Manufacturing PV Metal Structures for Tashkent’s Climate

Features of Tashkent’s climate and their impact on PV metal structures

Tashkent means high insolation, hot summers, sharp daily temperature fluctuations, and dusty winds. For metal structures of rooftop and ground‑mounted PV systems this implies:

• increased requirements for corrosion resistance due to the combination of high temperature and periodic humidity;
• thermal deformation of long mounting rails and trusses;
• wind loads and uplift forces on panels, especially in open areas and on roofs;
• dust‑induced abrasive wear on coatings and moving joints;
• locally — snow loads in winter, which must not be ignored in calculations.

Therefore, the manufacturing technology for PV metal structures in Tashkent must be tailored to the region’s actual climatic loads, not to averaged catalog solutions.

Types of metal structures for rooftop and ground‑mounted PV systems

For solar plants in Tashkent, several basic types of metal structures are usually used:

Rooftop PV systems

• Frames for pitched roofs
  Brackets, clamps, mounting rails, connecting elements. Important aspects:

  • minimal additional load on existing trusses and beams;
  • reliable sealing of attachment points to the roof;
  • versatility for different types of roofing.

• Frames for flat roofs
  Support frames, ballast systems, inclined trusses. Key points:

  • wind stability calculation taking into account building height;
  • distribution of load over the floor slab;
  • ease of transportation and assembly on the roof.

Ground‑mounted PV systems

• Single‑row and multi‑row support structures
  Columns, cross beams, trusses, mounting rails. Important aspects:

  • accounting for soil bearing capacity and foundation depth of supports;
  • optimization of steel consumption while maintaining stiffness;
  • ease of installation in large blocks.

• Structures for trackers (if used)
  Require higher precision in manufacturing hinge joints and supports, and stable geometry under cyclic loads.

In all cases, the basic approach is custom manufacturing of metal structures according to the technical specification, adapted to the specific site, panel type, and layout scheme.

Stage 1. Collecting initial data and calculation based on the technical specification

The quality of the initial data determines the design, lead time, and final cost. At the start of the project it is important to define:

• system type: rooftop (flat/pitched) or ground‑mounted;
• project location (Tashkent district or region);
• roof or soil type, bearing capacity of the base (according to client data or geotechnical reports);
• model and dimensions of solar panels, layout scheme;
• required tilt angle and orientation;
• service life and maintenance requirements;
• constraints on height, support spacing, and service walkways;
• project size: kW/MW, number of rows, modules.

Based on the technical specification, a calculation of metal structures for solar panels is performed:

• selection of cross‑sections for columns, trusses, mounting rails;
• calculation of wind and snow loads for the region;
• verification of deflections and joint stability;
• preliminary estimation of steel consumption and labor intensity.

The result of this stage is a technical solution and indicative manufacturing lead times. The final cost is refined after design completion and material approval.

Stage 2. Design and verification of load‑bearing capacity

The technological approach to designing PV systems for Tashkent includes:

• 3D modeling of metal structures aligned with actual panels and fastening pitch;
• optimization of joints for serial production: minimizing the number of unique parts, unifying holes and fasteners;
• accounting for thermal deformation: expansion gaps, longitudinal joints of mounting rails;
• stiffness verification of long spans, especially for ground‑mounted systems;
• development of installation tolerances: ability to adjust in height and horizontally.

At this stage it is important to coordinate with the client in time:

• geometry tolerances (what is critical and what can be simplified);
• type of fasteners (galvanized, stainless, combined);
• coating requirements (thickness, color if powder coating is used).

Stage 3. Selection of materials and technologies for climatic loads

Materials for metal structures

For PV fasteners and load‑bearing elements the following are used:

• Carbon steel with anti‑corrosion protection
  Used for columns, trusses, beams, mounting rails. Advantages:

  • optimal price/stiffness ratio;
  • wide possibilities for welding and bending;
  • high load‑bearing capacity with proper cross‑section.

• Stainless steel
  More often for fasteners, clamps, critical joints. Advantages:

  • high corrosion resistance under temperature and humidity fluctuations;
  • dimensional stability of threaded connections.

• Combined solutions
  Load‑bearing elements made of protected carbon steel, small fasteners and clamps made of stainless steel. This is often the optimal balance for projects in Tashkent.

Protection and processing technologies

Given Tashkent’s climate, the following are used:

• hot‑dip or thermodiffusion galvanizing (if provided by the design);
• powder coating on a prepared surface for additional protection and, if necessary, color coding of zones;
• careful edge preparation after laser cutting to prevent localized corrosion;
• protection of welds (mechanical cleaning, subsequent treatment).

The specific combination of materials and coatings is always selected according to the technical specification and project budget, considering the required service life and operating conditions.

Stage 4. Technological preparation: laser cutting, bending, welding

Laser cutting

Laser cutting is widely used to manufacture PV structure elements:

• high accuracy of holes for bolted connections;
• clean edges, reducing subsequent processing time;
• ability to quickly adapt the program to changes in the technical specification.

This is especially important for contract manufacturing of serial batches of fasteners and mounting rails.

Metal bending

Metal bending is used for:

• manufacturing C‑, Z‑ and other profiles for mounting rails;
• forming brackets and clamps for a specific panel or roof type;
• increasing part stiffness without increasing metal thickness.

Proper bending allows reducing the structure’s weight without losing load‑bearing capacity, which affects both roof load and steel consumption.

Welding

Welding is used for:

• assembling columns, trusses, frames, and support joints;
• manufacturing non‑standard joints to existing metal structures;
• forming installation blocks delivered to the site pre‑assembled.

Key points:

• adherence to welding procedures for the selected steel grade;
• geometry control after welding (accounting for deformation);
• weld preparation for subsequent galvanizing or painting.

Stage 5. Anti‑corrosion protection and powder coating

In Tashkent’s conditions, the durability of PV metal structures is largely determined by the quality of corrosion protection.

Basic approaches

• Zinc coating (if provided by the design) — for load‑bearing elements and mounting rails;
• powder coating — as a standalone or additional coating, especially for visible or color‑coded elements;
• thorough surface preparation: degreasing, cleaning, and, if necessary, phosphating.

When powder coating is relevant

• need for visual separation of rows or zones of the plant;
• additional requirements for protection against atmospheric effects;
• corporate requirements for the color of structures.

At the same time, it is important to consider that powder coating adds a stage to the production cycle and affects lead time and cost.

Factors affecting lead time and cost of PV fastener manufacturing

The cost and lead time for manufacturing metal structures for solar plants depend on several groups of factors. Below is a summarized table.

Specific figures are determined after calculation based on the technical specification and selection of materials/coatings.

Typical technological mistakes in PV structure manufacturing

Even with experience in general metal structures, switching to PV systems without considering their specifics leads to mistakes.

1. Ignoring thermal deformation of long rails
   As a result — bending, additional stress in fasteners, risk of panel damage.

2. Insufficient attention to wind loads on roofs
   Using ground‑mounted calculation schemes for rooftop systems leads to under‑designed anchors and risk of panel uplift.

3. Metal too thin in critical joints
   Saving on profile and bracket thickness without calculation leads to deflections and vibrations.

4. Overly complex, non‑standardized fastening joints
   A large number of unique parts increases cost and creates a risk of confusion during installation.

5. Insufficient protection of welds and edges
   Even with generally high‑quality coating, local corrosion zones reduce the structure’s service life.

6. No adjustment allowance during installation
   A rigid, “zero‑gap” scheme causes problems when actual base geometry deviates from design.

7. Incomplete technical specification at the start
   Changes during the project (panel type, layout, tilt angle) lead to redesign and increased time and cost.

The manufacturing technology must initially account for these risks and minimize them at the design and production preparation stages.

How to organize contract manufacturing of metal structures for PV plants

For EPC contractors and investors with a project portfolio in the region, contract manufacturing of PV fasteners and metal structures is a relevant format.

Key points in organizing the process:

• Unified database of standard joints and parts
  Development and approval of a set of standard mounting rails, brackets, clamps, columns, and trusses that are replicated from project to project.

• Transfer of working documentation into the production loop
  Drawings, specifications, material and coating requirements are transferred as an agreed package.

• Flexible capacity utilization
  Ability to produce both pilot batches for test sites and large series for MW‑scale projects.

• Full processing cycle
  Laser cutting, metal bending, welding, powder coating — within a single production loop, reducing logistics between operations.

• Logistics and packaging tailored to installation
  Delivery of metal structures in batches, in labeled packaging by rows/zones of the plant, which speeds up installation and reduces the risk of errors on site.

This approach allows standardizing the technology and reducing the unit cost of structures across the project portfolio due to repeatable solutions.

FAQ on manufacturing metal structures for solar plants

1. Can the same type of metal structures be used for all sites in Tashkent?
Partially. Basic joints and mounting rails can be standardized, but height, support spacing, and base attachment type must be calculated for each specific site and technical specification.

2. What data are needed to calculate metal structures for solar panels?
At minimum: project location, system type (roof/ground), roof or soil type, panel model and layout scheme, required tilt angle, expected service life, and planned capacity (kW/MW).

3. What has a greater impact on cost: material or design?
Both factors are important. Switching to stainless fasteners increases price, but competent design and part standardization can significantly reduce steel consumption and labor.

4. How long does it take to manufacture a batch of PV metal structures?
Lead time depends on volume, design complexity, selected coatings, and current production load. An indicative schedule can be provided after calculation based on the technical specification and material approval.

5. Can existing metal structures be adapted for new panels?
In some cases — yes, using transition brackets and adapters. But this requires a separate survey and calculation of the load‑bearing capacity of existing elements.

6. How to account for maintenance and cleaning of panels when designing structures?
At the technical specification stage, you need to define walkways, spacing between rows, lower edge height, and the possibility of safe access for maintenance personnel.

7. How does the approach differ for rooftop and ground‑mounted PV structures?
For roofs, the key issues are load on existing trusses and roof watertightness; for ground‑mounted systems — working with soil, wind stability, and optimization of steel consumption.

8. Can future plant expansion be incorporated from the start?
Yes, when designing metal structures you can provide reserve rows, free zones, and standardized joints that allow increasing capacity without redesigning the base frame.

What to include in a request to obtain an accurate calculation and lead time

To obtain a correct calculation based on the technical specification and realistic lead times for manufacturing metal structures for a rooftop or ground‑mounted PV system in Tashkent, it is advisable to include in your request:

• project location (city/district, region);
• system type: rooftop (flat/pitched) or ground‑mounted;
• approximate plant capacity (kW/MW) and number of panels;
• panel model (dimensions, weight) and proposed layout scheme;
• roof type or soil description, availability of bearing capacity data;
• desired tilt angle and panel orientation;
• material preferences (carbon steel, stainless, combined);
• coating requirements (zinc, powder coating, color if needed);
• project schedule: desired start and end of installation;
• delivery format: in a single batch or in stages according to the construction schedule.

Submit a request for calculation

Prepare a brief technical specification with the data listed above and send it as a file (drawings, layout schemes) or a structured description. Based on the technical specification, it is possible to promptly:

• select a structural solution for Tashkent’s climatic conditions;
• propose options for materials and manufacturing technologies;
• estimate production lead times and the project’s indicative budget.