Manufacturing Carports for Solar Panels for Businesses

The role of canopies and carports for solar panels in commercial projects

Canopies and carports for solar panels are more than just parking structures. For commercial property owners, developers, and EPC contractors in Tashkent, they are a way to solve three tasks at once:

• provide shade and protection for vehicles or loading areas;
• install solar generation without using the roof;
• turn existing parking lots and open areas into an energy asset.

The key question for business is how technologically the metal structure is designed and manufactured. This determines safety, service life, ease of installation of PV equipment, and the total cost of ownership.

Types of canopies and carports for businesses: where each is used

For commercial facilities in Tashkent, several basic types of canopies for solar panels are most commonly used:

Single-row carports

• One row of parking spaces.
• Supports located on one or both sides.
• Suitable for small parking lots at offices, gas stations, retail pavilions.

Double-row carports (back-to-back)

• Two rows of cars under a common truss.
• Fewer supports per parking space.
• Optimal for shopping malls, business parks, logistics complexes.

Canopies over process areas

• Covering loading zones, storage yards, open production areas.
• The structure is selected for non-standard geometry and equipment layout.

Modular systems

• Frames that can be extended by rows and spans.
• Convenient for phased commissioning of solar capacity.

The type of structure affects not only the appearance, but also load calculations, truss layout, number of columns and, consequently, project cost.

Technical specification: what data is needed to calculate the structure

A proper technical specification is the basis for accurate calculation of the metal structure and price. For canopies and carports for solar panels, it is important to collect more data than when ordering a conventional parking canopy.

Recommended minimum information for calculation:

1. Purpose and type of facility

   • parking for shopping mall visitors, business center, warehouse, gas station, car dealership, industrial site, etc.

2. Dimensions and parking layout

   • number of parking spaces;
   • width and length of the row;
   • distances between rows and driveways;
   • height restrictions (for example, for trucks).

3. Type and model of solar panels

   • dimensions and power of the panel;
   • weight of one panel;
   • planned layout scheme (portrait or landscape orientation, in one or two rows in height).

4. Desired tilt angle and orientation

   • orientation to the cardinal directions (usually south or southwest);
   • required tilt angle based on generation calculations.

5. Site conditions

   • type of base (asphalt, concrete, soil);
   • presence of existing utilities in the support area;
   • restrictions on column placement (driveways, fire breaks).

6. Requirements for appearance and finish

   • exposed galvanized steel or powder coating in brand color;
   • need to integrate lighting, cable ducts, gutters.

7. Planned timelines

   • desired commissioning date;
   • whether there is a hard deadline (facility opening, solar plant launch under a PPA contract, etc.).

The more accurate the technical specification, the lower the risk of recalculations and changes during the project.

Design: loads, panel orientation, and layout schemes

Designing a frame for PV panels differs from a conventional canopy in that the structure must work as a single system with the solar equipment.

Load calculation

When designing, the following are taken into account:

• self-weight of the metal structure;
• weight of solar panels and PV mounting hardware;
• wind loads taking into account open parking lots and wind rose;
• snow loads (lower for Tashkent than in northern regions, but still considered);
• dynamic loads (wind gusts, possible vibrations).

This determines the cross-section of columns and trusses, support spacing, and type of foundation or embedded parts.

Orientation and tilt angle

Panel orientation and tilt angle affect:

• the height of the rear and front parts of the canopy;
• truss length;
• possible shading of adjacent rows or buildings.

For parking lots, it is important to maintain sufficient clearance for vehicles while providing the required angle for generation.

Panel layout scheme

At the design stage, the following are determined:

• number of panels per span;
• spacing of transverse purlins for mounting rails;
• routing of cable trays and placement of inverters.

This affects not only steel consumption, but also the ease of installation and maintenance of the PV system.

Choice of materials and technologies: steel, aluminum, combined solutions

The frame material and type of treatment directly affect service life and cost.

Steel (carbon steel with protection or galvanized)

• The main solution for commercial carports.
• High load-bearing capacity at a reasonable cost.
• Possible protection options:
  • hot-dip galvanizing;
  • primer + powder coating;
  • combined solutions to meet customer requirements.

Aluminum

• Lightweight structures, convenient when there are limitations on base loads.
• Higher material cost.
• More often used in areas with increased requirements for corrosion resistance and design.

Combined solutions

• Load-bearing frame made of steel, while panel mounting elements and rails are made of aluminum or stainless steel.
• A balance between cost, corrosion resistance, and installation convenience.

For Tashkent, with its climate and dust, it is important to carefully plan metal protection to prevent accelerated corrosion at fastening points and joints.

Metal structure production: cutting, bending, welding, corrosion protection

After the design is approved, metal structure manufacturing begins.

Preparatory operations

• Laser cutting — precise cutting of sheet and profile for plates, gussets, and joint elements.
• Metal bending — forming profiles, stiffeners, brackets for PV mounting.

The accuracy of these operations reduces installation tolerances and speeds up assembly on site.

Welding and assembly of joints

• Assembly of trusses, columns, beams into larger elements.
• Welding of critical joints according to the design.
• Geometry control to avoid problems with panel fit on mounting rails during installation.

Anti-corrosion treatment

Depending on the chosen technology:

• surface preparation (cleaning, shot blasting);
• priming and powder coating in the required color;
• or transfer for hot-dip galvanizing.

For parking canopies, powder coating in corporate colors is often chosen — this increases the visual value of the project for the developer and tenants.

PV mounting hardware and rails: integration with the canopy frame

The canopy frame must initially be designed for a specific type of PV mounting hardware.

Mounting rails and support profiles

• Rail spacing is determined according to panel dimensions.
• Attachment points to trusses and purlins are laid out.
• Technological gaps are provided to compensate for thermal expansion.

Brackets and clamps

• Selected according to panel frame thickness.
• The method of grounding through the mounting hardware is taken into account.
• It is important to ensure sufficient clamping force without damaging the frames.

Cable management

• Trays or cable ducts for DC cables;
• locations for inverters and junction boxes;
• protection of cables from mechanical damage and ultraviolet radiation.

Proper integration of PV mounting hardware at the design stage reduces EPC contractor labor costs during installation and minimizes on-site rework.

On-site installation: base preparation, assembly, panel installation

Project implementation timelines largely depend on how installation is organized.

Base preparation

• Marking the locations of supports.
• Construction of foundations or embedded parts (if the base already exists).
• Checking elevation marks and axes.

Assembly of metal structures

• Installation of columns and beams.
• Installation of trusses and transverse purlins.
• Geometry alignment, tightening of bolted connections.

With high-quality preparation at the factory, installation is carried out with larger assemblies, which reduces time on site.

PV system installation

• Installation of mounting rails and hardware.
• Laying and securing solar panels.
• Cable routing, connection to inverters and switchboards.

Coordinating the schedule between the metal structure manufacturer and the EPC contractor helps avoid downtime and schedule conflicts.

What affects the cost of a canopy or carport for solar panels

The final project price is formed from many factors. Below are the main ones.

To obtain an approximate cost, a calculation based on the technical specification and specific initial data for the facility is required.

Common mistakes when ordering canopies and carports for PV panels

1. No clear technical specification at the start
   The order is limited to the phrase “make a parking canopy for panels.” As details are clarified, dimensions, tilt angle, and parking layout change — the project becomes more expensive and deadlines shift.

2. First they build the canopy, then think about PV panels
   The frame is not designed for specific panels and mounting hardware. During installation, additional elements have to be added, trusses reinforced, and purlin spacing changed.

3. Ignoring wind loads
   In open areas near Tashkent, wind creates significant loads on the panel surface. Underestimation leads to deformations and accelerated wear of mounting hardware.

4. Saving on corrosion protection
   Minimal metal protection in open parking lots quickly leads to corrosion at joints and in areas of contact with water and de-icing agents.

5. Poorly planned cable management
   Cables are routed “on the fly” without embedded solutions. The result is visual clutter, increased risk of damage, and difficulties in maintenance.

6. Uncoordinated production and EPC installation schedules
   Metal structures are delayed or delivered in a sequence that does not match installers’ needs. This causes downtime and higher on-site labor costs.

7. No allowance for expansion
   The carport is built “just enough” for the current capacity, with no option to extend rows or add panels. Expansion then requires major rework of the structure.

FAQ on manufacturing and project timelines in Tashkent

1. Where to start a canopy or carport project for solar panels?
Start with forming the technical specification: parking layout, number of parking spaces, panel type, desired tilt angle, design and timeline requirements. Based on this data, a preliminary calculation of the metal structure and PV mounting hardware can be made.

2. Can a standard solution be adapted to a specific facility?
Yes, modular solutions are often used and adapted in terms of row length, height, and tilt angle. It is important to consider site and parking layout specifics at the design stage.

3. What are realistic timelines for manufacturing and installing such structures?
The timeline depends on volume, complexity, and production workload. It is affected by design time, manufacturing cycle (cutting, bending, welding, painting), and organization of on-site installation. Timeline estimates are provided after analyzing the technical specification.

4. Is it possible to carry out design and site preparation in parallel?
Yes, this is common practice: while design and production are underway, the customer prepares the base and utilities. It is important to synchronize schedules to avoid downtime.

5. Is it mandatory to specify the exact panel model right away?
Preferable. Panel dimensions and weight determine purlin spacing, number of mounting rails, and type of mounting hardware. If the model changes during the process, the structure has to be recalculated.

6. What materials are most commonly used in Tashkent?
For commercial carports — steel structures with corrosion protection (galvanizing and/or powder coating). For panel mounting hardware — steel, aluminum, or their combinations, depending on project requirements.

7. Can lighting and other engineering systems be integrated into the carport?
Yes, during design, locations for luminaires, cable ducts, and sometimes CCTV elements or EV charging stations are provided. This should be specified in the technical specification from the outset.

8. How to assess how ready the structure is for solar system expansion?
Modularity can be provided at the design stage: the ability to extend rows, add spans, and reserve load capacity for individual elements. These requirements should be voiced when setting the task.

How to request a calculation for a canopy or carport for solar panels

To obtain a technically sound solution and an accurate cost estimate, it is important to provide the contractor with the most complete technical specification possible.

Submit a request for calculation

Recommended data set for calculation:

• city and address of the facility (Tashkent/region);
• facility purpose (shopping mall, business center, warehouse, gas station, etc.);
• parking or site layout (plan, photos, and drawings if available);
• required number of parking spaces or canopy area;
• desired type of structure (single-row, double-row, modular);
• solar panel data (size, weight, power, planned layout scheme);
• desired tilt angle and panel orientation;
• information on the base (asphalt, concrete, soil, presence of existing foundations);
• appearance requirements (color, powder coating, brand elements);
• need to integrate lighting, cable ducts, and other engineering systems;
• planned start and completion dates.

Based on this data, it is possible to develop a structure for a canopy or carport for solar panels that is optimal in terms of technology and cost, agree on manufacturing and installation timelines, and proceed to project implementation.