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

In 2024, the global PV mounting systems 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 academic breakthroughs in open‑source mount designs – 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 DAS Solar Flexible Mounts: Successfully Withstand Super Typhoon (Category 17)

In 2024, flexible mount technology achieved major breakthroughs in large‑span applications and extreme weather adaptability. 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 Ding’an Longhu, 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 – a significant improvement.

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. The design enables flexible cable connection through a rotating connector, further advancing the maturity of flexible mount technology.

1.2 Intelligent Tracking Systems: Driven by Standardisation and AI Algorithms

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 completed its enterprise standard for “Wind Load Design Calculation of Horizontal Single‑Axis PV Trackers” and 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. The release of this standard fills a gap in China’s test methods for intelligent trackers, providing project owners with a unified technical benchmark for evaluating different smart tracking solutions.

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. This breakthrough upgrades tracking mounts from simple “sun‑following” to true “intelligent sensing”.

Part Two: Product Innovation – Multi‑Scenario Coverage and Installation Efficiency Revolution

2.1 Flat Roof Fast‑Install System: Click‑Fit Installation Leads Efficiency Revolution

In August 2024, AEROCOMPACT launched the COMPACTFLAT S_BASE flat roof fast‑install system at the RE+ exhibition in North America. Its core highlight is “click‑fit” installation – the brackets simply snap into place with an audible click, requiring no tools. The system features long‑side clamping, accommodating PV modules up to 2.5 metres long to suit the trend toward larger modules. The base integrates a ballast platform and deflector, reducing point loads and ballast material usage. With fewer components, transport and storage costs are significantly reduced.

2.2 Rail‑less Metal Roof Systems: S‑5! Secures 50 New Patents in One Year

In 2024, S‑5!, the global leader in metal roof solar attachment solutions, announced that it had been granted 50 new patents in a single year, bringing its total patent portfolio to 194. These patents span multiple major markets worldwide: 12 in the European Union, 9 in China, 8 in the United States, 6 in India, 4 in Australia, and others.

The Indian Patent Office granted S‑5! patent #423672‑001 for its new Protea™ rail‑less PV solar mounting solution, designed for mounting framed solar modules to trapezoidal metal roofs while providing certified electrical bonding and grounding. S‑5! mounting solutions are now installed on more than 2.5 million metal roofs worldwide, representing 8 GW of rooftop solar.

2.3 Vertical Installation System: Nordic Solution Challenges Conventions

In July 2024, Nordic mounting system manufacturer RAULI launched the innovative RAULI FLAT flat‑roof system, featuring a unique vertical installation and welded fixation design. The system weighs only 10 kg/m², making it suitable for roofs that cannot support ballasted systems. Attachment points withstand wind loads of 3.5 kN/m², eliminating the need for ballast and wind deflectors. The rail system uses a telescopic design – no on‑site cutting required. RAULI notes that vertical installation allows 20% more solar panels in the same row, with a 15‑20% lower cost per panel compared to horizontal installation.

Part Three: Material Innovation – Zn‑Al‑Mg Coating Becomes the New Choice

3.1 U‑Good New Energy: Zn‑Al‑Mg Coated C‑Channel Mounts

In November 2024, Xiamen U‑Good New Energy Co., Ltd. launched a C‑channel PV mounting solution, whose core highlight is the use of high‑quality zinc‑aluminium‑magnesium (Zn‑Al‑Mg) coated steel. The material has self‑healing ability – after minor damage, the coating quickly restores the surface protection layer, preventing further corrosion spread. It offers excellent corrosion resistance, effectively resisting salt spray, humidity and other harsh environments, with a service life exceeding 35 years.

3.2 HUEG: Zn‑Al‑Mg Coated Steel Mounts + Patented Clamp Design

In December 2024, Chinese PV mounting manufacturer HUEG (Hua Ding New Energy) released a new C‑section ground mounting system made of Zn‑Al‑Mg coated steel, featuring a patented new portable clamp design. Unlike traditional systems that require multiple flange holes in the rails, HUEG‘s design eliminates this need, enhancing bending resistance and overall stability. The clamp design reportedly increases system strength by 20%.

Part Four: Industry Standard – 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. The standard was led by Trina Solar and jointly developed by 15 organisations. It covers three optimisation directions for intelligent tracking:

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

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

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

The release of this standard provides project owners with a unified technical benchmark for evaluating different smart tracking solutions, driving the industry from “experience‑driven” to “standard‑driven”.

Part Five: Open‑Source and Low‑Cost Designs – Academic Research Promotes Affordable PV

In 2024, academia also made important progress in low‑cost, open‑source PV mounts. A study published in the journal Designs developed two novel variable tilt mount designs – the first stilt‑mounted designs that allow manual tilt angle adjustment from 0° to 90° by varying cable length. The system can save one‑third to two‑thirds of the capital expenditure of commercially available alternatives, is easy to build, and requires minimal manufacturing operations. The design is particularly suitable for agrivoltaic settings, providing farm workers with shaded, ergonomic access for planting, weeding and harvesting.

Another study proposed ballasted foundation designs that eliminate the need for drilling and concrete pouring, applicable to both fixed‑tilt and variable‑tilt systems. Overall, wood‑based PV mounting systems provide users with cost‑effective, easy‑to‑DIY alternatives to conventional metal mounts.

Part Six: 2024 PV Mounting Industry Trend Summary

Outlook

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

Deepening intelligence: The integration of AI algorithms and digital twin technology will further improve the 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: The use of environmentally friendly materials such as Zn‑Al‑Mg coated steel and bio‑based materials will become more widespread

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, PV mounting systems are undergoing a profound transformation from “passive support” to “active empowerment” – flexible mounts are tougher, intelligent tracking is smarter, new materials are more durable, and open‑source designs are more affordable – building a solid foundation for the global energy transition.