I. Introduction

In 2022, the global photovoltaic industry continued to develop rapidly amid the wave of energy transition. Ballasted solar mounting systems, as one of the mainstream solutions for flat-roof PV installation, gained significant traction in the commercial and industrial distributed PV sector due to their core advantage of "no penetration, no damage to the roof waterproofing membrane." By securing PV arrays on flat roofs using the weight of concrete ballast blocks or cement foundations without drilling or penetrating the roof, these systems provide an efficient and safe solution for large-scale rooftop PV deployment while preserving the integrity of the building structure.

From product innovations to large-scale project completions, and from industry trends to technical standards, ballasted mounting systems saw important milestones both domestically and internationally in 2022. The following is a compilation of real news from that year.

II. New Product Launches: Accelerated Technological Iteration

2.1 AEROCOMPACT Launches Mounting System for Bifacial PV Modules and Green Roofs

On October 14, 2022, Austrian PV mounting manufacturer AEROCOMPACT officially launched the COMPACTFLAT GS, a flat-roof mounting system specifically designed for green roofs and bifacial PV modules. The system positions modules approximately 40 cm above the roof, leaving sufficient light for plants on green roofs while facilitating easy maintenance. Markus Burger, Development Manager at AEROCOMPACT, stated: "The plants receive sufficient light and can be easily maintained."

A key technical highlight of the system is its optimization for bifacial PV modules. Independent laboratory tests confirmed that when installed on light-colored reflective roof surfaces, bifacial modules can increase power generation by up to 20% through reflected light. Philipp Pejcl, Product Manager at AEROCOMPACT, noted: "Bifacial modules are increasingly replacing conventional foil modules. The high clearance of our new system improves the reflection effect and ensures higher energy yields."

In terms of installation, the COMPACTFLAT GS offers two tilt angles: the COMPACTFLAT GS15 with a 15-degree tilt for south-facing systems, and the COMPACTFLAT GS10PLUS with a 10-degree tilt for east-west facing systems. The system can be installed on foil roofs, bitumen roofs (with or without insulation beneath the waterproofing layer), concrete roofs, and gravel roofs. Its aerodynamic design requires fewer components and no long rails, enabling quick and easy installation. AEROCOMPACT offers a 25-year warranty for this product, which has been integrated into its planning and engineering tool, AEROTOOL.

In the North American market, AEROCOMPACT showcased the new system for the first time at the RE+ clean energy industry exhibition held in Anaheim, California, from September 19 to 22, 2022.

2.2 Roll-A-Rack Launches Rainwater-Collecting Flat Roof Mounting System

On July 19, 2022, Ohio-based Roll-A-Rack announced the development of an innovative roll-formed solar mounting system capable of collecting precipitation from PV panels and using the rainwater for irrigation. Designed for flat roofs or ground-mounted systems, its compact design requires only 11 inches of row spacing, significantly reducing the erosion control space required by traditional vegetation methods. The company stated that this solution generates the same amount of energy using only half the land compared to conventional racking systems.

The core innovation lies in its roll-forming installation equipment, operating similarly to gutter installation machinery. It is particularly suited for membrane flat roofs – a roof type traditionally difficult to equip with PV arrays because penetrations would compromise roof integrity. To avoid damaging the structural integrity of membrane roofs, the company installs 12-inch metal channel brackets distributed among existing roof ballast to secure the solar modules. The brackets can be as thin as 22 gauge (approx. 0.76 mm) and withstand snow loads of 50 psf and wind uplift of 37.5 psf.

From an economic perspective, Roll-A-Rack claims its solution can reduce racking and installation costs by up to 30%, material costs by 50%, and installation time and labor costs by 65% compared to traditional racking systems. The product's development was supported by a Small Business Innovation Grant from the U.S. Department of Energy's Solar Energy Technologies Office. Company President Don Scipione presented the innovation at the Ohio Department of Natural Resources Statewide Floodplain Management Conference held in Columbus, Ohio, on August 24-25, 2022.

2.3 Suzhou Chengkang New Energy Launches Single-Sided Ballasted System

In 2022, Suzhou Chengkang New Energy Co., Ltd. introduced a "single-sided ballasted system" for flat roofs. This completely innovative design reduces the number of components and the overall weight of the single-sided ballasted system, better accommodates east-west orientation variations, while ensuring the same power output from the solar system, achieving a balance between lightweight construction and power generation efficiency.

III. Large-Scale Project Completions: Notable Performance in the Chinese Market

3.1 Largest Single Distributed PV Power Plant in Fujian Province Grid-Connected (Zhengxin Enterprise Project, 30MW)

On August 3, 2022, the Zhengxin Enterprise distributed PV project, for which Mibet provided the mounting systems, was successfully connected to the grid. Located within the Zhengxin Enterprise factory areas in Jimei District and Haicang District of Xiamen City, and Longhai District of Zhangzhou City, Fujian Province, the project had a total installed capacity exceeding 30 MW, making it the largest single distributed PV power generation project in Fujian Province at the time.

For the concrete roof sections, the project utilized Mibet's proprietary matrix ballasted PV system. Through a stable matrix structural design combined with concrete foundations and wind deflectors, the system achieved the required strength and stability, making it suitable for concrete roof PV installations in various regions and geographic conditions. For the metal roof sections, corresponding metal roof clamps (for trapezoidal, standing seam, and angle-fixing profiles) were matched, with pull-out resistance exceeding 1500N, effectively ensuring system strength and stability.

The project provides approximately 41.10 million kWh of electricity annually for the enterprise, reducing CO2 emissions by about 36.75 million tons, delivering significant economic and environmental benefits.

3.2 GRENERGY Supplies 4.5MW Roof Ballasted PV Project for SM Group in the Philippines

On December 20, 2022, GRENERGY announced that it had provided the exclusive PV mounting solution for three SM Group shopping malls in the Philippines. The project had a total installed capacity of 4.5 MW, with construction nearing completion.

The project selected GRENERGY's ballasted mounting system from its "Nengshe-BAPV System Solution," a next-generation ballasted mounting solution for commercial and industrial roofs that integrates six major performance advantages: safety, reliability, economy, applicability, convenience, and aesthetics. Given the consistently high wind speeds in the Philippines, which impose stringent requirements on roof ballast stability, GRENERGY's technical team optimized the design – reducing concrete block weight while effectively ensuring the fixing function of the mounting system. During project construction, GRENERGY not only completed product delivery quickly but also dispatched a professional technical team to provide on-site guidance.

Hans T. Sy, President of SM Group in the Philippines, had previously stated in a declaration: "SM Group has always been committed to reducing greenhouse gas emissions from its malls and maximizing energy efficiency."

3.3 Zhejiang Province's First "No-Roof-Dismantlement" BIPV Project Commissioned

On January 18, 2022, Zhejiang Province's first "no-roof-dismantlement" building-integrated PV rooftop project was officially commissioned at Zhoushan Wanbang Shipbuilding Heavy Industry Co., Ltd. The project was independently developed and constructed by State Grid Zhoushan Power Supply Company. After full grid connection, it is expected to generate 6.5 million kWh of electricity annually, equivalent to saving 2,626 tons of raw coal and reducing CO2 emissions by approximately 5,148 tons, while helping the enterprise save 3.027 million yuan in electricity costs annually.

The project adopted a flush-mounted installation method, subverting the traditional tilted installation approach. Roof area utilization increased by over 70%, multiplying the installed power generation capacity. It is worth noting that this project differs from traditional ballasted solutions – it uses penetration through the metal roof to firmly connect the PV module racking to the roof steel structure. By innovating the "no-roof-dismantlement" installation technique, State Grid Zhoushan Power Supply Company retained the existing metal roof to save construction costs while significantly reducing high-altitude work risks and saving approximately 30% of installation costs. Although this technical path uses penetration rather than ballasting, its design philosophy of "avoiding roof dismantlement" aligns with the ballasted system's goal of "reducing roof damage," providing an alternative technical approach for flat-roof PV installation.

3.4 Ancai Photovoltaic New Materials Rooftop Power Station Phase II Project Grid-Connected

On March 16, 2022, the Phase II project of the Ancai Photovoltaic New Materials rooftop power station was successfully connected to the grid. The project installed a total of 3,452 modules covering the canteen, rolling workshop, homogenization silo, and chemical warehouse roofs. Using fixed-tilt mounting systems, the project consists of PV modules, grid-tied inverters, metering devices, and AC distribution systems, fully utilizing idle rooftop space for distributed PV generation.

IV. Industry Trends and Technical Directions

4.1 Intersolar Europe 2022: Lightweight and Aerodynamic Design Become Mainstream

The Intersolar Europe exhibition held in Munich, Germany, in May 2022 served as an important window for observing industry trends. The trends presented at the exhibition indicated that PV mounting systems are being optimized toward greater flexibility, modularity, lighter weight, and higher strength – applicable to roofs, facades, and ground-mounted installations.

Notably, the trend in the commercial flat-roof segment was clearly toward "aerodynamically designed mounting structures that require minimal ballast, can be installed or placed without tools, and do not penetrate the roof." Pre-assembled base units can be unfolded on the roof and connected to each other, often integrating cable trays or cable management systems. Most mounting systems offer different tilt angles (e.g., 8°, 10°, or 15°), can be elevated or flush-mounted, and can have different orientations (south-facing or east-west). In most cases, structural protection mats made of rubber granules, polyester protective layers, non-woven fabrics, or rubber gaskets are laid beneath the mounting structure to protect the roof covering from damage.

4.2 Esdec: Reducing Ballast Through Aerodynamics and Mechanical Coupling

On March 16, 2022, Esdec, a leading global supplier of PV mounting systems, published a technical article outlining key success factors for high-quality flat-roof PV mounting systems. The article noted that mounting systems account for only 10% of a PV project's total investment but bear the responsibility for safe operation for over 20 years. Since ballasted systems are not fixed to or penetrated through the roof structure but are placed on the roof via ballast, precise calculation of the required ballast weight and position is crucial.

Esdec emphasized two approaches to reducing ballast through aerodynamic design and mechanical coupling. First, inclined side panels can close off the open sides of double-row PV arrays, making the entire system more aerodynamic, thereby reducing the required ballast in actual installations. Studies have also shown that bolts, screws, and clamps used to fix panels to the mounting system generate about 18% additional wind resistance. Therefore, a "build-inward" design philosophy – without protruding components and only flat components on the outside – reduces wind resistance and positively affects ballasting. Second, increasing mechanical coupling strength between panels (e.g., through bidirectional strong cross-connections) can also effectively reduce required ballast. Using Esdec's FlatFix Wave Plus system as an example, the application of stabilizers and dual-base units significantly reduced ballast requirements.

The article also emphasized the importance of wind tunnel testing and calculation tools. Conducting extensive wind tunnel tests on mounting systems including panels under various scenarios (different array sizes, roof heights, configuration schemes, etc.) enables the establishment of reliable ballast calculation methods, ensuring the system resists strong winds without imposing additional burdens on the roof structure.

4.3 Industry Widely Recognizes "No-Penetration" Advantage

In 2022, ballasted systems gained wider application in both commercial, industrial, and residential sectors. Multiple industry sources pointed out that ballasted installation is the fastest and simplest method for installing PV on flat roofs, especially when roof drilling is not permitted – no drilling or anchoring is required, as the PV array is secured solely by the weight of concrete blocks.

At the same time, the industry increasingly recognized that different installation methods suit different scenarios: for metal roofs, attachment-type solutions are generally used, where modules are laid flat on the metal roof. Particularly for metal roofs without parapets, the flush-mounted form provides the best and safest wind resistance.