5 times that of carbon steel brackets), so it is not recommended for non-special environments.

2. Classification by Structure: Fixed vs. Tracking – Trade-Off Between Efficiency and Cost

(1) Fixed PV Brackets (Cost-Effective Choice)

  • Structural Features: Fixed installation angle (adjusted according to latitude; for example, areas at 30°N latitude are usually set to 30°-35°), divided into sloped roof fixed type, flat roof ballasted type, and ground pile type;

  • Core Advantages: Simple structure (no mechanical transmission components), low failure rate (annual failure rate ≤0.5%), low cost (40%-60% less than tracking type), and easy maintenance;

  • Application Scenarios: Most distributed power plants and small-to-medium ground-mounted power plants, especially suitable for low-latitude areas (south of 25°N latitude) where the change in sunlight angle is small.

(2) Tracking PV Brackets (Preferred for High-Efficiency Power Generation)

  • Structural Features: Driven by a motor or hydraulic system, it automatically adjusts with the sun's azimuth angle (divided into single-axis tracking and dual-axis tracking). Single-axis tracking can increase power generation by 15%-20%, and dual-axis tracking by 20%-25%;

  • Core Advantages: Maximizes solar energy absorption, suitable for high-latitude areas (north of 40°N latitude) and scenarios with abundant sunlight but large changes in sunlight angle;

  • Notes: High cost, dependent on power supply (daily power consumption is approximately 0.5 kWh per set), regular maintenance of mechanical components is required (inspection of the transmission system every quarter), and it needs to automatically reset to the wind-resistant angle in strong winds (when wind speed ≥18m/s).

II. 4 Core Application Scenarios of PV Brackets: Suitable Solutions for Different Scenarios

The selection of PV brackets must be closely combined with the installation environment (roof/ground, climate, terrain). Blindly applying a "universal solution" may lead to efficiency loss or safety risks. Below are suitable strategies for 4 typical scenarios:

1. Rooftop Distributed Power Plants: Lightweight and Low Load Are Key

  • Flat Roofs: Choose aluminum alloy ballasted brackets (no drilling required, fixed by counterweights to avoid damaging the roof waterproof layer). The bracket height should be controlled at 0.3-0.5m (for easy roof maintenance), and the angle should be designed according to the local optimal tilt angle (e.g., 32° for Shanghai);

  • Sloped Roofs (Asphalt Shingles/Color Steel Tiles): Choose aluminum alloy hook-type brackets (hooks are fixed on the roof purlins without penetrating the roof surface). The fitting degree between the brackets and the roof should be ≥90% to avoid increased wind resistance due to excessive gaps between modules and the roof.

2. Large Ground-Mounted Power Plants: High Load-Bearing Capacity and Low Cost Are Priorities

  • Plain Areas: Choose carbon steel pile-type brackets (pile depth 1.2-1.5m, wind resistance ≤25m/s). The bracket spacing is 3-4m (suitable for 440W-550W modules), and it can be equipped with fixed or single-axis tracking systems (tracking type is preferred for high-latitude areas);

  • Mountainous and Hilly Areas: Choose carbon steel adjustable brackets (tilt angle can be adjusted by ±5° according to terrain), and adopt independent piles (to avoid bracket deformation caused by terrain undulations). Modules are arranged along contour lines (to reduce shadow shielding).

3. Agri-PV Complementary Power Plants: Balancing Power Generation and Agricultural Production

  • Core Requirements: The bracket height must meet the growth needs of crops (economic crops are 1.5-2m tall, so the bracket height should be ≥2.2m), and the load-bearing capacity must accommodate both modules and the passage of agricultural machinery (a single bracket can bear ≥300kg);

  • Suitable Solution: Choose carbon steel portal brackets (span 5-8m, convenient for agricultural machinery to pass through). The surface should be treated with enhanced anti-corrosion (hot-dip galvanizing + spray coating double treatment) to avoid corrosion from pesticides and chemical fertilizers.

4. Fish-PV Complementary Power Plants: Corrosion Resistance and Flooding Resistance Are Key

  • Environmental Characteristics: High salt spray, long-term humidity (water surface humidity ≥85%), and the bottom of brackets may be temporarily submerged (water level rises by 0.5-1m during flood seasons);

  • Suitable Solution: Choose 316 stainless steel pile-type brackets (piles go 1.5-2m underwater and are wrapped in concrete for anti-corrosion). The bracket height should be ≥1.8m (to avoid the impact of water surface reflection on module efficiency), and the surface salt frost should be regularly washed with fresh water.

III. 3 Key Techniques for PV Bracket Selection: Avoid "Efficiency Loss" and "Safety Hazards"

Selection is crucial to the cost-effectiveness of PV brackets. Blindly pursuing "over-design" leads to cost waste, while "under-specification selection" causes risks. Master the following 3 points for accurate decision-making:

1. Determine Material and Structure Based on "Climatic Conditions"

  • Areas with Strong Winds (e.g., Coastal Areas, Grasslands): Choose carbon steel brackets (wind load resistance ≥0.75kN/m²). Fixed brackets need additional diagonal braces (spacing ≤2m), and tracking brackets need wind-resistant functions;

  • High Humidity/High Salt Areas (e.g., Coastal Areas, Tidal Flats): For aluminum alloy brackets, choose enhanced anti-corrosion models (anodized layer thickness ≥15μm); carbon steel brackets need double anti-corrosion treatment, or stainless steel brackets can be used directly;

  • Snowy Areas (e.g., Northeast China, Xinjiang): The load-bearing capacity of brackets should be designed according to the local maximum snow depth (e.g., for Harbin, calculated based on snow depth of 0.6m, load ≥0.5kN/m²) to prevent brackets from being crushed by snow.

2. Determine Structure Type (Fixed vs. Tracking) Based on "Power Generation Needs"

  • Limited Budget, Pursuing Stability: Choose fixed brackets (suitable for most scenarios, with a shorter investment payback period of 1-2 years);

  • High-Latitude Areas, Large Changes in Sunlight Angle: Choose single-axis tracking brackets (e.g., Northeast China, which can increase power generation by approximately 18%, with an investment payback period 0.5-1 year longer than fixed brackets);

  • Scarce Sunlight Resources, Pursuing Extreme Efficiency: Choose dual-axis tracking brackets (e.g., cloudy areas such as Sichuan and Guizhou, which can increase power generation by over 22%, but with high cost, suitable for large power plants).

3. Determine Fixing Method Based on "Installation Conditions"

  • Rooftop Power Plants (No Drilling Allowed): Choose aluminum alloy ballasted brackets (counterweight weight ≥1.2 times the weight of modules + brackets to prevent wind uplift);

  • Rooftop Power Plants (Drilling Allowed): Choose aluminum alloy hook-type brackets (hooks are embedded in roof purlins to a depth of ≥50mm to ensure firm fixation);

  • Ground-Mounted Power Plants (Solid Soil): Choose carbon steel pile-type brackets (pile diameter ≥150mm, depth ≥1.2m);

  • Ground-Mounted Power Plants (Soft Soil Foundation): Choose carbon steel concrete foundation brackets (foundation size ≥600mm×600mm×800mm to enhance stability).

IV. 3 Key Maintenance Points for PV Brackets: Extend Service Life and Ensure Efficiency

PV brackets are exposed to the outdoors for a long time, and wind, sun, and rain easily cause component aging and corrosion. Regular maintenance can extend their service life (from 25 years to 30 years) and avoid module damage caused by bracket issues. Below are key maintenance measures:

1. Regular Inspection: Once Every Quarter, Focus on 3 Types of Components

  • Structural Components: Check the connecting bolts of bracket beams and diagonal braces (for looseness; torque should be maintained at ≥30N·m), and the transmission gears of tracking brackets (for wear; apply lubricating grease once every six months);

  • Anti-Corrosion Layer: For carbon steel brackets, check the galvanized layer (for peeling and rust; repair rust spots with anti-corrosion paint in a timely manner); for aluminum alloy brackets, check the anodized layer (for scratches to prevent rainwater infiltration);

  • Foundation Parts: For ground brackets, check if piles are tilted (tilt angle ≤1°); for rooftop brackets, check if counterweights are displaced (to avoid insufficient ballast leading to wind uplift).

2. Seasonal Maintenance: Respond to Extreme Weather

  • Before Rainy Season: Clean up accumulated water at the bottom of brackets (to avoid foundation corrosion caused by long-term immersion), and check the fitting between rooftop brackets and the waterproof layer (for water leakage; repair with waterproof glue in a timely manner);

  • Before Snowy Season: Reinforce bracket diagonal braces (to increase snow load-bearing capacity), and debug the wind-resistant mode of tracking brackets (to ensure automatic reset when wind speed ≥18m/s);

  • Before Typhoons/Dust Storms: Check all connecting bolts (retighten to the standard torque), and remove debris around brackets (to avoid debris hitting modules).

3. Fault Handling: Repair in a Timely Manner to Avoid Chain Reactions

  • Loose Bolts: Tighten them to the standard torque with a torque wrench (torque for aluminum alloy bracket bolts: 25-30N·m; for carbon steel bracket bolts: 30-35N·m). Replace bolts if they are severely loose (choose stainless steel bolts of the same specification);

  • Damaged Anti-Corrosion Layer: For carbon steel brackets, sand the rust spots until the metal surface is exposed, then apply epoxy zinc-rich primer + topcoat (thickness ≥80μm);

  • Tracking System Faults: Switch to manual mode immediately (to avoid modules staying at an unfavorable angle), and contact the manufacturer to repair the transmission system (do not disassemble the motor by yourself).

V. Frequently Asked Questions (FAQ): 5 Common Queries About PV Brackets

  1. Q: What is the service life of PV brackets? Is it compatible with the service life of modules?

A: The service life of aluminum alloy/stainless steel brackets is 25-30 years, and that of carbon steel brackets (with proper anti-corrosion treatment) is 20-25 years, all of which are compatible with the 25-year design life of PV modules. With proper maintenance, the service life of stainless steel brackets can be extended to over 30 years.
  1. Q: Will installing PV brackets on the roof damage the waterproof layer?

A: No. For flat roofs, choose ballasted brackets (no drilling required); for sloped roofs, choose hook-type brackets (hooks are fixed on purlins without penetrating the roof waterproof layer). After installation, waterproof glue can be applied at the contact between brackets and the roof to further prevent water leakage.
  1. Q: How much more expensive are tracking PV brackets than fixed ones? How long does it take to recover the cost?

A: Single-axis tracking brackets are 40%-50% more expensive than fixed ones, and dual-axis ones are 60%-80% more expensive. Taking North China as an example, single-axis tracking power plants generate 18% more electricity than fixed ones, and the additional cost can be recovered in approximately 5-6 years; dual-axis ones generate 22% more electricity, with a cost recovery period of approximately 6-7 years.
  1. Q: Are aluminum alloy PV brackets suitable for coastal areas?

A: Yes, but enhanced anti-corrosion models should be selected (anodized layer thickness ≥15μm, or additional fluorocarbon coating). Washing the surface salt frost of brackets with fresh water once every 2 years can effectively resist salt spray corrosion.
  1. Q: How to determine the installation angle of PV brackets? Can it be adjusted?

A: The angle of fixed brackets is determined according to the local optimal tilt angle (which can be queried via a "PV tilt angle calculator"; e.g., the optimal tilt angle for Beijing is 35°) and cannot be adjusted after installation. Tracking brackets automatically follow the sun's angle without manual adjustment, with approximately 20-30 adjustments per day.

Conclusion

PV brackets are the "framework" of a PV system. Choosing the right type and conducting proper maintenance ensures that modules absorb solar energy stably for a long time and maximize power generation benefits. Whether for rooftop distributed systems or large ground-mounted power plants, accurate selection based on "climatic conditions, power generation needs, and installation environment" is essential to avoid blindly pursuing "low cost" or "high configuration". If you encounter special scenarios (such as complex mountainous areas or highly corrosive environments) during selection, you can consult professional bracket manufacturers to obtain customized solutions, making your PV investment more worry-free and efficient.


SEND US A MESSAGE
Haina Solar is a high-tech enterprise specializing in the design, production, sales, and related consulting services of solar photovoltaic fasteners. Its main products include rooftop solar mounting systems, ground solar mounting systems, solar mounting accessories...

QUICK LINKS

PRODUCT CATEGORY

CONTACT US

 1-405 Canaan Plaza No.1888 Zuili Road, Nanhu District Jiaxing City Zhejiang , 314050
 Tony Fang
 +86-573-82272371
 +86-573-82210271
 +86-18668368299
 1751167386
 tony@hainasolar.com
Copyright © 2025 Jiaxing Haina Solar Tech Co., Ltd. | Privacy Policy | Sitemap 浙ICP备2023026353号-1