Metal Structures for Solar Power Plants in Uzbekistan

The role of the metal structure in an industrial solar power plant

For an industrial solar power plant in Uzbekistan, the metal structure is not just a “panel holder.” It determines:

• the reliability of module fastening under wind loads and dust storms;
• the service life of the entire PV plant without unscheduled repairs;
• precise panel orientation (tilt and azimuth) and actual energy yield;
• installation speed and the cost of construction and installation works;
• ease of service and module replacement.

For developers, industrial enterprises, and RES investors, this directly affects the project’s CAPEX and OPEX: a properly designed and manufactured metal structure reduces downtime and damage risks and lowers operating costs.

Requirements for PV mounting in Uzbekistan’s climate

The climate of Tashkent and most regions of Uzbekistan imposes increased requirements on metal structures for solar power plants:

• High summer temperatures — heating of metal and panels, thermal deformation.
• Significant daily temperature fluctuations — compensators and correct profile selection are important.
• Dust and sand — impact on moving parts, threaded connections, and coatings.
• Gusty winds in open areas — truss, post, and foundation calculations are critical.
• Occasionally aggressive environments (industrial zones, agricultural facilities) — increased corrosion.

Therefore, when designing a metal structure for a PV plant, the following are taken into account:

• wind region and site specifics (open steppe, industrial zone, urban development);
• soil type or roof structure type;
• planned service life of the plant;
• maintenance format (access to modules, possibility of dismantling and repositioning).

All these parameters must be recorded in the technical specification (TS) and considered in the structural calculations.

Materials and corrosion protection of metal structures

For PV mounting and metal structures for solar panels in industrial applications, the following are usually used:

Carbon steel with protective coating

• Hot-dip galvanizing — a common option for outdoor metal structures.
• Powder coating — can be used as additional protection and for zone marking.

Advantages:

• high load-bearing capacity;
• optimal price/strength ratio for large volumes;
• flexibility in cross-sections and profile types (posts, trusses, beams, brackets).

Disadvantages:

• demanding to surface preparation quality and adherence to galvanizing/painting technology;
• need to control coating damage during installation.

Stainless steel (for individual elements)

Stainless steel is more often used locally:

• fastening elements;
• individual nodes in high-corrosion areas (for example, near aggressive media);
• elements with increased service life requirements.

Advantages:

• high corrosion resistance;
• dimensional and performance stability over a wide temperature range.

Disadvantages:

• higher material cost;
• need for careful calculation to avoid “overpaying for redundancy.”

Aluminum profiles and combined solutions

In some cases, aluminum mounting rails and profiles are used:

• to reduce structure weight on roofs;
• to speed up installation due to standardized elements.

Combined systems are often used: steel supports and trusses + aluminum rails for module mounting. This allows optimization of weight, cost, and assembly speed.

Technologies for mounting solar panels on the ground

Ground-mounted metal structures for PV plants in Uzbekistan are most often used at industrial sites and for large-scale plants. The main solutions are:

Driven piles and screw foundations

• Steel piles are driven or screwed into the ground using special equipment.
• Posts and trusses forming the rows of the metal structure are attached to the piles.

Advantages:

• high installation speed without “wet” processes;
• possibility of dismantling and relocating part of the structure if necessary;
• minimal soil disturbance.

Key TS points:

• site geology (soil type, frost depth);
• wind loads and structure height;
• row spacing and distance between posts.

Concrete foundations (strip, pad, block)

Used where:

• soil is complex or wind loads are high;
• increased stability and rigidity are required;
• there are restrictions on the use of pile-driving equipment.

Advantages:

• high stability under extreme loads;
• possibility of precise geometry with proper formwork.

Disadvantages:

• longer timelines due to concrete works;
• dependence on season (temperature during concreting).

Fixed and tracking structures

Two basic approaches are used on the ground:

• Fixed metal structures — panels are mounted at a constant angle.
• Tracking systems — panels change tilt/azimuth during the day.

Fixed solutions are simpler and cheaper to manufacture and install. Tracking systems require more complex metal structures, precise mechanics, and higher requirements for welding quality and part finishing.

Technologies for mounting solar panels on roofs

Industrial enterprises in Tashkent and the regions often use workshop and warehouse roofs for PV plants. Here, the roof type and permissible load are key.

Mounting on flat roofs

Options:

• Ballasted systems — frames are installed with weights (ballast), without rigid fastening to the slab.
• Mechanical fastening — anchors into the slab or load-bearing roof elements.

Key TS parameters:

• slab and waterproofing type;
• permissible additional load per m²;
• required panel tilt angle.

Ballasted systems reduce the risk of waterproofing damage but require accurate calculation of weight and wind stability.

Mounting on pitched roofs

Special brackets and mounting rails are used here, adapted for:

• metal tiles and profiled sheeting;
• standing seam roofs;
• slate and other materials.

Key points:

• minimal interference with the roof build-up;
• sealing of fastening points;
• even load distribution across the rafter system.

For industrial facilities, it is important to obtain in advance from the client:

• roof drawings or its structural scheme;
• data on load-bearing capacity;
• information on existing engineering utilities on the roof.

Production technologies: from drawing to finished frame

A high-quality metal structure for a solar power plant is the result of a combination of engineering and production. On the production side, the following are usually used:

• Laser cutting — for precise geometry of parts, holes for fasteners, and slots;
• Metal bending — forming profiles, brackets, and mounting elements;
• Welding — assembling posts, trusses, and fastening nodes;
• Machining and CNC — when precise fits are required;
• Powder coating or preparation for galvanizing — final protection.

For the client, it is important that the contractor can work according to the TS and working drawings, and, if necessary, refine the design to suit site specifics.

What affects the cost of a metal structure for a PV plant

The final price of the metal structure and PV mounting is formed individually based on the TS. It is influenced by a number of factors.

Without initial data at the request stage, even an approximate price cannot be correctly stated. Therefore, the first step is a calculation based on the TS taking into account the specific site and tasks.

Typical mistakes when ordering PV mounting and metal structures

Below are mistakes that often lead to higher costs and schedule disruptions:

1. No clear TS at the start
   No data on soil, roof type, wind loads — resulting in several recalculation iterations and time loss.

2. Copying other projects’ solutions without site adaptation
   A frame that works well at one site may not withstand loads or may be excessive at another.

3. Underestimating roof weight and loads
   Installing a PV plant on a roof without checking load-bearing capacity leads to power limitations or reinforcement of the structure during implementation.

4. Overly generic approach to corrosion protection
   The same coating for a dry region and an aggressive industrial environment means either overpayment or accelerated corrosion.

5. Ignoring service and access requirements
   The metal structure is designed without walkways and service zones — maintenance becomes expensive and inconvenient.

6. Unapproved replacement of materials and profiles
   Attempts to “optimize” the project on the fly without recalculation can reduce load-bearing capacity and lead to deformation.

7. Requesting only by price without technology analysis
   The cheapest metal solution often results in higher installation and maintenance costs.

How the TS-based calculation and manufacturing process is organized

For a developer or industrial client, predictability from first request to installation is important. A typical process looks like this:

1. Receiving the TS and initial data
   Site (ground or roof), PV plant capacity, panel type, tilt angle requirements, service life, maintenance format.

2. Engineering calculation of metal structures
   Selection of post, truss, and mounting rail cross-sections; load calculations; choice of material and protective coating type.

3. Development of drawings and nodes
   Detailing of elements for laser cutting, bending, welding; elaboration of mounting nodes and brackets.

4. Commercial offer
   Formed based on calculated metal volume, selected materials, and processing technologies, with indicative production timelines.

5. Manufacturing of metal structures
   Laser cutting, metal bending, welding of nodes, preparation for galvanizing or powder coating.

6. Kitting and logistics
   Assembling kits by site sections, marking elements, preparing documentation, and shipping to the site.

7. Technical support during installation (by agreement)
   Consulting on node assembly, coating protection recommendations, acceptance after installation.

Production timelines and factors affecting the project schedule

The production time for a metal structure for a solar power plant depends on:

• project size (number of posts, trusses, mounting rails);
• design complexity (fixed/tracking, special nodes, combined materials);
• production workload at the time of order;
• need to refine or develop design documentation from scratch;
• protection technologies (galvanizing, painting) and their cycle.

If a ready TS and elaborated drawings are available, calculation and production launch take less time. If the TS needs refinement, it is important to allow extra time for approvals.

For industrial and investment RES projects, it is advisable to plan work with metal structures in advance, synchronizing the schedule with module and inverter deliveries.

FAQ on metal structures for solar power plants

1. Can the same type of metal structure be used for different sites?
Not recommended. Even if geometry is similar, wind loads, soils, and maintenance requirements differ. The optimal approach is to adapt a standard solution to the specific site.

2. What data is needed for a preliminary PV mounting calculation?
Site location, type (ground/roof), PV plant capacity and number of panels, panel type, desired tilt angle, planned service life, and maintenance format.

3. Can steel and aluminum be combined in one project?
Yes, this is a common approach: steel supports and trusses plus aluminum mounting rails. It is important to properly design connection nodes and account for differences in thermal expansion.

4. How to choose between driven piles and concrete foundations?
The decision is made based on soil analysis, wind loads, and equipment availability. On soft soils and with high wind loads, concrete foundations may be preferable.

5. What if there is no accurate data on roof load-bearing capacity?
It is recommended to request information from the building designer or conduct a survey. Without this data, correct calculation of the metal structure and roof load is impossible.

6. How does the choice of coating (galvanizing/powder coating) affect cost and timelines?
Additional operations increase cost and production time but extend the service life of structures. The choice is made based on the operating environment and required service life.

7. Is it possible to upgrade an existing PV plant by adding new rows to the same frame?
As a rule, no: the metal structure is calculated for specific loads. Adding modules without recalculation can lead to overload and deformation. For plant expansion, additional rows are usually designed.

8. Is it realistic to meet tight deadlines for metal structures?
It is possible if the TS and drawings are ready and the volume and technology allow parallel production. At the same time, real production capacity and logistics must be considered.

What to prepare to quickly obtain a metal structure calculation

To speed up the calculation of metal structures and PV mounting for your solar power plant, prepare:

• a brief project description (object type: ground or roof, region, PV plant capacity);
• a plan or layout of the site/roof with dimensions;
• solar panel type (dimensions, power, layout scheme);
• required tilt angle and panel orientation;
• soil data or roof structure data (if possible — report or drawings);
• planned plant service life and corrosion protection requirements;
• desired production and delivery timelines.

Submit a request for calculation

In your request, specify:

1. Contact details (company, full name, phone, e-mail).
2. City and region of the PV plant location.
3. Object type (ground / roof, roof or soil type, if known).
4. Plant capacity and number of panels.
5. Preferred structure type (fixed / tracking, if applicable).
6. Required service life and coating preferences (galvanizing, painting, combined).
7. Desired production and delivery timelines.

The more accurate the TS, the faster you will receive a substantiated metal structure calculation and be able to include it in the financial model of your solar generation project in Uzbekistan.