Introduction: Ground Screws – The “Green Revolution” in PV Foundations

As global PV power plants expand toward large‑scale development and complex terrains, the limitations of traditional concrete foundations in terms of construction time, environmental impact, and cost control are becoming increasingly evident. In early 2024, ground screw technology achieved multiple breakthroughs – from customised solutions for Indian soil conditions, to new hot‑dip galvanised products launched by European companies, and to patented double‑ground‑screw designs for solar trackers. Ground screws, with their unique advantages of “no concrete, fast installation, and recyclability”, are becoming an important choice for foundation engineering in ground‑mount PV projects.

According to industry analysis, ground screw technology originated in defence engineering research at the Technical University of Munich in the 1960s‑70s, and has been widely used in PV projects in China since 2006. In 2024, this technology is moving from a “niche option” toward a “mainstream solution”.

Part One: India Market – Localised Ground Screw Solutions Debut at REI 2024

1.1 Ground Screw Company: Customised Products for Indian Soils

In November 2024, at REI Expo 2024 in New Delhi, Indian company Ground Screw Company showcased its metal helical anchor system developed specifically for the Indian market. The product uses galvanised steel ground screws that are screwed into the soil to form a metal pile foundation, supporting PV module mounting structures.

Key technical parameters:

Prasad Bhagare, founder of the company, explained that this technology was originally developed at the Technical University of Munich in the 1960s‑70s and has been widely used in PV projects in China since 2006. Through analysis of India‘s diverse soil types and technology transfer, the company has developed customised ground screw products for India’s specific geological conditions.

Agrivoltaics advantage: In agrivoltaic projects, ground screws avoid the use of concrete, chemicals, and large‑scale soil disturbance, eliminating the long‑term risk of cement and calcium carbonate leaching into the soil, making them a sustainable installation solution.

1.2 Product customisation capability

Ground Screw Company offers application‑specific customised ground screw products – depending on the soil type, custom solutions can be provided for different applications such as solar water pumps and street light foundations. This localised, customised product strategy reflects the trend of ground screw technology moving from “universal” to “scenario‑specific”.

Part Two: European Market – New Hot‑Dip Galvanised Ground Screw Launched

2.1 ESG: Galvanised Ground Screw Compliant with UNE EN ISO 1461

In October 2024, Spanish company Elementos de Sujeción Galvanizados (ESG) launched a new hot‑dip galvanised ground screw specifically designed for ground‑mount PV power plants.

Key product parameters:

An ESG spokesperson stated: “This method significantly reduces installation time and cost, while providing optimal stability and strength. Its robust design makes it an ideal solution for supporting solar modules and other light infrastructure.”

Customisation capability: ESG can customise ground screw designs according to project specifications, adjusting materials, dimensions, and characteristics to meet customer requirements. The hot‑dip galvanising process ensures excellent corrosion resistance, with a maintenance‑free service life exceeding 30 years.

2.2 Product technical features

The ground screw features a metal structure with helical blades that is screwed directly into the ground, requiring no excavation or concrete foundations. The company claims the product works efficiently in different soil types while reducing environmental impact.

Part Three: Product Innovation – Double‑Blade Design and Adjustable Flange Technology

3.1 Double‑Blade Ground Screws: Enhanced Load Capacity and Multi‑Terrain Adaptability

In 2024, PV Mounts‘ double‑blade ground screw product (model PVM‑GS‑04C) achieved several technical breakthroughs.

Technical parameters:

Key product advantages:

Double‑blade design: Ensures rapid penetration in various soils (from soft clay to rocky terrain), providing a stable foundation

Sustainable and reusable: Easy to remove and relocate, offering flexibility for future projects

Easy installation: No heavy machinery or complex foundation engineering, reducing labour time and project costs

High load capacity: Welded thread design supports horizontal and vertical loads, ensuring structural stability

Applicable scenarios: The product is suitable for PV projects, fence foundations, building construction, road signs, billboards, and various other applications.

3.2 Adjustable Flange Ground Screws: Solving Height Alignment Challenges

PV Mounts also launched the adjustable flange ground screw (model PVM‑GS‑04B), which achieves a breakthrough in height adjustment.

Core innovation: A unique non‑fixed flange design allows fine height adjustment, providing a perfectly level foundation for solar modules. After installation, the flange is firmly fixed to the screw shaft by tightening three nuts.

Installation process:

Screw the ground screw into the ground to the required depth (600‑3500 mm)

Loosen the flange and adjust the height according to module installation requirements

Check levelness using a spirit level

Tighten the three nuts to secure the flange

Suitable soils: Sandy soil, soft soil, mountainous terrain, and other geological conditions.

Part Four: Patent Innovation – Dual Ground Screw Support System for Solar Trackers

In May 2024, an international patent for a “Support System and Installation Device for Solar Trackers” (AU2022364583) was published, demonstrating an innovative application of ground screws in the tracker field.

Technical solution: The support system includes two helical piles or blade piles screwed into the ground, spaced apart along the longitudinal axis of the solar tracker. An upper support structure has a first leg and a second leg, installed respectively on the two piles and extending upward, with the upper region connecting the two legs.

Technical value: This design integrates ground screw foundations with tracker systems, providing a more efficient and flexible foundation solution for large‑scale tracker‑based PV power plants.

Part Five: Engineering Application Advantages – Addressing Frost Heave and Complex Terrain

5.1 Frost Heave Resistance

According to a December 2024 report in Solar Builder magazine, ground screws perform excellently in resisting frost heave forces in cold regions such as Maine. Chase Anderson of Terrasmart noted: “The reason ground screws are so successful at dealing with frost heave is that they have a much smaller surface area – about one‑third to one‑quarter of a traditional pile foundation. Therefore, the frost heave force itself is reduced, and the helical blades are always located below the frost line.”

5.2 Terrain Adaptability

For sites with challenging topography, the “exposure window” (the range of torque tube height above ground) of ground screw systems is more flexible than that of traditional H‑piles. Charles Almy of Nextracker explained: “We have a larger exposure window, which allows us to overcome obstacles that we couldn‘t before.”

5.3 Environmental Compliance Advantages

With increasing requirements from agencies such as the U.S. Bureau of Land Management for “zero site grading”, the terrain‑following design of ground screw systems has become an important advantage. Some sites have limited equipment movements to avoid disturbing topsoil. Ground screw solutions eliminate the need for pre‑drilling equipment, reducing land disturbance.

Part Six: 2024 Ground Screw Technology Trend Summary

Outlook

Looking ahead to 2025 and beyond, ground screw technology for PV applications will continue to deepen development in the following directions:

Material upgrades: High‑corrosion‑resistance coatings and high‑strength steel will further extend ground screw service life

Installation efficiency revolution: Mechanised and automated installation equipment will further improve construction efficiency

Scenario segmentation: Dedicated products for agrivoltaics, fishery‑solar hybrids, tracker mounts and other specific scenarios will continue to emerge

Strengthened environmental compliance: In ecologically sensitive areas and zero‑grading projects, the environmental advantages of ground screws will become even more prominent

Standardisation progress: Countries will accelerate the development of technical standards and acceptance specifications for ground screw products

In a Nutshell

In 2024 – from Ground Screw Company‘s localised customisation for India to ESG’s 30‑year‑life hot‑dip galvanised products in Spain, from PV Mounts‘ double‑blade and adjustable flange innovations to the dual ground screw tracker patent – ground screw technology is providing a “green” solution for the foundation engineering of ground‑mount PV power plants, with faster installation speeds, stronger environmental adaptability, and lower ecological impact.