1. Classification by Structural Type

Fixed-tilt systems account for about 70% of utility‑scale projects. With low installation costs ($0.08‑0.12/W) and virtually no maintenance, they are an ideal choice for projects seeking stable returns. Using high‑strength steel and optimised design can greatly reduce material consumption.

Single-axis trackers are gaining penetration globally. In 2025, global tracker penetration is expected to reach 72%. Driven by large‑scale “desert, gobi, wasteland” base projects in China, the market share of 1P trackers is expected to exceed 80% by 2027.

2. Classification by Application Scenario

Flexible mounts excel in complex terrains such as mountains, ravines, and wastewater treatment plants. Using a pre‑stressed steel cable‑net structure, they significantly reduce the number of piles while keeping modules stable, and minimise ground disturbance.

Terrain‑following trackers incorporate adjustable mechanisms at bearing housings and main shaft connections, allowing the main shaft to automatically adapt to undulating terrain without extensive grading. A patented dual‑spherical bearing design enables the main shaft to automatically follow terrain slopes, increasing installation efficiency by 25% while reducing manual adjustment work. The octagonal tube main shaft structure improves specific stiffness by about 40% and specific strength by about 50%, enabling spans of up to 143 m and reducing pile count by 20%.

3. Special Scenarios: Flexible Mounts and Offshore PV

Flexible mounts use a pre‑stressed steel cable‑net structure. Two steel strands bear loads in the east‑west direction, while a stabilising wind‑resistant system in the north‑south direction forms a spatial cable‑net. Compared to conventional rigid mounts, flexible mounts greatly reduce the number of piles while maintaining module stability under wind‑induced vibration. They are particularly suitable for complex terrains such as mountains, ravines, and wastewater treatment plants.

Fixed offshore mounts face extreme environmental challenges: high salt spray, high humidity, high wind loads, and strong ocean currents. A 400 MW offshore PV project in Yantai, Shandong, adopted an industry‑first “large‑span bolted ball‑joint steel grid + tapered steel pipe pile” technical solution. A single mount unit can support 590 kW of modules, carrying about 120 tonnes – both the unit capacity and mount size are the largest in China’s PV industry. The project has obtained over 70 patents, increasing pile driving efficiency by 5 times and reducing construction costs by more than 50%.

4. Foundation Types: Screw Piles vs. Concrete Piles

Screw piles, with their concrete‑free construction, fast installation (2‑3 minutes per pile), and removability, are increasingly used in agrivoltaics, temporary projects, and soft‑soil sites. In a 100 MW project in Kabwe, Zambia, 65,584 anchor screw piles were completed, laying a solid foundation for subsequent installation. For mountain terrain, a patent for screw piles specifically for PV mounts on slopes uses flange positioning, sleeve embedment, and backfill cavities to significantly improve installation stability. In a 1.2 GW high‑altitude project in Batang County, Sichuan, 12,000 tonnes of PV mounts and 67,000 screw piles were supplied to serve a large single‑plant project on complex, high‑altitude terrain.

5. Material Upgrades: Zn‑Al‑Mg Coated Steel Becomes the New Standard

Zinc‑aluminium‑magnesium (Zn‑Al‑Mg) coated steel offers corrosion resistance 5‑10 times that of conventional hot‑dip galvanising, with coating thickness reduced by 50‑66%, and self‑healing properties at cut edges to effectively combat corrosion at scratches and cuts. Zn‑Al‑Mg coated steel produced by Pangang has shown no red rust after 4,000 hours of salt‑spray testing, achieving full coverage of steel grades and applications for PV‑grade coated steel.

A 550 MPa high‑strength Zn‑Al‑Mg strip (S550GD+ZM) developed by Shanxi Jianlong allows purlin thickness to be reduced to 1.8 mm and column thickness to 2.0‑2.5 mm, with an overall weight reduction of 12%, significantly lowering material costs and installation difficulty. Coating thickness of at least 275 g/m² provides reliable protection for PV mounts for more than 25 years. The next‑generation Zn‑Al‑Mg product from Jiuquan Steel has entered final testing for PV frame applications, marking the transition from R&D to large‑scale commercial use.

In C5 high‑corrosion environments, conventional hot‑dip galvanising requires a coating thickness of 140 μm to achieve a 25‑year life, but such a thick coating leads to increased brittleness, reduced manufacturing efficiency, higher zinc consumption, and increased emissions. Zn‑Al‑Mg coatings, with their superior corrosion resistance, achieve the same or even longer service life with thinner coatings.

6. Intelligent Tracking Systems: From Mechanical Sun‑Following to AI‑Driven

A new‑generation intelligent PV tracker was released in November 2025. It incorporates a smart tracking control system driven by algorithms that consider direct, diffuse, and reflected irradiance and terrain differences, optimising rack angle for higher generation. The system also features four intelligent protection modes, automatically adjusting attitude in response to high wind, snow, flood, hail, and other extreme weather events to ensure safe operation.

As a major contributor to the national standard “Technical Requirements for Sun Tracking Systems of PV Power Plants” (GB/T 29320‑2024), a leading manufacturer released three core products at SNEC 2025: a horizontal single‑axis tracker (supports up to 120 modules, with patented composite sprocket drive technology), a high‑efficiency manual adjustable mount (0‑70° ultra‑wide angle adjustment), and a north‑south tracker (intelligent altitude‑angle adjustment), forming a complete product matrix covering different application scenarios.

A control package for extreme weather/terrain was introduced in 2025, adding a hail‑stow function to existing wind, snow, and terrain‑aware back‑tracking features, further improving tracker self‑protection under extreme weather. A new SkyLink Tracker system will begin shipment in 2025, featuring an eight‑module architecture, PV‑powered brushless DC motors, Zigbee wireless communication, and comprehensive passive wind load mitigation.

7. Selection Guide

Choosing a ground‑mount racking system requires balancing terrain conditions, wind/snow loads, soil type, and investment budget. Fixed‑tilt systems offer the lowest initial cost and simplest O&M, suitable for projects seeking stable returns. Trackers, with 15‑25% generation gain, provide better LCOE in high‑irradiation regions. Flexible mounts and fixed offshore mounts offer customised solutions for special scenarios such as mountains, wastewater treatment plants, and near‑shore waters. With continuous advances in intelligent control algorithms and high‑corrosion‑resistant materials, ground‑mount racking systems are evolving from “passive support” to “active empowerment.”