I. Market Overview: Distributed PV Drives Demand for Ballasted Racking

Driven by the global energy transition and the “dual carbon” goals, distributed PV power generation has entered a phase of rapid development. In 2024, the global PV racking market size is estimated to reach RMB 117.7 billion, with tracker racking showing particularly strong growth. As an important sub-category of fixed racking, ballasted roof racking is now entering a rapid growth window.

The ballasted PV racking system market was valued at approximately USD 2.1 billion in 2024 and is projected to reach USD 5.6 billion by 2033. Growth drivers come from three main aspects: first, the urgent global demand for clean energy drives substantial growth in rooftop PV installations; second, commercial and industrial users have strong demand for low-cost, high-efficiency distributed generation solutions; third, supportive policies for distributed PV in various countries provide a favorable development environment.

The rooftop PV installation market was valued at about USD 13.5 billion in 2024 and is expected to reach USD 26.5 billion by 2032, with a CAGR of 8.3%. Distributed PV is becoming the core force driving growth in rooftop PV installations.

In the Chinese market, distributed PV development policies continue to release dividends. In January 2025, the National Energy Administration issued the “Distributed PV Power Generation Development and Management Measures,” which divides distributed PV into four types: residential (natural person), residential (non-natural person), general commercial & industrial, and large commercial & industrial. The measures clarify access methods and grid integration models for each type, providing clear policy guidance for rooftop PV project development. Local governments have also successively introduced supporting policies encouraging whole-town and whole-village distributed PV development in qualified towns and villages.

II. Product Innovation and Technological Breakthroughs in 2024

In 2024, multiple global PV racking companies launched new-generation ballasted roof mounting systems, achieving important breakthroughs in product design, material application, and certification standards.

2.1 Aerocompact S_Base: Simplifying Commercial Rooftop PV Installation

In October 2024, at the RE+ 2024 exhibition in Anaheim, USA, Austrian PV racking manufacturer Aerocompact officially launched its latest flat-roof racking system, the S_Base. Designed specifically for commercial and industrial roofs, the system consists of only four core components – a lightweight aluminum ballast tray, a post, a wind deflector, and a module clamp.

The S_Base’s biggest highlight lies in its efficient logistics and installation design: one standard pallet can hold 144 ballast trays, enough to support 120 commercial PV modules (approximately 60 kW system). The entire bill of materials for a 120-module system includes only 9 major categories and about 1,700 parts. The S_Base ballast tray measures 32.87 inches × 16.57 inches and weighs only 2.8 pounds, with a load of 0.74 pounds per square foot. Its larger surface area allows it to more effectively support and distribute ballast on the roof, accommodating up to six 34-pound ballast blocks or 12 half-blocks.

Additionally, Aerocompact launched the Aerotool.CAD online design tool, an AutoCAD plugin supporting 3D layout visualization, shadow simulation integrated with PVSyst, ballast calculations based on wind, snow, and seismic factors, and seamless configuration of cables and inverters. The company also announced plans to begin producing rooftop components in the United States in 2025 to comply with Inflation Reduction Act domestic content tax credit requirements.

2.2 DCE Solar Eco-Top: UL 3741 Safety Certification

In August 2024, US PV racking manufacturer DCE Solar announced that its Eco-Top rooftop PV mounting structure had successfully obtained UL 3741 certification, meeting NEC 2020 standards. Designed for commercial and industrial roofs, the system uses recyclable rubber ballast pads and minimizes roof loading through optimized aerodynamics and structural performance.

The Eco-Top system’s core advantage is its cost-effectiveness: compared to traditional solutions, the system requires five times fewer mechanical connectors and ballast blocks, saving USD 0.03 to 0.06 per watt in material and labor costs. The system offers two main configurations – Eco-Top High Density (20% capacity increase) and Eco-Top-MR for metal roofs. All structural components are manufactured from G115 galvanized steel. The integrated wind deflector also functions as a ballast tray, featuring built-in vibration resistance and integrated grounding connections, with nuts coated with a wax layer to prevent wear.

2.3 Sollega FastRack510: Lightweight Plastic Racking in Cooperation with BASF

In April 2024, Sollega partnered with global plastic supplier BASF to launch the FastRack510 (FR510), a new-generation lightweight ballasted hybrid roof mounting solution. Manufactured using BASF’s Ultramid® engineering plastic, the racking weighs only 4.5 pounds yet can withstand loads more than 200 times its own weight.

The FR510 features an integrated, stackable design that greatly simplifies project logistics – half a megawatt of racking materials can be loaded into one standard 40-foot shipping container. The system supports tilt angles of 5 and 10 degrees, is compatible with any type of module, and arrives pre-assembled, significantly reducing on-site installation costs and time. The Ultramid® glass-reinforced nylon contains built-in UV inhibitors and has demonstrated over 40 years of durability in demanding automotive applications, ensuring long-term strength in rain, chemicals, sunlight, and vibration environments.

2.4 Enerack Ballasted-Ult: East-West Integrated Rear Leg Racking

Chinese PV racking manufacturer Enerack released the Ballasted-Ult east-west integrated rear leg racking system in April 2024. The system supports tilt angles of 10 to 15 degrees, is manufactured from AL6005-T5 aluminum alloy and EPDM material with an anodized surface finish, and is equipped with 304 stainless steel clamps.

Designed for concrete flat roofs or trapezoidal metal sheet roofs, the system improves efficiency and convenience through simplified installation steps, effectively reducing overall project costs. The east-west integrated rear leg design reduces the number of installation parts, making installation faster and more convenient.

2.5 Grace Solar BM4: Highly Adaptable Ballasted Racking

In January 2024, at the Open Energies 2024 exhibition in Lyon, France, Grace Solar launched its new-generation BM4 ballasted racking system. The system offers excellent flexibility, is suitable for flat roofs with some slope requirements, features strong compatibility without damaging the roof structure, enables more convenient installation, and precisely adapts to European building characteristics and market demands.

2.6 K2 Systems Dome Zero: Ultra-Low Installation Height System

K2 Systems’ Dome Zero system was successfully installed on the roof of a residential building in Malmö, Sweden, with a 90 kWp PV system using 216 PV modules. The system features a 0° tilt design, keeping modules parallel to the roof surface at an extremely low installation height, making the modules as concealed as possible against the roof. It requires relatively low ballast, making it particularly suitable for roofs with limited load-bearing reserves. The project generates approximately 70,000 kWh of electricity annually, with a payback period of only four years.

III. Chinese Companies’ Patent Breakthroughs and Market Performance

In 2024, Chinese PV racking companies achieved multiple patent results in the field of ballasted roof racking, demonstrating strong technological innovation capabilities.

3.1 Zhangzhou Jingzhao Technology: Adjustable Ballast Foot Component Patent

In December 2024, Zhangzhou Jingzhao Technology Development Co., Ltd. obtained a patent titled “A Roof Ballasted PV Racking and Roof PV Panel System” (Patent Authorization Announcement No. CN 222127984 U). The core innovation of this patent lies in the design of the first adjustable ballast foot component and the second adjustable ballast foot component, achieving vertical adjustability of the first panel pressing component through the cooperation of bolts and threaded holes, enabling adjustable adaptive installation of PV panels of different specifications and thicknesses.

3.2 Guangdong Powerway New Energy: Lightweight Double-Slope Symmetrical Design

In September 2024, Guangdong Powerway New Energy Co., Ltd. obtained a patent for “A Convenient Lightweight Ballasted PV Racking” (Patent Authorization Announcement No. CN221669775U). This patent adopts a double-slope symmetrical structural design of two PV panels and the bottom beam, creating a relatively enclosed space for the entire PV racking system. This effectively reduces the shape coefficient of wind forces, lowers wind loads, significantly improves the stability of the PV racking, and prevents overturning accidents. Additionally, this design makes full use of limited roof space, solving the problems of poor wind resistance and easy overturning found in traditional PV racking.

3.3 Skyworth PV: Ballast Block Fixation Solution

In August 2025 (patent application date September 2024), Skyworth PV obtained a patent for a flat-roof PV ballasted racking structure and system. This solution fixes the racking onto the roof by inserting ballast blocks through the racking components, relying on the weight of the ballast blocks themselves. This avoids both the problem of drilling holes and damaging the roof waterproof layer and eliminates on-site drilling steps, making installation more convenient and improving installation efficiency.

IV. Companies’ Global Market Presence

In 2024, Chinese PV racking companies accelerated their global expansion, actively promoting ballasted roof racking products in major PV markets worldwide.

4.1 Mibet: Global Exhibitions and Large-Scale Projects

In 2024, Mibet showcased its ballasted roof racking products at multiple international exhibitions. At the SNEC Shanghai exhibition in June, Mibet exhibited its S10 flat-roof matrix system, which features a full wind-deflector structure. Some connections utilize a fixture-limited installation method to improve efficiency, while three ballasting methods are provided to adapt to installation needs in different environments.

In September, Mibet brought its full range of racking systems to the Solar & Storage Live UK exhibition. Among them, the S10 full wind-deflector matrix system, which can be installed on flat roofs without penetration, was well received by foreign customers due to its multi-sided wind protection, short-side module fixation, high degree of factory assembly, and flexible ballasting options. At the same time, fixture-limited components allow tool-free installation of system connectors, improving on-site installation efficiency.

In October, Mibet exhibited at the All-Energy Australia exhibition. The flat-roof matrix ballasted system uses a non-penetrating installation method. The selected aluminum profiles are lightweight and highly corrosion-resistant. The system distributes weight using concrete ballasting to reduce roof loading, combines wind deflectors to improve wind resistance, and adapts to various module types on the market.

In terms of large-scale projects, Mibet provided a 22 MW flat-roof matrix ballasted system to Fujian Fuqing BOE Technology Group. The project covers approximately 170,000 square meters of roof area and generates an average of about 23 million kWh of electricity annually. The system incorporates wind deflector design to withstand typhoons up to Category 14, uses non-penetrating installation, secures the racking on the roof using matrix arrangement and concrete ballasting, and selects high-quality anodized aluminum for both lightweight and stability characteristics.

4.2 Kesun New Energy: Full-Scenario Racking Solutions

In August 2024, Kesun New Energy exhibited five major PV racking solutions at the 16th Guangzhou International Solar Photovoltaic & Energy Storage Exhibition, including rooftop ballasted PV racking solutions, covering both rooftop and ground application scenarios, precisely targeting domestic and international PV market demands.

V. Standards and Certification System Development

In 2024, the PV racking industry made important progress in standards system development.

Regarding safety testing, the anti-overturning performance test of ballasted racking is particularly critical. Testing must comply with national and international standards such as the GB/T 19115 series and IEC 62446. From a quality and safety perspective, it ensures the anti-overturning performance of the racking; from a compliance certification perspective, it meets standard requirements; from a risk control perspective, it prevents overturning accidents caused by wind loads, snow loads, or improper installation. Test items cover structural stability, material properties, mechanical properties, wind load simulation, snow load simulation, ballasting systems, connectors, corrosion protection performance, fatigue life, and multiple other dimensions.

Regarding overseas market access, Chinese PV racking companies face different national