Introduction: From “Passive Support” to “Active Empowerment”

In 2024, the global solar PV mounting solutions industry experienced a dual drive of technological breakthroughs and market transformation. Driven by the dual‑carbon goals and energy security demands, PV mounting has evolved from a “supporting component” of power plant construction into a “core technology unit” that enhances power generation efficiency, conquers complex terrains, and reduces the levelized cost of electricity. From flexible mounts withstanding a Category 17 typhoon, to intelligent tracking systems driven by AI algorithms; from the large‑scale application of zinc‑aluminium‑magnesium coated materials, to the widespread adoption of non‑penetrating installation solutions – the 2024 PV mounting market exhibited four prominent characteristics: intelligence, scenario‑specific design, green development, and standardisation.

Part One: Technological Breakthroughs – Flexible Mounts and Intelligent Tracking Advance Together

1.1 Flexible Mounts: From Conceptual Design to Extreme Weather Validation

Flexible mount technology achieved major breakthroughs in large‑span applications and extreme weather adaptability in 2024. DAS Solar‘s self‑developed fourth‑generation flexible PV mounting system successfully withstood Super Typhoon Yagi at a 70 MW fishery‑solar hybrid project in Hainan. At landfall, the typhoon had maximum sustained winds exceeding Category 17 (about 245 km/h), while the project – located only 50 km from the landing point – continued to operate stably.

Technical highlights: The system uses a spatial cable‑net structure. Two pre‑stressed steel strands bear the load in the east‑west direction, while a unique inter‑row stabilising wind‑resistant system in the north‑south direction forms a spatial cable‑net structure that effectively resists external loads. In terms of installation efficiency, only 30 bolts are required per module string, compared to 228 bolts for traditional systems – an 87% reduction.

At the same time, LONGi Green Energy obtained a patent for a “Flexible PV Mount Anchor Structure and PV Power Generation System” in December 2024, further advancing the maturity of flexible mount technology.

1.2 Intelligent Tracking Systems: Standardisation and AI Algorithms Drive Progress

Tracking mounts, which can increase power generation by 15‑25% by adjusting module angles in real time, have become “standard equipment” for large‑scale ground power plants. In 2024, the intelligent tracking field achieved milestone progress in both standardisation and technological innovation.

Trina Solar led the drafting of China‘s first intelligent tracker standard, “T/CPIA 0082‑2024 – Test Method for Intelligent Tracking Performance of PV Trackers”, which came into effect on 15 September 2024. This standard fills a gap in China’s test methods for intelligent trackers, providing project owners with a unified technical benchmark.

Field data: Trina Solar‘s new‑generation intelligent tracking system has obtained TÜV SUD product certification. Field data show that on top of the generation increase provided by conventional trackers, the system can deliver an additional 2‑4% annual average gain, and over 10% on cloudy/rainy days – upgrading tracking mounts from simple “sun‑following” to true “intelligent sensing”.

Part Two: Material Innovation – Zn‑Al‑Mg Coating Becomes the Industry Standard

2.1 Zn‑Al‑Mg Coated Steel: Self‑Healing, 35‑Year Service Life

In 2024, zinc‑aluminium‑magnesium (Zn‑Al‑Mg) coated steel emerged as a game‑changing material for PV mounts. The material offers self‑healing ability – after minor damage, the coating quickly restores the surface protection layer – and excellent corrosion resistance, effectively resisting salt spray, humidity and other harsh environments.

U‑Good New Energy: Launched C‑channel mounts using Zn‑Al‑Mg coated steel, with service life exceeding 35 years

HUEG: Released C‑section ground mounting system with Zn‑Al‑Mg coating and patented clamp design, reportedly increasing system strength by 20%

Firstsolar: Hot‑dip galvanised carbon steel mounts with 60 m/s wind resistance and 1.4 kN/m² snow load capacity

2.2 Aluminium Alloys: Lightweight and Corrosion‑Resistant

Aluminium alloys remain the preferred choice for rooftop and residential applications due to their lightweight and corrosion‑resistant properties.

IntegraRack: Aerospace‑grade 6061‑T6 aluminium alloy with 150 mph wind resistance certification

Mibet: AL6005‑T5 aluminium alloy for universal standing seam clamp kits

K2 Systems: Hot‑dip galvanised + Galfan + impact‑resistant powder coating, 30‑year material warranty

Part Three: Non‑Penetrating Systems – Rooftop Installations Enter the “No‑Damage” Era

3.1 Ballasted Systems: Lightweight Design and High Density

Ballasted racking systems rely on concrete block weight to hold PV mounts down without roof penetration, preserving roof integrity and warranties.

Mibet RM‑Ad: 22 MW project in Fujian with matrix ballast, wind deflectors resisting level 14 typhoons, lightweight aluminium structure

Unirac RM10 EVO: 13‑inch row spacing, 20% higher module density, only three main components, single‑tool installation

3.2 Clamp‑Based Systems: Rail‑Less Direct Attachment

S‑5! was granted 50 new patents in 2024, including the Protea™ rail‑less solution for trapezoidal metal roofs, with FM 4478 and FPA HVHZ certifications. The company‘s solutions are now installed on more than 2.5 million metal roofs worldwide, representing 8 GW of rooftop solar.

Mibet‘s Universal Standing Seam Clamp Kit combines mechanical fixation and integrated grounding, with 60 m/s wind resistance and 1.6 kN/m² snow load capacity.

3.3 Adhesive Systems: Structural Bonding for Flexible Modules

Adhesive solutions use structural adhesives to bond mounting brackets directly to roof surfaces. Mibet developed a flexible module adhesive solution for a 13.6 MW project, using clamps fixed to metal roofs with adhesive bonding for flexible modules – no penetration, no rails, fast installation.

Part Four: Product Innovation – Efficiency and Adaptability Redefined

4.1 Flat Roof Fast‑Install Systems

AEROCOMPACT‘s COMPACTFLAT S_BASE, launched in August 2024, features:

Click‑fit installation: brackets snap into place without tools

Long‑side clamping: accommodates modules up to 2.5 metres long

Integrated ballast platform: reduces point loads and ballast material

Lightweight design: fewer components, lower transport and storage costs

4.2 Vertical Installation Systems

RAULI FLAT, launched in July 2024, features:

Vertical installation: optimises east‑west generation curve

Welded fixation: withstands 3.5 kN/m² wind loads, no ballast

Ultra‑lightweight: only 10 kg/m²

20% more panels in the same row, 15‑20% lower cost per panel

4.3 Adjustable Tilt Systems

IntegraRack IR‑G series offers:

30‑minute installation

0°, 15°, 30°, 45° tilt adjustment with fast‑locking clamp handle

150 mph wind resistance (67 m/s) UL 2703 certified

No concrete required – ballast, screw piles, or driven piles

4.4 Screw Pile Foundations

Ground screws are gaining traction for concrete‑free, fast‑install foundations:

PV Mounts PVM‑GS‑04C: double‑blade design, 25‑year life, 60 m/s wind resistance

PV Mounts PVM‑GS‑04B: adjustable flange for fine height adjustment

Ground Screw Company: customised solutions for Indian soils, 2‑minute installation per screw

Part Five: Industry Standards – China‘s First Intelligent Tracker Test Standard Released

On 15 September 2024, China’s first intelligent tracker standard, “T/CPIA 0082‑2024 – Test Method for Intelligent Tracking Performance of PV Trackers”, officially came into effect. Led by Trina Solar and jointly developed by 15 organisations, the standard covers three optimisation directions:

High‑scattering irradiance weather optimisation: dynamically optimising tracking angles under diffuse light conditions using meteorological data, generation data, and cloud cameras

Back‑tracking optimisation: identifying shading scenarios on complex terrain through generation data and terrain measurements

Bifacial module optimisation: establishing bifacial irradiance models or using reference arrays to determine optimal tracking angles for bifacial modules

This standard provides project owners with a unified technical benchmark, driving the industry from “experience‑driven” to “standard‑driven”.

Part Six: 2024 PV Mounting Solutions Trend Summary

Outlook

Looking ahead to 2025 and beyond, solar PV mounting solutions will continue to deepen development in the following directions:

Deepening intelligence: AI algorithms and digital twin technology will further improve generation gain and reliability of tracking mounts

Scenario‑specific customisation: Dedicated mounting solutions for agrivoltaics, offshore PV, floating PV, and other special scenarios will continue to emerge

Green manufacturing: Zn‑Al‑Mg coated steel, bio‑based materials, and other environmentally friendly materials will be used more widely

Non‑penetrating proliferation: Ballasted, clamp‑based, and adhesive systems will become standard for rooftop installations, preserving roof warranties and eliminating leak risks

Standardisation progress: From intelligent tracking test methods to structural design codes, the industry standard system will become increasingly refined

Continuous cost optimisation: Open‑source and low‑cost designs will further lower the barrier to PV installation, promoting global energy affordability

In a Nutshell

In 2024, solar PV mounting solutions underwent a profound transformation from “passive support” to “active empowerment” – flexible mounts are tougher, intelligent tracking is smarter, new materials are more durable, and non‑penetrating solutions are preserving roof integrity – building a solid foundation for the global energy transition.