PV Panel Mounting Structures for Industrial Roofs in Tashkent

Task: why industrial roofs need a high-tech PV mounting structure

For industrial and warehouse buildings in Tashkent, switching to solar generation is not only about saving electricity, but also a serious engineering challenge. A PV mounting structure on the roof must simultaneously:

• safely transfer loads to the existing steel structures;
• withstand the region’s wind and snow loads;
• take into account the roof type (corrugated sheet, roll roofing, membrane, concrete);
• avoid compromising the integrity of the roofing system;
• be convenient for installation and maintenance.

BRIX approaches PV mounting structures as industrial steel structures, not as a simple “set of rails”. The basis is an engineering calculation according to the technical specification (TS), optimization for a specific site, and a high-tech production chain in Tashkent.

Initial data: what is needed to calculate the structure according to the TS

A correct calculation of the structure starts with a technical specification. The more accurate the TS, the more reliable the solution and the more transparent the cost.

To calculate according to the TS, you usually need:

1. Building data

   • site address (to account for climatic conditions);
   • building type: warehouse, production facility, logistics center, retail facility;
   • roof dimensions, building height.

2. Roof and load-bearing structures

   • roof type: corrugated sheet, sandwich panels, roll roofing, membrane, concrete slab;
   • spacing and type of load-bearing trusses/beams, material (steel, reinforced concrete);
   • presence of existing superstructures, shafts, guardrails, canopies.

3. PV system parameters

   • type and dimensions of solar panels;
   • number of panels and total project capacity;
   • layout scheme (if there is a preliminary solution);
   • required tilt angle and orientation.

4. Customer constraints and requirements

   • possibility/prohibition of drilling through the roof;
   • permissible load on the roof;
   • corrosion resistance requirements (environment, aggressiveness);
   • material preferences: carbon steel, galvanized steel, stainless steel;
   • planned project service life.

Based on this data, BRIX engineers develop the structure concept, select the type of fasteners and mounting rails, and calculate the sections of trusses and support elements.

Engineering calculation: loads, aerodynamics, and working with the existing roof

Loads and combinations

For industrial roofs in Tashkent, the following are critical:

• self-weight of the system: panels, structure, fasteners;
• wind loads: especially along the edges and corners of the building;
• snow loads: taking into account possible snow redistribution;
• installation and operational loads: personnel, maintenance.

The calculation takes into account unfavorable load combinations and the specific features of the building: height, exposure of the site, presence of neighboring structures.

Aerodynamics and structure configuration

A PV mounting structure on a roof is an additional “sail”. Incorrect orientation or height of the structure can lead to:

• increased wind forces;
• vibrations and fatigue damage;
• risk of fastener pull-out.

When designing, BRIX engineers:

• select the optimal tilt angle considering wind conditions;
• calculate the spacing of supports and trusses;
• provide additional bracing and ties in critical areas;
• develop connection details to the load-bearing steel structures.

Working with the existing roof

The key question is how to transfer the load from the PV structure to the load-bearing frame of the hangar or warehouse without damaging the roofing system.

Possible approaches:

• fastening through the roof into the load-bearing elements using special support details and sealing;
• bearing on additional steel structures that distribute the load over an area;
• ballasted systems (where the structure and conditions allow this).

BRIX develops connection details taking into account the specific roof type and its installation technology, so as not to create leakage points and not to reduce the roof’s service life.

Material selection: carbon steel, galvanized steel, stainless steel and their combinations

The material of the structure and fasteners directly affects the system’s service life and the project cost.

Main options

1. Carbon steel with subsequent powder coating

   • used for load-bearing elements, trusses, and columns (if required);
   • offers a good strength/cost ratio;
   • requires proper surface preparation and coating thickness control.

2. Galvanized steel

   • optimal for mounting rails and brackets;
   • resistant to atmospheric corrosion;
   • works well with bolted connections.

3. Stainless steel

   • used in joints with increased corrosion resistance requirements;
   • relevant for aggressive environments (food and chemical industries, coastal areas);
   • more expensive, but minimizes corrosion risk in critical points.

Combined solutions

In practice, a combination is often used:

• load-bearing trusses and beams — carbon steel with powder coating;
• mounting rails and part of the fasteners — galvanized steel;
• critical elements and roof fasteners — stainless steel.

BRIX selects the material configuration for the specific site and budget, explaining to the customer where it is reasonable to use more expensive solutions and where optimization is possible.

BRIX process chain: from 3D model to ready-to-install kits

The BRIX production facility in Tashkent enables a closed cycle from the engineering model to a complete PV mounting kit.

Stage 1. Design and 3D modeling

• development of a 3D model of the steel structures considering the panel layout;
• detailing of fastener joints and mounting rails;
• issuance of drawings for production and installation.

Stage 2. Laser cutting and metal bending

• laser cutting of sheet and profile metal for precise part geometry;
• CNC bending to manufacture brackets, supports, and fastener elements;
• minimization of manual operations due to high-precision blanks.

Stage 3. Welding of steel structures

• welding of trusses, frames, and support elements according to drawings;
• geometry control to ensure fit-up on site;
• preparation of joints for bolted connections.

Stage 4. Surface treatment and powder coating

• surface cleaning and preparation;
• application of powder coating where required;
• color selection according to customer requirements or site standards.

Stage 5. Kitting and logistics

• packaging of elements by installation zones;
• part marking to simplify assembly on the roof;
• delivery to the site in Tashkent and across Uzbekistan.

This technological approach reduces the amount of on-site rework and speeds up PV system installation.

Types of structures for industrial and warehouse roofs

Depending on the roof type and TS, BRIX offers different steel structure configurations.

For corrugated sheet and sandwich panels

• linear systems on mounting rails with fastening into load-bearing elements;
• structures with minimal elevation above the roof to reduce wind load;
• solutions with longitudinal and transverse rails for optimal panel layout.

For flat concrete roofs

• support frames with adjustable tilt angle;
• systems that distribute the load over the slab;
• possibility of using ballasted schemes where loads allow.

For membrane and roll roofs

• special support elements compatible with the roofing technology;
• minimization of fastening points and careful sealing;
• transferring supports to existing steel structures where necessary.

Each type of structure is developed for a specific building, not as a universal kit “for any roof”.

What affects the price of a PV mounting structure

The cost of a PV mounting structure for an industrial roof is always calculated individually. Below are the main factors that affect the final budget.

When you contact BRIX, you receive a TS-based calculation with details: steel volume, material types, technological operations, and indicative timelines.

Timelines: what determines delivery and installation schedule

Project timelines for a PV mounting structure depend not only on production workload, but also on the quality of the initial data.

Main time stages

1. TS collection and preliminary calculation

   • clarification of initial data;
   • basic calculation of steel structures and indicative budget.

2. Design and documentation

   • 3D modeling and drawings;
   • approval of solutions with the customer and, if necessary, with the building designer.

3. Production

   • laser cutting and metal bending;
   • welding, assembly of joints;
   • powder coating (if provided).

4. Kitting and delivery

   • packaging and marking;
   • delivery to the site;
   • if necessary — supervision or installation.

The earlier a steel-structure manufacturer is involved at the PV project development stage, the lower the risk of schedule shifts due to redesign.

Common mistakes when ordering rooftop PV mounting structures

1. Lack of a full TS
   Ordering “by eye” without roof and load-bearing data leads to excessive safety margins or, conversely, underdesigned elements.

2. Copying solutions from another site
   A structure that works well on one warehouse may be inefficient or unsafe on another due to different height, roof type, and wind conditions.

3. Ignoring the condition of existing steel structures
   Failure to consider the actual condition of trusses and beams leads to overloading and extra strengthening costs during installation.

4. Saving on materials in critical joints
   Using unsuitable fasteners or corrosion-prone elements in leak-prone areas reduces the service life of the entire system.

5. No marking and kitting
   Supplying a “pile of steel” without part marking complicates installation, increases time on the roof, and raises the risk of errors.

6. Lack of coordination with building operation
   Ignoring roof maintenance routes, roof access, and equipment access creates problems after commissioning.

7. Separate selection of suppliers for the structure and PV equipment without coordination
   Lack of coordination between the PV designer and the structure manufacturer leads to incompatibility of fasteners and layout.

BRIX helps avoid these mistakes through TS-based work, engineering calculations, and an integrated approach to steel structures.

How cooperation with BRIX works step by step

1. Request and TS
   You send the initial data on the site and PV system. If necessary, BRIX specialists help structure the TS.

2. Engineering calculation and concept
   Engineers assess loads, develop the structure type, materials, and fastening details.

3. Commercial offer
   A TS-based calculation is prepared with a description of the solution, composition of steel structures, and technological operations.

4. Design and detailing
   Development of a 3D model, issuance of drawings for production and installation.

5. Production and quality control
   Laser cutting, metal bending, welding, powder coating, kitting.

6. Delivery and installation support
   Delivery to the site in Tashkent or regions, and, if necessary, supervision or installation works.

FAQ on PV mounting structures for industrial roofs

1. Can existing hangar steel structures be used without strengthening?
This depends on their actual condition and load-bearing reserves. BRIX recommends relying on survey data and load calculations. In some cases, local strengthening is required.

2. What is the best material for an industrial roof structure?
A combined approach is optimal: load-bearing elements from carbon steel with powder coating, mounting rails and part of the fasteners from galvanized steel, critical joints from stainless steel. The exact choice depends on the environment and budget.

3. Is it possible to install the structure without drilling the roof?
In some cases, ballasted or special support systems can be used, but this requires load calculations and roof assessment. The decision is made individually based on the TS.

4. How are Tashkent’s wind conditions taken into account?
When calculating the structure, building height, site exposure, and location are analyzed. The structure configuration and support spacing are selected considering the region’s wind loads.

5. How does production in Tashkent differ from importing ready-made systems?
Local production allows adapting the structure to a specific building, quickly making changes, and shortening delivery and service times.

6. Can the PV mounting structure be integrated into existing warehouse steel structures?
Yes, provided data on the existing hangar or warehouse frame is available. BRIX engineers develop connection details and, if necessary, design additional elements.

7. What data is needed for a preliminary calculation?
At minimum — roof type and dimensions, panel type and planned capacity, photos or a roof diagram. A detailed TS is required for an accurate calculation.

8. Do you only supply the structure, without the PV panels themselves?
Yes, BRIX specializes in the design and manufacture of steel structures and fasteners. Panels and inverters can be supplied by your PV contractor.

What to prepare for a “Request a quote” inquiry

To receive an accurate calculation of a PV mounting structure for an industrial or warehouse roof, prepare:

• site address and brief building description;
• roof plan with dimensions (if available);
• photos of the roof and existing steel structures;
• roof type and spacing of load-bearing trusses/beams;
• type and dimensions of solar panels, planned capacity;
• requirements for panel tilt angle and orientation;
• material preferences (carbon steel, galvanized steel, stainless steel);
• expected system service life and indicative project timeline.

Request a quote
Send this data to the BRIX team in any convenient way. Based on the TS, you will receive an engineering-based solution for a PV mounting structure for your industrial roof in Tashkent, indicating the composition of steel structures, applied technologies, and indicative production and delivery times.