Estimate of the metal package for a solar power plant

The role of a comprehensive metal package in the economics of a solar power plant

For an industrial solar power plant in Uzbekistan, the metal package is not just the supports for the panels. It is a set of metal structures that determine:

• capital expenditures (CAPEX) for the construction of the PV plant;
• installation speed and commissioning time;
• reliability of the plant’s operation in the climate of Tashkent and the regions;
• ease of maintenance and personnel safety.

A properly prepared estimate for a comprehensive metal package (supports, trusses, cable trays, service walkways) allows the developer and EPC contractor to:

• compare layout and material options;
• manage the budget without losing reliability;
• plan the delivery and installation schedule in advance;
• minimize design changes on site.

BRIX.UZ works with metal structures and PV mounting as a single package: from calculation according to the technical specification to custom manufacturing and delivery to the site.

What the metal package for a PV plant consists of

A comprehensive metal package for a ground-mounted or rooftop solar power plant usually includes several groups of products.

Supports and load-bearing frame for solar panels

• Vertical supports (posts) for ground-mounted plants.
• Trusses and beams forming the frame of a canopy or open rows.
• Transverse and longitudinal rails for mounting modules (PV mounting rails).
• Brackets and embedded parts for fastening to the roof or concrete foundations.

For tracker systems, the requirements for metal structures are higher: additional elements of the rotation mechanism, reinforced joints, and increased requirements for geometric accuracy.

Cable trays and supporting structures for cables

• Perforated and solid cable trays.
• Brackets and hangers for fastening trays to supports or canopy structures.
• Transitions and branches of trays between rows and to inverter stations.

Proper design of cable routes affects not only the cost of metal, but also installation and maintenance costs.

Service walkways, ladders and platforms

• Walkways between rows or above cable routes.
• Ladders and ramps for access to equipment.
• Small service platforms for servicing inverters, switchgear cabinets, etc.

These elements are often underestimated at the concept stage, but they are the ones that ensure safe access and affect operating costs.

What data is needed for the estimate: basic list for the technical specification

The accuracy of the estimate directly depends on the quality of the technical specification. To calculate the metal package according to the technical specification, the metal structure manufacturer usually needs:

1. Type and configuration of the plant

   • ground-mounted, rooftop, carport;
   • fixed frames or trackers;
   • single-post/double-post rows, installation height.

2. Layout and characteristics of the modules

   • number and size of solar panels in a row;
   • orientation (portrait/landscape);
   • spacing between rows, row length.

3. Site engineering conditions

   • soil type (for selecting foundation and support solutions);
   • wind and snow loads according to the project;
   • presence of slope, terrain features.

4. Requirements for materials and corrosion protection

   • black steel with hot-dip galvanizing;
   • galvanized rolled steel;
   • stainless steel for individual joints or cable trays;
   • powder coating in addition to zinc (if required).

5. Scope and format of supply

   • total installed DC capacity (MW);
   • phased or one-time delivery of the metal package;
   • need for pre-assembly of joints.

6. Requirements for installation and logistics

   • delivery location (Tashkent or region);
   • dimensional and weight restrictions for transportation;
   • availability of lifting equipment on site.

The more detailed the technical specification, the lower the risk of revising the estimate during the project.

Materials and technologies: how the choice affects cost and lead time

Materials for metal structures

1. Black steel with galvanizing

   • Often optimal in terms of price/service life for supports and trusses.
   • Affects the estimate through metal weight, galvanizing cost and logistics to the galvanizing plant.

2. Galvanized rolled steel

   • Used for mounting rails, cable trays, light elements.
   • Allows shortening lead times due to the absence of a separate hot-dip galvanizing operation.

3. Stainless steel

   • Used selectively: fasteners, individual tray sections, elements in aggressive environments.
   • Significantly increases the unit cost of the product, but can reduce operating costs.

4. Powder coating

   • Additional protection and aesthetics (relevant for visible areas, carports, B2G projects).
   • Affects the estimate due to the cost of surface preparation and painting, as well as increased lead times.

Manufacturing technologies

• Laser cutting — precise geometry, consistent quality of holes and chamfers, minimal rework during installation.
• Metal bending — reduces the number of welds, lightens structures, shortens installation time.
• Welding — forming trusses, support joints, walkways; welding labor intensity directly affects price.
• Machining and CNC — for precise seats, flanges, tracker system elements.

The choice of technology combination is a balance between cost, accuracy and lead time. For large PV plants in Tashkent and the regions of Uzbekistan, a combination of laser cutting, bending and serial welding of standard joints is often optimal.

Table: key price factors by metal package element

The final estimate is formed as the sum across product groups, taking into account volume, manufacturing technology, logistics and possible installation.

Lead times for manufacturing and supplying the metal package in Tashkent

Lead times depend on volume, complexity and production workload, but they can be influenced already at the technical specification and estimate stage.

What usually affects lead times:

• Degree of standardization of elements: the more repeating parts, the faster serial production goes.
• Availability of ready 3D models and drawings: saves engineers’ time.
• Choice of technologies: laser cutting and bending speed up the cycle compared to manual rework.
• Need for hot-dip galvanizing: adds logistics and technological time buffer.
• Phased shipment: allows installation to start before the entire metal package is ready.

When calculating according to the technical specification at the estimate stage, it is advisable to immediately agree on an indicative schedule:

• lead times for design documentation (KM/KMD) if done by the manufacturer;
• start and end dates of serial production;
• shipment schedule to the site.

Typical mistakes when preparing the technical specification and estimate for PV metal structures

1. Incomplete data on loads and soils

Lack of clear initial data leads to excessive metal safety margins or to project revision after the first on-site tests.

2. Ignoring cable routes at an early stage

Cable trays and their supports are often added “at the end”, which increases cost and complicates installation. It is better to include routes in the metal package from the start.

3. Too many unique sizes

Each new profile type, length or joint increases cost and lead time. When calculating according to the technical specification, it makes sense to standardize solutions for rows and walkways.

4. No installation requirements in the technical specification

If you do not specify restrictions on equipment, assembly and lifting conditions, you may end up with structures that are inconvenient or expensive to install.

5. Underestimating service walkways and ladders

Trying to save on these elements, the developer faces access problems and additional work after the plant is commissioned.

6. Lack of coordination of materials and protective coatings

Combining different types of steel and coatings without a well-thought-out scheme can lead to localized corrosion and complicate logistics and storage.

7. Requesting an estimate without a clear scope

Phrases like “approximately for 10 MW” without a module layout and list of structures provide only a very rough estimate, unsuitable for investment decisions.

How to organize cooperation with the metal structure manufacturer

To make the metal package estimate a working tool rather than an indicative figure, it is important to organize interaction according to a clear scenario.

1. Transfer of initial data

   • Master plan and module layout.
   • Load and material requirements.
   • Preliminary list of metal products.

2. Engineering elaboration

   • Analysis of the technical specification and optimization proposals (standardization, change of cross-sections, choice of technologies).
   • If necessary, development or adjustment of KM/KMD.

3. Estimate calculation according to the technical specification

   • Breakdown by product groups: supports, trusses, rails, trays, walkways, ladders.
   • Linking to delivery stages and possible material options.

4. Coordination of options

   • Comparison of several solutions in terms of metal consumption and lead times.
   • Selection of the base option for the contract.

5. Contract manufacturing and supply

   • Launch of serial production according to the approved documentation.
   • Quality control at the stages of cutting, bending, welding, painting.
   • Shipment to the site according to the approved schedule.

BRIX.UZ can join both at the concept stage and at the stage of detailed elaboration of the metal package for a PV plant.

FAQ on the estimate and calculation of the metal package for solar power plants

1. Is it possible to get a rough estimate without a complete technical specification?
Yes, but it will be a rough estimate based on aggregated indicators (tonnage per MW, plant type). For investment decisions and contract signing, a calculation based on a detailed technical specification is required.

2. What has the greatest impact on the cost of the metal package?
Loads and spans, choice of materials (black steel, galvanized, stainless), batch volume, complexity of joints (amount of welding), coating and logistics requirements.

3. Is it possible to optimize the estimate without changing the plant capacity?
Often yes. Through standardization of sizes, changing truss schemes, choosing other profiles, revising solutions for cable routes and service walkways.

4. How should installation be accounted for in the metal package estimate?
Installation can be included as a separate line item if performed by the same contractor. For an accurate estimate, data on the site, available equipment and work schedule are needed.

5. What if there are no ready drawings of metal structures?
Provide the plant layout, module arrangement schemes and load requirements. The manufacturer’s engineers can prepare the necessary documentation for calculation and production.

6. How are cable trays accounted for in the estimate?
As a separate section: route length, tray type (perforated/solid), width, presence of covers and branches, number of brackets and hangers.

7. How far in advance should the metal package be included in the project schedule?
It is advisable to synchronize the development of metal structures with the plant design. This helps avoid delays due to galvanizing, painting and logistics of large batches.

8. Is it possible to combine different materials in one project?
Yes, this is a common approach: load-bearing supports made of black steel with galvanizing, rails and trays from galvanized rolled steel, individual elements from stainless steel. It is important to agree on such a scheme in the technical specification in advance.

What a calculation based on the technical specification at BRIX.UZ provides and how to request it

A calculation based on the technical specification for a comprehensive metal package allows you to:

• see the cost structure by product groups;
• compare material and technology options;
• assess the impact of project changes on budget and lead times;
• plan phased deliveries according to the PV plant construction schedule.

BRIX.UZ works with developers and EPC contractors in Tashkent and the regions of Uzbekistan, offering custom manufacturing of a full set of metal structures: supports, trusses, mounting rails, cable trays, service walkways, ladders, fencing.

Checklist of data for requesting a metal package estimate

To receive a meaningful estimate and lead times, prepare:

1. Brief project description:

   • plant type (ground-mounted/rooftop/carport);
   • installed capacity (MW);
   • region of installation.

2. Schemes and plans:

   • master plan or row layout scheme;
   • inverter and cable route layout (if available);
   • planned service walkways and access zones.

3. Requirements for metal structures:

   • materials (black steel with galvanizing, galvanized rolled steel, stainless steel);
   • protective coatings (galvanizing, powder coating);
   • special corrosion resistance requirements.

4. Engineering data:

   • design wind and snow loads;
   • soil data (for supports);
   • dimensional and weight restrictions for delivery to the site.

5. Work organization:

   • indicative construction schedule;
   • need for phased shipment;
   • need for installation by the manufacturer.

Submitting a request for calculation

To receive an estimate for a comprehensive metal package for your solar power plant, send a request via the form on the BRIX.UZ website or through the sales department contacts.

Specify in the request:

• project name and region;
• plant type and installed capacity (MW);
• brief layout description (ground-mounted/roof/carport, fixed/tracker);
• requirements for materials and protective coatings;
• availability/lack of ready drawings (KM/KMD);
• planned start dates for installation and commissioning;
• need to include in the calculation: supports, trusses, mounting rails, cable trays, service walkways, ladders, fencing;
• contact details for feedback.

Based on your technical specification, BRIX.UZ engineers will prepare a metal package calculation taking into account volume, selected materials, manufacturing technologies and the planned construction schedule.