Amit Nirmal | Shirsh Energy Solutions Pvt Ltd

Sterling Strips Ltd is a multi-disciplined

E.P.C, planning, design and engineering
company providing comprehensive services
Boiler Design, Manufacturing & Commissioning

Solar PV Structural EPC

Turnkey Projects

Shirsh Energy is a system Integrator for Solar

Rooftop and other services on turnkey basis.

PV array mounting options

Engineering variables for designing the
mounting system
Design methodology for Mounting structures
Construction Methodology
Installation Overview
Q &A

Photovoltaic module mounting systems are

one piece of a solar electric project that
generally does not receive a lot of attention

But a mounting system is an important

component that shouldnt be overlooked.

Roof-top Mounting

Ground Mounting

Top-Down Rail System

Rack Mounts: Adjustable- & Fixed-Tilt
Top-of-Pole Mounts
Commercial mounting systems
Tracking System
Single Axis
Dual Axis

One of the most common

and very popular PV module
mounting methods is the
top-down rail system,
since modules attach from
their upper side to the rails
with specified clamps.
This versatile system can be
used with almost all roofing
types.
Top-down rail mounts are popular
in both home and business scale
installations.

It consist of 4 main
component
Feet or posts (also called

footings or standoffs) that are typically

secured to the roofs
rafter system;
Extruded aluminium
rails fastened to the feet
or posts and the array;
End-clips that secure the
ends of the PV array to
the rails;
Mid-clips that hold the
junction of two modules Mounting clips attach PV modules to the rails
to a mounting rail.
from the top, allowing quicker installations.

Array is mounted
parallel to the roof
plane
PV modules are
attached to the
rails from the front
side, instead of the
back

Rail systems typically result in only 3 to 6 inches of space between the back of the modules and
the roof surface.
Modules mounted this close to the roof surface tend to reach higher temperatures

Rack mounts can be tailored to fit a variety of

situations, accommodating both ground
mount and roof-mount applications.

Biggest benefit to racks is that they can allow

for a variety of specific tilt angles.
The PV array can be set at an optimal tilt
angle based on the sites latitude or, if
adjustable racks are chosen, repositioned
seasonally to optimize energy output.
Main Components : legs, beams & Clamps for
panels

Since these mounts tilt the array away from

the mounting surface, the backs of the modules
can usually be conveniently accessed to get to
the wiring, junction boxes, and grounding
points, making installation and maintenance
easier.
The increased distance from the mounting
surface also facilitates greater airflow along
the back of the modules and results in a lower
array temperatures compared to the parallel-toroof method.

Same structure can be used for Ground

Mounted or Roof mounted in some situations
it can be used on side of buildings.

Many designs require ordering a specific

rack with mounting hole spacing that
matches the PV modules mounting
holes. In roof mounted systems, rack
mounts have less layout flexibility than
top-down rail systems.

The top-of-pole
mounting solution is a
favourite among many
installers
Top-of-pole arrays are
viable for locations with
enough land space and
where possible
aesthetic concerns are
not an issue.

The footing for the pole is encased in

concrete according to manufacturers
specifications for the array size and the sites
soil and wind-loading conditions.

Components
Pole
mounting sleeve which slips on top of the pole
All necessary bracing and cross members, as well as
module mounting hardware.

The ability to adjust the array tilt seasonally

is a natural function of any top-of-pole
mount.
In cold climates, top-of-pole mounts are one
of the most convenient racking options if
snow needs to be periodically cleared from
the array.
Top of-pole arrays can also be used with
tracker systems to help boost PV production
even more

Array sits several feet from the ground,

allowing for the greatest amount of airflow,
top-of-pole mounted arrays operate at lower
temperatures than roof- and groundmounted arrays.
This reduces the amount o power lost when
ambient temperatures are high.

Top-of-pole mounts generally are not viable

options in urban or suburban areas due to the
yard space required.
Additional excavation required to place a pole
and trench to the electrical distribution can
make top-of-pole mounts more costly in
certain situations

These solutions include

Custom designed and

fabricated mounting
structures,
Integrating the PV array
into the roofing material,
and using a
Non penetrating ballast
Ballast mounts rely on the weight of the
system for flat-roof
ballast, modules, and racking rather than
applications.
fasteners and roof penetrations to secure
the array.

The most common

type of commercial
racking system is the
ballast rack, which
uses the weight of the
modules and rack in
conjunction with
ballast to securely
keep the arrays in
place.

Masonry blocks are placed in

ballast pans that are located
either directly under, or in front
of and behind the PV array
These racks can add a significant
roof load, up to 146.47 Kg per
square meter, depending on the
.
array engineering requirements

Single Axis Tracker system

Dual Axis Tracking system

Trackers are used to minimize the angle of incidence

between the incoming light and a photovoltaic panel.

The single-axis method follows the suns path

from east to west, with the array tilted at a
fixed or manually adjustable angle off the
horizon.
This approach is common in large-scale,
commercial installations but can be used in
residential applications as well.

Dual-axis trackers adjust the PV array to track

the suns path from east to west and adjust
the arrays tilt to account for the change in
the suns altitude.

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Maximum design wind speed.

Snow Load
Exposure category.
Soil class.
Module type and quantity.
Desired tilt angle.
Ground clearance.
Number of modules in a string.

This is the highest wind gust speed probable

in 50 years, averaged over a 3-second gust at
a height of 10 metre. Refer IS 875 for info.
Because wind speeds vary (they are generally
higher close to the coast and at high
elevations), this is critical information for an
engineer
Maximum design wind speeds can be found
in the IS875 Section 3

deals with wind loads to be considered when

designing buildings,
structures and components thereof.

Location ( this determines basic wind speed)

Calculate design wind speed

Calculate Design
Wind Pressure

By Conducting FEA for structures we can

Approximately know the reaction forces which

will be responsible for uplift of structure

Stresses in each members, that then can be
compared with IS 875, IS800 andIS801 for
validation
Overall displacement and pinpoints exactly where
we have focus for optimizing the structure
Can be used for studying combinations of Wind,
Seismic, Self weight & Snow loads.

A good PV mounting system must be capable of one thing above all: It

must stand safely.

Measured in pounds per square foot (or

Kg/m2), the weight of snow on a structure can
stack up, depending on your location.
Snow can be five to more than 15 times
heavier than a PV module, and the rack must
hold the additional weight.
ASCE (American Society of Civil Engineer)
Standard 7-10 includes common snow-load
values

This is related to wind loading and takes into

account the turbulence at the site due to
surrounding objects (trees, buildings, etc.).
Terrain in which a specific structure stands
shall be assessed from IS 875 section 3,
typically there are 4 categories of terrain.

This is necessary for determining specifics for

anchors, which behave differently in different
soils.
Soil test report is necessary in determining
the anchoring which can Ramming or Piling
Soil report typically consists of Safe Bearing
Capacity, Moisture Content, Cohesion Value
of soil to hold the structure etc.

Acquire a specification sheet for your

modules for the rack manufacturer, who will
need at least
minimum the number of modules,

plus module depth, height,

width, and hole layout, to size the rack correctly.

This will be based on your locations latitude

and the seasonal variation in solar gain
The height to the lower edge of the first row
of modules (800mm to 1000mm is typical).
This basic design decision should be based on
site conditions:
potential snow accumulation,

ground covering ( accessibility)

aesthetics, etc.

This information can help the rack

manufacturer design an efficient layout, with
strings contained within a row or sub array for
less trenching and conduit.

Preliminary
Sitting: Review property lines, shading, setbacks, right-of

ways, or easements; and check for underground utilities.

Civil engineering: Will grading, storm water runoff
mitigation, or environmental reviews be needed? Check
with local permitting, planning, and inspection agencies.
Site access: Is the site accessible to heavy construction
machinery if needed?
Accessibility: Will the array need fencing for security from
theft and/or animals, and to comply with Standards ?
Be sure there is sufficient space so the fence will not shade
the array.

Design
Site-specific info: Catalogue wind speed, snow loads,

soil conditions, etc.

Electrical interconnection: Determine distance and
route to the interconnection point, and placement of
electrical equipment including combiner boxes,
disconnects, inverters, and other BOS components.
Orientation
Height
Layout
Maintenance

Columns : Can be hot rolled or Cold Rolled

section
Link or Brackets : Preferably Cold rolled as
good strength and weight factor
Link can tilting also for having seasonal tilt in

zenith

Beams: Preferably Cold rolled as good

strength and weight factor
Struts & Clamps: For mounting of PV panels

This code applies to general construction in

steel
The provisions of this code generally .apply to
riveted, bolted and welded constructions,
using hot rolled steel sections.
This code gives only general guidance as
regards the various loads to be considered in
design , For actual loads to be used reference
may be made to IS : 875

This code applies to the design of structural

members cold-formed to shape from carbon
or low-alloy, sheet or strip steels used for load
carrying purposes in buildings.
It may also be used for structures, other than
building provided appropriate allowances are
made for dynamic effects.

Hot dip Galvanized Steel or Aluminum for on

grid mounting structures
Aluminum / Galvanized Steel or Stainless
Steel in Off grid installations.
Fasteners : All Stainless Steel preferred
Galvanization : Upto 80-90 Microns but will
depend upon the soil and Chloride , moisture
content of soil & Ph Value of soil.

Surface preparation
Caustic cleaning- A hot alkali solution often is used to

remove organic contaminants such as dirt, paint

markings, grease and oil from the metal surface.
Acid pickling- Scale and rust normally are removed
from the steel surface by pickling in a dilute solution
of hot sulphuric acid
Fluxing- Fluxing removes oxides and prevents further
oxides from forming on the surface of the metal prior
to galvanizing.

Galvanizing the material is completely immersed in a bath

consisting of a minimum of 98% pure molten zinc.

Fabricated items are immersed in the bath until
they reach bath temperature.

Inspection
coating thickness and
coating appearance

A variety of simple
physical and laboratory
tests may be performed
to determine thickness,
uniformity, adherence
and appearance.

Structures are modularly constructed into

different parts and installed on site using
fasteners.
Cold Rolling methodology is used in making
brackets, beams and struts.
Hot rolled or cold rolled can be used in
columns.

Marking of Site as per layout for pole

mounting
Ramming or Piling of Poles / Post or Column
Checking Alignment of Poles
Mounting of brackets
Mounting of Aligner (Tilting link)
Mounting of Beams
Mounting of Struts
Mounting of Panels and supporting it with
Clamps

Before Designing know your parameters

exactly
Conduct geo technical survey to exactly
understand the soil conditions and in addition
do a PULL TEST on prototype at site
Use standard process for construction to
guarantee the structure for at least 25 years
Try to optimize the structure for weight, cost
of manufacturing & Transportation and
strength.