Overview

As the global photovoltaic (PV) industry expands into diverse applications — from large-scale ground-mounted plants to agrivoltaics, floating PV, and complex rooftop installations — the demand for custom-engineered solar racking solutions has surged significantly. In 2024, leading manufacturers across the globe are increasingly focusing on tailor-made steel racking systems designed to meet project-specific requirements for load capacity, terrain adaptability, corrosion resistance, and cost efficiency.

Unlike standardized systems, custom racking solutions involve close collaboration between engineers and clients to optimize material selection, structural design, and fabrication processes. The goal is to minimize material consumption while maximizing structural integrity, reducing installation time, and ensuring long-term reliability under site-specific environmental conditions.

"Off-the-shelf solutions often fall short when dealing with challenging terrain, high wind or snow loads, or unique project footprints," explains a representative from a leading European racking manufacturer. "Custom-designed systems address these gaps by delivering precisely what each project requires — no more, no less."

New Product Launches in 2024

1. Antaisolar's TAI SIMPLE Series Tracker

At Intersolar Europe 2024, Chinese racking and tracking system provider Antaisolar unveiled its latest 1P TAI SIMPLE series single-axis tracker, designed to meet the growing demand for customized tracking solutions. The system features multiple slew-drive mechanisms that provide enhanced module load-carrying capacity, improved tracking precision, and flexibility on undulating terrain.

The tracker accommodates up to three strings at 1,500V system voltage with a wide east-west rotational range of ±60°. Notably, Antaisolar offers structures made from different steel grades — pre-galvanized, hot-dip galvanized, and magnesium-zinc-coated — allowing clients to select materials based on specific corrosion resistance requirements and budget constraints. The system is certified for extreme wind loads of up to 55 m/s under ASCE 7-10 standards.

2. Oberhauser's ISYS Ground-Mount Systems

German manufacturer Oberhauser Bau-Systeme GmbH expanded its ISYS series of ground-mount racking solutions in 2024, offering tailored configurations for various project scales. The ISYS 1.1 "one-foot" system is optimized for sites requiring mowing or sheep grazing underneath panels, with table lengths up to 30m and module inclinations from 0° to 30°. The ISYS 2.2 "two-foot" system features large spans and accommodates up to six modules horizontally, maximizing system performance.

The company emphasizes its ability to produce custom steel and aluminum substructures with high dimensional accuracy, including project-specific posts, beams, clamps, and connectors. Optional features include standard or custom hole patterns, pre-assembled subassemblies, and clear part labeling for on-site identification.

Material Innovations Driving Customization

1. High-Strength Steel for Lightweight Racking

In December 2024, Chengde Vanadium and Titanium Co., Ltd. successfully produced and delivered custom-developed PV racking steel with a thickness of 5.5mm and tensile strength of 750MPa for an overseas premium client. The company has now achieved full coverage of its racking steel series, with thicknesses ranging from 1.5mm to 5.5mm and strengths up to 800MPa.

These high-strength steels offer significant advantages for custom racking applications: they are lighter, require no coating (reducing environmental impact), resist corrosion naturally, and eliminate the need for regular maintenance. For the first ten months of 2024, the company reported an 8% year-over-year increase in PV racking steel sales, driven by growing demand from both domestic and international PV projects.

2. Zinc-Aluminum-Magnesium Coated Steel Breakthrough

In July 2024, the Cold Rolled Sheet Company of New Tianjin Steel successfully produced 3.0mm ultra-thick specification zinc-aluminum-magnesium S420GD grade steel for PV racking applications. This product, with thickness far exceeding the typical 2.0mm design limit, achieved full coverage of mainstream cold-based zinc-aluminum-magnesium steel thickness specifications for the PV racking market.

The zinc-aluminum-magnesium coating offers exceptional corrosion resistance, making it ideal for PV installations in harsh environments such as deserts, shoals, and coastal areas. Products based on this steel have already been exported to Japan, South Korea, Thailand, Singapore, and Saudi Arabia, receiving strong market recognition.

Customization Approaches

1. Design Flexibility

Custom racking solutions today offer unprecedented design flexibility. Engineers can adjust:

Foundation types: Driven piles or concrete foundations depending on soil conditions, each engineered for specific load-bearing requirements

Material selection: Aluminum alloy for lightweight rooftop applications, galvanized or zinc-aluminum-magnesium coated carbon steel for ground-mount systems

Surface finishes: Hot-dip galvanizing, powder coating, or anodizing based on corrosion protection needs

Structural configurations: Single-pole systems to minimize land occupation for agrivoltaics, double-pole systems for maximum stability in high-wind areas

2. Project-Specific Applications

Agrivoltaics: Custom racking solutions for agricultural applications feature elevated mounting heights (typically 2.5m or higher) and wide spans to accommodate farming machinery. Single-pole racking systems are particularly favored as they minimize land occupation and reduce interference with crop growth.

Complex Terrain: For mountainous or undulating sites, custom tracking systems with multiple slew-drive mechanisms can maintain tracking precision even on slopes. Antaisolar's TAI SIMPLE series, for example, offers flexibility on undulating terrain while maintaining structural stability.

High-Corrosion Environments: For coastal or desert installations, custom racking systems utilize zinc-aluminum-magnesium coated steel or stainless steel components to ensure long-term durability. The 3.0mm ultra-thick zinc-aluminum-magnesium steel from New Tianjin Steel is specifically designed for such applications.

Notable Project Developments

Nucor Gallatin Automatic Racking System (Kentucky, USA)

While not a PV project, the Nucor Gallatin facility demonstrates the scale and precision achievable with custom steel racking systems. Spanning 396,000 sq ft, this state-of-the-art tube mill produces 270,000 tons of steel tubing annually, including galvanized solar torque tubing. The project required fabrication and erection of over 4,600 tons of structural steel racking, installation of six fully automated overhead cranes, and precise alignment of more than 3,100 ft of crane rail.

The project's success highlights the importance of custom fabrication approaches: the contractor designed a jig for installing over 3,500 post-installed epoxy anchors, implemented modularization to reduce field connections by 20,000 units, and developed on-site assembly systems that eliminated significant elevated work.

Global Localization Trends

2024 has seen accelerating localization of PV racking manufacturing across major markets. The U.S. Inflation Reduction Act (IRA) is expected to drive 200-300GW of additional PV capacity and over $200 billion in new investment, with domestic racking capacity expanding accordingly. The EU's Net Zero Industry Act (November 2023) has set local manufacturing targets, though financial support still lags behind the U.S. The Middle East and North Africa region is attracting foreign investment through differential tariffs and subsidies for local capacity building.

These localization trends are driving demand for custom racking solutions, as manufacturers establish regional production facilities capable of delivering project-specific designs with shorter lead times and reduced logistics costs.

Future Outlook

The custom solar racking market is expected to continue its rapid growth through 2025 and beyond. Key trends shaping the industry include:

Increased use of AI and digital twins: For optimizing structural designs and predicting performance under site-specific conditions

Integration with energy storage: Racking systems designed to accommodate battery storage units alongside PV modules

Expansion of agrivoltaics: Growing demand for high-clearance, wide-span racking systems that enable dual land use

Advanced corrosion protection: Wider adoption of zinc-aluminum-magnesium coatings and other innovative materials

Automated fabrication: Increased use of robotics and precision manufacturing to reduce costs and improve quality

As one manufacturer representative noted: "The era of one-size-fits-all racking is ending. Every project has unique requirements — terrain, climate, land use, budget. Custom solutions are no longer a luxury; they are becoming the industry standard."

In a Nutshell

Tailor-made steel racking solutions are transforming the PV mounting industry in 2024. From high-strength, lightweight steels and advanced zinc-aluminum-magnesium coatings to flexible tracking systems and project-specific structural designs, customization is enabling solar installations in increasingly diverse and challenging environments. As the global PV market continues to expand, the ability to deliver precise, cost-effective, and reliable custom racking solutions will be a key differentiator for manufacturers and a critical success factor for project developers.