🛠️ 2024 Product & Technology Core Trends

Ballasted system development in 2024 focused on the following directions:

Extreme installation convenience: Tool‑free installation and highly pre‑assembled “plug‑and‑play” designs became mainstream. For example, AEROCOMPACT‘s S_BASE system uses a click‑fit “snap‑in” installation requiring no tools. Its optimised pallet design allows a single standard pallet to hold 144 base plates – enough to support up to 120 modules – significantly improving logistics and installation efficiency.

Lightweight materials: The industry widely adopted high‑strength lightweight aluminium alloys, combined with lightweight designs to reduce roof loading. For instance, a patent from Zhangzhou Jingzhao Technology uses adjustable pressure‑foot components to adapt to different module thicknesses, enhancing system versatility. AEROCOMPACT also emphasised that its new system‘s base plates are lightweight, helping to save storage, transport and installation costs.

Improved wind resistance and safety: Wind deflectors were widely adopted to enhance wind resistance. For example, Mibet‘s full‑wind‑deflector matrix ballasted system S10 uses multi‑faceted wind deflection and short‑side module fixation to improve system stability. Some products achieved critical third‑party safety certifications: DCE Solar‘s Eco‑Top system obtained UL 3741 certification, demonstrating compliance with NEC 2020 and, under qualifying conditions, eliminating the need for module‑level rapid shutdown devices (MLPE), thereby reducing system cost. Additionally, a patent from Guangdong Powerway New Energy uses a dual‑slope symmetrical structure to reduce wind loads, while Zhangzhou Jingzhao‘s patent enhances versatility through adjustable pressure‑foot components.

Digital system integration: Supporting design software became a key tool for improving efficiency and accuracy. AEROCOMPACT‘s AEROTOOL.CAD plugin enables 3D layout, shading simulation, ballast calculation under wind and snow loads, and one‑click generation of detailed bills of materials (BOM) directly within the AutoCAD environment, greatly simplifying engineering design.

📈 2024‑2025 Market Dynamics & Project Cases

In 2024, ballasted mounts were widely adopted across various project types, with expanding application scenarios.

Commercial & industrial roofs: This remains the most mature and common application for ballasted mounts. DCE Solar‘s Eco‑Top ballasted system, designed for C&I roofs, uses recycled rubber ballast pads and minimises roof loading through aerodynamic and structural performance.

Distributed PV projects: The technology was widely used in distributed PV projects in China, ranging from large logistics centres to schools. For example, a 200 kW distributed PV carport project at Wuhu Port in Anhui Province used ballasted mounting.

Residential projects: Ballasted systems are also favoured in residential settings because they do not penetrate the roof. In Portugal, Sun Ballast‘s system was used on a 27 kW residential flat‑roof project, achieving fast, non‑penetrating installation.

Large‑scale installation evidence: AEROCOMPACT demonstrated that its S_BASE 5° version can build systems with 3,000 modules and the 10° version with 2,100 modules, showing the technology‘s efficient deployment capability in large commercial projects.

📊 2024‑2025 Representative Product Specifications Overview

To illustrate the technical parameters of mainstream ballasted systems in 2024, here is a comparison of selected products:

🏛️ Intellectual Property Landscape (2024 Chinese Patent Developments)

In 2024, Chinese companies were highly active in patent filings for ballasted mounts, reflecting accelerating technological innovation.

September 2024: Guangdong Powerway New Energy obtained a patent for a “convenient lightweight ballasted PV mount”, using a “dual‑slope symmetrical” structure to reduce wind loads and improve wind stability.

November 2024: China Railway Xi‘an Survey, Design and Research Institute filed a patent for a “heavy‑duty profiled steel sheet roof sliding mount”, optimised for specific roof structures.

December 2024: Zhangzhou Jingzhao Technology Development Co., Ltd. obtained a patent for a “roof ballasted PV mount and roof PV panel system”, featuring an adjustable design that accommodates different module thicknesses, enhancing product versatility.

August 2025: Shenzhen Skyworth PV Technology Co., Ltd. obtained a patent for a “flat roof PV ballasted mount structure and system”, whose core advantage is avoiding roof penetrations that could damage the waterproof membrane – aligning with the mainstream trend toward non‑penetrating installation.

💡 Challenges & Future Directions

Core challenges: Despite significant technical progress, ballasted systems still face two main challenges: (1) the complexity of wind load calculation, especially in high‑wind regions where wind tunnel testing is required to verify structural stability, increasing design costs; (2) roof load limitations, particularly on older buildings where additional ballast weight may be a constraint.

Market growth: Market data show that the global solar panel mounting structure market was valued at approximately RMB 7.41 billion in 2024, and is projected to grow steadily at a CAGR of 4.4%. Ballasted mounts, as an important segment, have significant growth potential, especially in commercial & industrial distributed PV.

Regulatory drivers: With the spread of safety certifications such as UL 3741 and related policies, future market requirements for safety, reliability, and certification will continue to increase, likely accelerating industry consolidation and giving technologically leading manufacturers a competitive advantage.