Introduction: Foundations – The “Roots” of PV Power Plants

In PV power plant construction, the mounting foundation is the “root” of the entire system, responsible for transferring external loads such as wind and snow loads to the ground. The selection of the foundation type directly affects the structural safety, construction cost, and long‑term reliability of the power plant. In 2024, as PV projects extend to complex geological conditions such as deserts, mountains, and soft soils, and as the industry demands higher construction efficiency and environmental friendliness, ground PV foundation technology has seen multiple innovations – from Nextracker‘s NX Anchor pile system, to ESG’s hot‑dip galvanised ground screws in Spain, to Ground Screw Company‘s localised screw pile solutions in India, and to the systematic research on desert‑area pile foundations by the Northwest Electric Power Design Institute – all driving PV foundation engineering toward greater efficiency, environmental sustainability, and economy.

Part One: Screw Piles – Global Proliferation of Concrete‑Free Solutions

Screw piles are metal pile foundations installed by screwing into the ground. They require no concrete pouring, no curing time, and can bear the superstructure immediately after installation. In 2024, this technology accelerated its adoption worldwide.

1.1 Nextracker NX Anchor: 50% Steel Savings, 70% Depth Reduction

In September 2024, Nextracker, a global leader in tracking systems, officially launched NX Foundation Solutions, including the new NX Anchor pile system. This system is the result of Nextracker‘s acquisition of Ojjo and is designed to adapt to a wide variety of soil types.

Key technical parameters:

Nextracker CEO Dan Shugar stated: “The goal is to provide high‑quality, cost‑effective solutions that help improve productivity, safety, accelerate project timelines, and achieve ‘gentle land use’ construction practices.” Stephen Jones, President of Renewables at Primoris Services Corporation, added that this foundation solution simplifies design, procurement, and installation processes while reducing risk for EPC contractors and developers.

1.2 ESG Hot‑Dip Galvanised Ground Screws: 30‑Year Maintenance‑Free Life

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 said: “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.”

1.3 Ground Screw Company: Localised Customised Solutions for India

In November 2024, India‘s Ground Screw Company showcased its metal helical anchor system, developed specifically for the Indian market, at REI Expo 2024.

Technical highlights:

Company founder Prasad Bhagare 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.

Part Two: Concrete Pile Foundations – The Preferred Solution for Desert Areas

Concrete pile foundations remain the mainstream choice for large‑scale ground‑mount power plants due to their high load capacity, good stability, and mature construction techniques. In 2024, the Northwest Electric Power Design Institute of China conducted systematic comparative research on PV pile foundations in desert areas.

2.1 Comparative Pile Testing in Desert Areas: Prestressed Pipe Piles Show Significant Advantages

In 2024, the Northwest Electric Power Design Institute of China Power Engineering Consulting Group, together with other organisations, published a research paper in Northwest Hydropower journal. Taking a PV new energy project in a desert area as an example, the study compared three foundation types: prestressed pipe piles, pre‑drilled grouted anchor piles, and steel screw piles.

Research conclusions:

The study pointed out that, compared with the other two pile types, prestressed pipe piles are more suitable for use in desert areas both in terms of construction and load‑bearing capacity. The research findings provide important references for the design of PV pile foundations in desert areas.

2.2 Cast‑in‑Place Concrete Piles and Precast Concrete Piles

According to industry technical literature, concrete pile foundations mainly include the following types:

Part Three: Ballasted Foundations – A Non‑Penetrating Alternative

Ballasted foundations rely on the self‑weight of concrete blocks or other heavy objects to hold the mounting system in place on the roof or ground, without penetrating the structural layer.

3.1 Academic Research: Economic Validation of Ballasted PV Systems

In May 2024, the journal Renewable Energy published a study on the applicability and feasibility analysis of ballasted PV systems on concrete roof slabs.

Key research findings:

3.2 Ballasted Foundation Applications

Ballasted foundations are particularly suitable for:

Flat concrete roofs: Where penetration is prohibited or would void warranties

Hard ground surfaces: Where excavation or pile driving is not feasible

Leased sites: Where foundations must be removable at the end of the lease term

Brownfield sites: Where soil contamination makes excavation undesirable

Typical ballast materials include:

Precast concrete blocks with embedded connection points

Recycled materials such as crushed concrete or gravel in retaining structures

Water‑filled ballast tanks for temporary installations

Part Four: 2024 Ground Mount Foundation Technology Trend Summary

Outlook

Looking ahead to 2025 and beyond, ground PV mounting foundations will continue to evolve in the following directions:

Screw pile proliferation: Concrete‑free solutions will continue to gain market share, especially in agrivoltaics, temporary installations, and areas with challenging soil conditions

Desert‑area standardisation: Prestressed pipe piles are likely to become the standard foundation type for large‑scale desert PV projects

Hybrid foundations: Combinations of screw piles with concrete caps or grouted sections will emerge to address specific soil challenges

Installation automation: GPS‑guided rigs, automated driving systems, and real‑time torque monitoring will become standard

Environmental compliance: Low‑impact foundations (no excavation, no concrete, minimal soil disturbance) will be increasingly required for projects in ecologically sensitive areas

Lifecycle optimisation: Life‑cycle cost analysis, considering not only initial cost but also removal, recycling, and environmental remediation, will guide foundation selection

In a Nutshell

In 2024, ground PV mounting foundations have evolved to meet the challenges of diverse geological conditions – from Nextracker‘s steel‑saving NX Anchor to ESG’s 30‑year galvanised screw piles, from India‘s localised solutions to desert‑area prestressed pipe piles – providing faster installation, lower environmental impact, and greater reliability for the global energy transition.