Against the backdrop of the global energy structure accelerating its transition toward clean and low-carbon sources, the photovoltaic (PV) industry has encountered unprecedented development opportunities. As a critical component of PV systems, solar mounting structures achieved significant technological breakthroughs and market growth in 2022. Among them, non-penetrating solar mounting solutions emerged as a focal point for the industry due to their roof-friendly installation methods and efficient energy output.

I. Overview of the Global and Chinese PV Mounting Market in 2022

In 2022, the global PV mounting market maintained robust growth. According to market research data, the global solar PV mounting system market size reached $13.368 billion in 2022 and is projected to grow to $24.027 billion by 2030, with a compound annual growth rate (CAGR) of 7.60% during the forecast period. The Chinese PV mounting market also performed impressively, reaching a market size of RMB 19 billion in 2022, reflecting a year-on-year increase of 8.6%.

In terms of mounting system tenders, from January to August 2022, the tender volume by domestic PV plant developers exceeded 35.5 GW. State Power Investment Corporation (SPIC) ranked first with 8.68 GW, followed by PowerChina with 6.15 GW and Datang Group with 5.74 GW. Trina Solar anticipated a total shipment growth of over 50% for mounting systems in 2022, indicating robust market demand.

As PV installed capacity grows, the mounting industry market continues to expand. Dongxing Securities projected that the overall market size for the mounting industry could reach RMB 117.7 billion by 2025, with an average annual compound growth rate of 15.4%.

II. Primary Technical Pathways and Innovation Highlights of Non-Penetrating Mounts in 2022

In 2022, non-penetrating solar mounting solutions primarily achieved innovation through the following technical pathways:

1. Flexible Mounting Technology

In September 2022, Huaneng Clean Energy Research Institute, China General Certification Center (CGC), and Nanjing Guangxiang New Energy jointly released the industry's first White Paper on Photovoltaic Flexible Mounting Systems, signifying the entry of flexible mounting technology into a phase of standardized development. Pei Huichuan, Secretary-General of the National Technical Committee for Solar Photovoltaic Energy Systems Standardization, noted that the group standard Technical Guidelines for Design and Installation of Photovoltaic Flexible Mounting Systems was under review and would provide crucial direction for the industry's technological advancement.

Flexible mounting systems offer significant advantages, including "large spans, high clearance, and long row spacing." They can better adapt to terrain variations, complement agriculture, animal husbandry, and fisheries, substantially improve comprehensive land utilization efficiency, and reduce project construction costs.

2. Non-Penetrating Hot-Air Welding Technology

In 2022, non-penetrating solar base technology for PVC flexible roofs saw widespread application. A case in point is a distributed solar power station installed on the PVC membrane roof of an automotive parts factory in Shanghai. The project utilized BCS Solar Fasteners, where the lower part of the base is made of PVC—the same material as the roof waterproofing membrane—and is secured via hot-air welding to the existing PVC membrane, achieving a truly non-penetrating installation.

Sika's Sika SolaRoof® system employs prefabricated PVC "clicks" components fixed to Sarnafil roof membranes via hot-air welding, eliminating potential leak points entirely while providing secure mounting without additional ballast. The component material formulation matches the roof membrane, fundamentally eliminating compatibility concerns.

3. Modular Ballasted Mounting Systems

AEROCOMPACT's COMPACTFLAT GS system is specifically designed for bifacial PV modules and green roofs. With minimal components and no need for long rails, installation is fast and simple. Independent laboratory tests confirm that bifacial modules on bright roof surfaces can increase power generation by up to 20% through reflected light. The system elevates the array approximately 40 cm above the roof surface, providing sufficient light for green roof vegetation.

Roll-A-Rack introduced a roll-formed mounting system that utilizes existing roof ballast to secure PV panels via 12-inch metal channels without penetrating the roof structure. This solution can reduce traditional system installation costs by up to 30%, material costs by 50%, and installation time and labor costs by 65%.

III. Analysis of Typical Application Cases in 2022

1. China's First Rooftop Flexible Mounting PV Project Connected to Grid

In August 2022, China's first rooftop flexible mounting PV project—the 6 MW distributed PV project at Fengzhu Textile—was successfully connected to the grid. Constructed by CHN Energy Fujian Jinjiang Thermal Power Co., Ltd., the project achieves an average annual power generation of 6.9868 million kWh.

Due to the narrow roof space and severe shading, the adoption of flexible mounting allowed for the addition of 7,359 PV modules within the same footprint, increasing the installed capacity by nearly 4.3 MW and adding 5.17 million kWh of annual generation, maximizing land and space utilization. Industry experts noted that flexible mounting systems can accommodate approximately three times the capacity of fixed-tilt systems in large-span areas with equivalent land usage.

2. PV Project on Automotive Parts Factory Roof in Shanghai

This project utilized BCS Solar Fasteners technology for a PVC membrane roof. The bases were securely bonded to the waterproofing membrane via hot-air welding without penetrating the roof structure, ensuring the integrity of the roof waterproofing while providing stable installation for the PV modules. This project serves as a reliable benchmark for PV installations on commercial building roofs.

3. Sika SolaRoof® System Achieves FM Approval

In December 2022, Sika announced that the Sika SolaRoof® system became the first commercial and industrial solar roof system globally to receive Factory Mutual (FM) Approval. The system successfully passed the rigorous testing requirements of FM Standard 4478, confirming that the PV mounting system does not negatively impact the performance of the underlying Sarnafil roof system.

FM Approvals' comprehensive systemic testing covered the effects of internal and external fire exposure and wind loads on the fully installed assembly, ensuring the design meets the highest safety standards. The system is backed by a 20-year single-source warranty covering both the roof assembly and the mounting system.

4. AEROCOMPACT Launches Mounting System for Bifacial Modules

In October 2022, Austrian PV mounting manufacturer AEROCOMPACT launched the COMPACTFLAT GS flat-roof mounting system. Specifically designed for bifacial modules and green roofs, it allows the installation of framed modules on membrane and bitumen roofs, insulated/uninsulated roofs, and concrete or gravel roofs.

The system offers two configuration options: a 15-degree south-facing tilt and a 10-degree east-west tilt to accommodate various installation requirements. The company provides a 25-year warranty for the system, demonstrating confidence in its product reliability.

5. Roll-A-Rack Introduces Water-Harvesting Mounting System

In July 2022, US-based Roll-A-Rack introduced a roll-formed solar mounting system capable of capturing precipitation runoff from PV panels for irrigation purposes. Suitable for flat roofs or ground-mount systems, the compact design requires only 11 inches of row spacing, significantly reducing the footprint needed for vegetation and soil conservation. This solution generates the same amount of electricity using only half the land area required by conventional racking systems, demonstrating substantial energy efficiency and environmental benefits.

IV. Technological Innovation and Patent Protection

In 2022, significant progress was made in patent technology for non-penetrating mounting systems in China. In July 2022, a utility model patent for a "Non-penetrating Rooftop Photovoltaic Mount" was officially disclosed. The patent features a protective plate around the support rod to prevent rainwater from flowing toward the mounting plate and corroding connecting bolts, along with barriers and guide channels to direct rainwater away from critical areas. This patented technology effectively addresses the issue of rainwater penetration causing internal roof corrosion during rainy weather and provides adjustable tilt functionality for the PV panels, enhancing solar energy conversion efficiency.