As nations accelerate their transition to renewable energy, the sheer volume of photovoltaic (PV) installations is staggering. Fundamental to achieving this massive deployment and ensuring the long-term efficiency and safety of any solar array is the photovoltaic mounting system.
These mounting systems, also known as solar module racking, fix solar panels securely onto various surfaces, including roofs, building facades, and the ground.
Since the relative cost of solar PV modules has dropped significantly, the cost and proper installation of the mounting structure have become increasingly critical to the overall economic viability of a solar system.
Explore Unitrade’s innovative BIPV solar panel mounting systems, combining strength, aesthetics, and seamless solar integration.
Why is a Mounting Structure Necessary in Solar Systems
A mounting structure is vital because, although solar panels possess outer layers of toughened glass, they are highly susceptible to damage if not secured properly. A robust structure ensures system efficiency and longevity, which should match the expected 25- to 30-year lifespan of the solar system.
Therefore, the materials used must be strong and resistant to corrosion. Commonly utilised materials include aluminium, which is strong, lightweight, and corrosion-resistant, making it compatible with most solar panel frames. Other options include galvanised steel or, for applications requiring decades of longevity despite high cost, stainless steel.
Components of Solar Mounting Systems
The mounting system consists of several essential components working together to maintain stability.
- Rails are the foundational elements that hold the solar panels on the structure; they must be sturdy and corrosion-resistant, with their size dependent on the number and dimensions of the panels.
- Mounts are used by installers to fasten the rails to the underlying structure, often bolted directly over a flashing.
- Clamps are used to securely hold the solar panels onto the rails, categorised as end-clamps at the edges of the module array and mid-clamps between individual panels.
- Flashings are non-negotiable components installed to prevent water and moisture from penetrating the roof, where installation requires drilling holes, thereby sealing gaps and protecting the roof’s integrity.
Major Types of Solar Mounting Structures
Mounting systems vary extensively based on the installation location and purpose, but they are broadly categorised by whether they are roof-mounted or ground-mounted.
Rooftop Mounting Structures
Rooftop mounting, often referred to as reinforced cement concrete (RCC) mounting, is the most common structure for residential and commercial installations. This method offers several key advantages, including a low installation cost and the generation of free electricity from previously unused rooftop space. Furthermore, the limited distance between the solar panel and the solar inverter reduces the chance of direct current (DC) losses.
Pitched Roof Systems
A pitched roof system is a sloped roofing design commonly used in residential and traditional-style buildings. Its angled structure helps water, snow, and debris slide off easily, reducing the risk of ponding and leaks. These roofs are typically supported by rafters or engineered trusses, and the pitch can vary based on climate and architectural style.
Pitched roof systems can be finished with various materials such as asphalt shingles, clay tiles, slate, or metal panels. Their design allows for attic ventilation and insulation, improving energy efficiency. In colder regions, the slope also helps prevent ice dam formation, making them both practical and durable in diverse weather conditions.
Metal Roof Systems
A metal roof system is a long-lasting roofing solution made from durable materials such as galvanised steel, aluminium, zinc, or copper. Known for its strength and resistance to extreme weather, metal roofing is used in both residential and commercial properties. Its design sheds rain and snow efficiently while withstanding wind, fire, and impact damage.
Metal roof systems come in different profiles, including standing seam panels, corrugated sheets, and metal tiles. They can be coated for rust protection and are often recyclable, making them a sustainable choice. Metal roofs also offer excellent lifespan—typically lasting 40 to 70 years—and require minimal maintenance over time.
Flat Roof Systems (Ballasted)
A ballasted flat roof system is a type of flat roofing where the membrane is loosely laid over the deck and held in place with heavy materials like gravel, concrete pavers, or stone. This system is common in commercial and industrial buildings due to its ease of installation and cost-effectiveness. Unlike fully adhered or mechanically fastened systems, it relies on weight for stability.
Ballasted roof systems offer several benefits, including wind uplift resistance, UV protection, and natural insulation. The ballast layer also protects the membrane from thermal expansion and mechanical damage. However, they require strong structural support due to the added weight and are best suited for buildings with minimal slope.
Ground Mounting Structures
A ground mounting structure is a support system used to install solar panels directly on the ground instead of on rooftops. These systems are anchored into the soil using concrete foundations, driven piles, or screw anchors, depending on the site’s conditions. Ground mounts are ideal for large-scale solar farms, open land installations, or locations where roof space is limited or unsuitable.
Ground mounting structures can be fixed-tilt or tracking, allowing panels to either stay at a set angle or follow the sun throughout the day for maximum energy output. They offer easier access for maintenance, better airflow around the panels, and enhanced system efficiency due to optimised tilt and orientation. These structures are crucial in utility-scale and agricultural solar projects where land use can be optimised for power generation.
Specialised and Alternative Mounting Solutions
Beyond the standard rooftop and ground options, various specialised mounting systems cater to unique environments or requirements.
Tracking Systems
A solar tracking system maximises energy generation by monitoring the sun’s trajectory and automatically orienting the solar panels to maintain a 90-degree angle to the sun for the longest period each day. This technology significantly increases productivity.
Tracking systems are classified as single-axis (tracking movement in one direction, such as East-West) or dual-axis (tracking movement in both horizontal and vertical directions). Despite their superior performance, tracking systems incur much higher installation costs and demand complex maintenance by expert engineers.
Carport Mounting Structures
Carport mounting structures are installed atop parking lots, sports stadiums, or malls. They serve a dual purpose: generating electricity and utilising the space beneath the panels as a shade that protects vehicles from adverse weather while creating a cooling effect in the parking lot. These structures can also be equipped with solar electric vehicle (EV) charging facilities.
Although the upfront installation cost is higher than for traditional rooftop systems, carports efficiently maximise land use. Similarly, solar canopies are elevated racks designed to share space with other land uses, providing shade and utilising substantial potential area, such as vast retail parking lots.
Floating Mounting Structures
Floating mounting structures are specifically engineered for water bodies, such as lakes, reservoirs, and ponds with still waters. Constructed from high-density polyethene (HDPE), these structures are anchored to dead weights.
They are highly suitable where free land area is scarce and large water bodies are abundant. A notable benefit is the conservation of water by reducing the evaporation rate, while the cooling effect of the water can enhance the system’s efficiency. However, floating systems are typically only commercially viable for large-scale solar projects.
Building Integrated Photovoltaics (BIPV)
Building Integrated Photovoltaics (BIPV) involves incorporating PV materials seamlessly into the building structure, often replacing conventional building materials like roofing tiles or facades. This creates a visually appealing and energy-efficient solution, where the higher initial cost is offset by reducing the need for separate building materials and labour.
Niche Mounting Applications
In addition to traditional placement, PV panels can be used in unique configurations. Panels can be mounted as external shading devices on buildings. Bifacial PV modules, installed vertically, can function as low-cost racking when used as fencing systems. Similarly, mounting PV panels on or as sound barriers (photovoltaic noise barriers, or PVNBs) along highways offers excellent land utilisation for grid-connected PV installations and is one of the cheapest ways to deploy large-scale systems.
Solar Mount Installation Factors and Safety
Effective planning and structural considerations are essential for maximising energy generation and ensuring safety.
Orientation and Efficiency
To maximise the annual energy yield, fixed PV modules are commonly tilted at an angle that matches the latitude of the installation location. In certain regions, particularly the tropics, the highest annual yield occurs when the panel surface is inclined close to the horizontal direction.
Installers must also consider the angle of solar incidence, as electricity generation is highest when sunlight strikes the panels perpendicularly and lowest when it falls obliquely.
Furthermore, recent studies indicate that, in some areas, non-optimal orientations, such as east–west facing arrays, can be valuable because they generate power during economically crucial morning and evening peak demand periods.
Area and Shadows
The size of the mounting structure depends directly on the number of panels required to meet the desired electricity generation capacity. For example, a 1 kW solar system may require approximately 59.2 square feet of area. Crucially, the chosen location must be free from shadows cast by trees, buildings, or other obstructions, as shadows can drastically reduce output.
Safety and Installation Protocols
Installing solar PV systems constitutes high-risk construction work due to the involvement of working at heights and near live electrical installations. Therefore, safety planning is paramount. Before installation, a site inspection must be completed to identify and cost the required safety control measures, such as temporary edge protection, scaffolding, exclusion zones, or mechanical lifting aids like panel lifters. A site-specific safe work method statement (SWMS) is a legal requirement for high-risk work.
The Hierarchy of Control
The Hierarchy of Control mandates that risks must be eliminated first. For falls, the highest level of protection is a fall prevention device, such as a perimeter scaffold or temporary edge protection. Only if these are not reasonably practicable should a work positioning system or, as a last resort, a fall arrest system (which relies on user behaviour and requires an emergency rescue plan) be considered.
Furthermore, workers must ensure electrical risks are controlled by turning off and isolating all electricity supply at the main switchboard and using a lock-out/tag-out (LOTO) procedure before commencing any work, especially when entering ceiling voids. Specialised training and adherence to manufacturer instructions are vital to a safe and successful installation.
Secure Your Solar Investment with the Right Mounting System
Choosing the right mounting structure is critical to the safety, efficiency, and long-term success of any solar installation. Whether for rooftops, ground mounts, carports, or floating PV systems, Unitrade brings over 40 years of engineering expertise to every solution we deliver.
As a trusted name in construction and building materials, Unitrade offers a complete range of solar products, including high-performance solar panels, inverters, battery storage systems, and precision-engineered mounting structures. Our solutions are built for durability, backed by deep technical knowledge, and tailored to residential, commercial, and industrial applications.
Contact Unitrade today for a free consultation and quotation on solar mounting systems for your next project.
FAQ
1. Why are mounting structures important in a solar PV system?
Mounting structures provide the support framework that holds solar panels in place. They ensure panels are angled correctly for optimal sun exposure and protect the system from damage caused by wind, weather, or structural instability.
2. What materials are used in solar mounting structures?
Common materials include aluminium, known for its corrosion resistance and lightweight strength, and galvanised or stainless steel for heavy-duty applications. The right material depends on the environment, budget, and project scale.
3. What is the difference between rooftop and ground-mounted systems?
Rooftop systems are installed on existing buildings and are ideal for urban spaces. Ground-mounted systems are installed directly on land and offer flexibility in tilt, orientation, and scale—ideal for solar farms or where rooftop space is limited.
4. Where can I get quality solar mounting systems in Malaysia?
Unitrade supplies high-performance rooftop and ground-mount solar structures designed for Malaysia’s climate. With over 40 years of experience in infrastructure projects, Unitrade ensures durability, compliance, and expert support for every installation.