Production of PV Mounting Systems for Rooftops and Solar Parks in Uzbekistan

The role of PV mounting in solar projects in Uzbekistan

For engineering companies, EPC contractors, and owners of business centers, PV mounting often looks like a “minor” part of the project. Yet it is the mounting rails, trusses, supports, and connecting elements that determine how long a rooftop or ground-mounted solar plant will actually operate.

In Uzbekistan’s conditions of high insolation, wind loads, and temperature fluctuations, the requirements for metal structures for solar panels are increased. An error in calculation or in the choice of production technology leads to:

• excess metal consumption and higher project cost;
• roof tightness issues;
• deformation of trusses and columns in ground-mounted parks;
• accelerated corrosion and increased service costs.

Therefore, the key focus is not only on the “steel” itself, but also on the technology: how the calculation, material selection, laser cutting, metal bending, welding, and corrosion protection are organized.

Initial data and calculation based on the specification: what matters at the start

Production of PV mounting systems always starts with a technical specification. The completeness of the specification determines the accuracy of the calculation, the final cost, and the lead time.

Critical specification parameters for rooftop systems

For roofs of business centers, warehouses, and industrial buildings, the following are important:

• Roof type: profiled sheeting, standing seam, membrane, concrete, accessible roof, etc.
• Load-bearing capacity of the roof build-up: permissible loads per square meter.
• Tilt angle and orientation: flat or pitched roof, orientation to the cardinal directions.
• Module layout: portrait/landscape, number of rows, service walkways.
• Height and windage limitations: especially in urban areas with wind corridors.

The more accurate these data, the easier it is to optimize the metal structures: select the type of mounting rails, supports, brackets, and roof attachment nodes.

Key specification parameters for ground-mounted parks

For ground-mounted solar parks and fields, other inputs are important:

• Geology and soil type: affects the choice of foundation, piles, or concrete blocks.
• Terrain: flat area, slope, terraces.
• Row layout: spacing between rows, height of the first panel, access for machinery.
• Required tilt angle and possibility of adjustment.
• Operating conditions: open steppe, industrial area, proximity to a road.

Based on the specification, a calculation model is formed: trusses, columns, cross members, diagonal bracing, mounting rails, and fasteners.

Load calculations for rooftop and ground-mounted systems

Load calculation is a key stage that determines the geometry and cross-section of the metal structures.

What loads are considered

For PV mounting in Uzbekistan, the following are usually analyzed:

• Self-weight of the system: panels, rails, trusses, fasteners.
• Wind loads: especially critical for ground-mounted parks and high roofs.
• Snow loads: locally, depending on the region and elevation of the site.
• Installation and operational loads: weight of personnel, equipment, possible impacts.

For rooftop systems, the transfer of loads to the existing building metal structures—beams, purlins, columns—is additionally evaluated.

Specifics of calculations for rooftops

For flat roofs, ballasted or combined solutions are often used, where part of the load is transferred through supports and part through ballast. Important points:

• minimizing point loads on soft roof build-ups;
• preserving watertightness (brackets, bypassing drains, joints, abutments);
• accounting for wind uplift at the edges and corners of the building.

The result of the calculation is the requirements for the cross-section of mounting rails, support spacing, type of brackets, and fasteners.

Specifics of calculations for ground-mounted parks

For ground-mounted parks, the key issue is the stability of trusses and columns under gusty winds and possible uneven soil settlement. The calculation considers:

• height of the lower and upper edges of the panels;
• spacing of columns and their embedment depth or foundation type;
• need for diagonal bracing and struts;
• permissible deflection of rails and trusses.

Accurate calculation helps avoid excessive safety margins that directly increase metal consumption and project cost.

Material selection: carbon steel, aluminum, stainless steel

The material for PV mounting is selected based on a combination of loads, type of facility, service life requirements, and budget.

Steel (carbon steel)

Steel structures are the basic solution for ground-mounted parks and part of rooftop systems:

• high load-bearing capacity with reasonable cross-sections;
• predictable behavior in harsh wind conditions;
• convenience for welding and bolted connections.

Steel is most often used for trusses, columns, supports, and load-bearing frames. A mandatory condition is high-quality corrosion protection suitable for Uzbekistan’s climate.

Aluminum systems

Aluminum is in demand primarily on roofs of business centers and warehouses, where the following are important:

• reducing the load on the building’s existing metal structures;
• neat appearance and compatibility with architecture;
• ease of installation (lower weight, bolted connections).

Aluminum mounting rails and profiles are often combined with steel supports and brackets.

Stainless steel

Stainless steel is used selectively—for nodes where durability and resistance to aggressive environments are critical:

• fasteners near ventilation exhausts;
• nodes near chemical or food production facilities;
• individual parts where maintenance is difficult.

Fully “stainless” systems are used less often due to cost, but stainless elements in combination with galvanized steel or aluminum can increase the service life of the structure.

Technological chain: from blanks to finished assemblies

Production of PV mounting systems is not just metal stock and bolts. A well-tuned technological chain is important.

1. Preparation and cutting of blanks

At this stage, the geometry of future elements is formed:

• laser cutting of sheet and profile metal for brackets, plates, connecting parts;
• mechanical cutting and sawing of profiles for rails and trusses;
• optimization of cutting patterns to reduce waste.

Accurate laser cutting makes it possible to obtain holes, slots, and chamfers that ensure precise assembly and repeatability.

2. Metal bending and profile forming

The next step is metal bending on press brakes and roll forming machines:

• forming Z, C, and U profiles for rails and truss elements;
• bending brackets for a specific roof or column type;
• creating stiffening ribs without increasing metal thickness.

Well-designed bending allows reducing the weight of the structure without losing stiffness.

3. Welding and assembly of nodes

Depending on the project, the following are used:

• welded assemblies (base plates, embedded parts, truss elements);
• bolted and combined connections for mounting rails and adjustable supports.

Welding must be technologically coordinated with subsequent corrosion protection: preparation for galvanizing, weld cleaning, geometry control.

4. Machining and preparation for coating

Before applying protective coatings, the following are performed:

• edge and weld cleaning;
• removal of scale and contaminants;
• inspection of holes for bolts and self-tapping screws.

The quality of preparation directly affects the service life of the coating and corrosion resistance.

5. Corrosion protection and final kitting

The final stage is the application of protective coatings (see next section) and kitting:

• sorting parts by assemblies and positions;
• packaging for transportation to the site (especially relevant for remote parks);
• marking for convenient installation by the EPC contractor.

Corrosion protection for Uzbekistan’s climate

Uzbekistan’s climate is a combination of high solar radiation, temperature fluctuations, and locally increased dustiness. For PV mounting, this means higher requirements for metal protection.

Basic approaches to steel protection

For steel elements, various options are used:

• hot-dip galvanizing—creating a thick zinc layer over the entire surface of the part;
• combined systems: zinc + paint coating;
• powder coating on a prepared surface.

The choice depends on the type of facility, expected service life, and budget.

Powder coating in PV projects

Powder coating is often used:

• for elements in the visible zone (roofs of business centers, façade areas);
• for additional protection in urban environments;
• for color marking of nodes and zones (maintenance, safety).

It is important to consider that powder coating is effective with proper surface preparation and adherence to the application process.

Specifics for aluminum and stainless steel

• Aluminum profiles can be used with a natural oxide film or with additional treatment/coating.
• Stainless steel is inherently more corrosion-resistant, but requires careful handling during welding and machining so as not to reduce its properties.

What affects the cost of PV mounting: key factors

The final cost of PV mounting is formed from several groups of parameters. Below is a generalized table of factors.

Therefore, without a detailed specification and calculation, it is incorrect to quote an exact price: a change in any factor can significantly affect the final cost.

Typical mistakes when ordering and designing mounting systems

Below are common mistakes that lead to higher costs or problems during installation.

1. Incomplete roof specification
   Roof covering type, abutment nodes, and load limitations are not considered. As a result, the project has to be reworked or the mounting is modified on site.

2. Ignoring actual wind conditions
   Averaged data are used without considering local specifics (open steppe, industrial zone, high-rise buildings). This leads either to excess metal consumption or to stability risks.

3. Material selection “by habit”
   For example, steel where aluminum would be more rational, or vice versa. The result is either excessive weight or unjustified budget growth.

4. Underestimating corrosion protection
   Attempts to save on coating lead to accelerated corrosion and higher maintenance costs.

5. Lack of node unification
   Too many unique parts are designed for a single facility. This complicates production and increases lead times and cost.

6. Late involvement of the manufacturer
   The metalwork contractor is brought in only after the layout is approved. As a result, some solutions have to be changed to match real technological capabilities.

7. Insufficient adjustment allowances
   Lack of adjustable elements for height and angle complicates installation on uneven roofs and soils.

Working with the manufacturer at the concept and specification-calculation stage helps avoid most of these problems.

Production and logistics timelines for facilities in Tashkent and the regions

Timelines depend on volume, complexity, and production workload, but there is a typical logic that should be considered when planning a project.

Stages affecting timelines

• Specification refinement and calculation: from a few days for standard solutions to several weeks for complex geometry.
• Design and issue of working drawings: detailing of trusses, rails, supports, brackets.
• Tooling and program preparation: for laser cutting, metal bending, welding fixtures.
• Series production: cutting, bending, welding, preparation for coating.
• Corrosion protection: galvanizing, powder coating, curing.
• Kitting and logistics: packaging, marking, delivery to the site.

For facilities in Tashkent, it is easier to organize phased deliveries synchronized with installation. For remote parks in the regions, it is important to plan packaging and shipment sequence in advance.

How to work with contract manufacturing and non-standard solutions

For many engineering companies and EPC contractors, it is more profitable to outsource PV mounting production to contract manufacturing while retaining design and overall responsibility for the facility.

Interaction format

• Transfer of specification and design data on loads and geometry.
• Joint development of structural solutions: types of rails, trusses, supports, attachment nodes.
• Preparation of working documentation tailored to real technological capabilities (laser cutting, bending, welding, powder coating).
• Production of a pilot batch or prototypes for on-site testing.
• Transition to series production with cutting optimization and node unification.

Benefits for the customer

• reduced in-house production load;
• access to established technologies and equipment;
• ability to quickly scale volumes as the project portfolio grows.

FAQ on PV mounting for rooftops and ground-mounted parks

1. Can the same type of mounting be used for both roofs and ground-mounted parks?
As a rule, no. Requirements for loads, types of supports, and attachment to the base differ. Unification of individual elements (bolts, clamps, some rails) is possible, but the main metal structures are designed separately.

2. What determines the choice between steel and aluminum?
The load-bearing capacity of the base, weight requirements, budget, and expected service life. For lightweight roofs, aluminum combined with steel attachment nodes is more common; for ground-mounted parks, steel trusses and columns are typical.

3. Is it possible to estimate the cost in advance without a detailed specification?
Only a very rough order of magnitude can be given. For an accurate cost estimate and metal optimization, initial data on the facility, loads, and panel layout are required.

4. How critical is corrosion protection in our climate?
It is critical. High insolation, temperature fluctuations, and dust accelerate corrosion processes. Saving on metal protection reduces the service life of the structure and increases operating costs.

5. Can existing foreign solutions be adapted to local production?
Yes, this is often a rational approach: profiles are adapted to available metal stock, thickness, coating type, and manufacturing technology are adjusted to reduce cost and simplify logistics.

6. How to account for future park expansions when designing mounting systems?
At the calculation stage, standard modules of trusses and rails are laid out, which can then be replicated. It is important to unify nodes from the outset and provide a logical grid for column spacing.

7. Is it mandatory to perform load calculations for small rooftop plants?
Yes, even for small systems it is important to understand how loads are transferred to the roof and the building’s load-bearing metal structures. This is a matter not only of service life but also of safety.

8. Can different types of coatings be combined on one facility?
Technically possible, but it complicates production and logistics. Usually it is more rational to choose a single approach, using combined solutions selectively—for highly loaded or visible zones.

How to request a PV mounting calculation: what data to prepare

To obtain a technically sound calculation and a proposal on production timelines, it is important to prepare a basic data package.

Submit a calculation request

Recommended set of initial information:

1. Type of facility: roof (business center, warehouse, industrial building) or ground-mounted park.
2. Location: city/region, local specifics (open area, industrial zone, urban block).
3. Plant area and capacity: approximate number of panels or kW.
4. Module layout: portrait/landscape, number of rows, plan or sketch.
5. Type of base: roof build-up (layers, covering) or soil/foundation data for ground-mounted parks.
6. Required system service life and maintenance constraints.
7. Preferred materials (if any): steel, aluminum, combined solutions.
8. Corrosion protection preferences: basic level, enhanced protection, presence of powder coating.
9. Expected commissioning date and delivery schedule (single shipment or phased).
10. Interaction format: one-off project or series of facilities, contract manufacturing.

The more accurate the initial data, the more efficiently PV mounting can be designed, metal consumption optimized, the right technology selected (laser cutting, metal bending, welding, powder coating), and realistic timelines proposed for your facility in Tashkent or other regions of Uzbekistan.