Industry Background: The Solar Mounting Market Continues to Heat Up

In 2022, the global PV industry continued its rapid growth driven by the “dual carbon” goals. As a key support component of power station systems, solar mounting systems welcomed new development opportunities. Industry data shows that in 2021, China’s solar mounting market recovered to approximately RMB 17.5 billion in scale. Strong downstream demand from the distributed PV market effectively drove the development of the mounting industry. At the same time, the national “whole-county promotion” distributed PV policy was intensively introduced, with over 20 provinces and cities issuing relevant policies. There is huge market potential for new energy-saving green buildings and PV additions to existing buildings.

In the metal-roof solar installation sector, 2022 saw a clear trend of accelerated product innovation, continuous optimization of installation techniques, and expanding application scenarios. Looking at exhibitions such as Intersolar, the diversification of PV mounting installation methods remained a core trend, with products constantly emerging to serve everything from standing-seam metal roofs to various commercial and industrial building roofs.

02 New Product Highlights: Several Metal-Roof Solar Mounting Kits Launched

In 2022, multiple PV mounting manufacturers intensively launched new solar mounting kits for metal roofs, achieving comprehensive upgrades in installation efficiency, material cost, and system durability.

S-5! PV Kit 2.0: Benchmark for Penetration-Free Technology

In June, global metal-roof PV accessory leader S-5! officially released its new-generation PV Kit 2.0 solar mounting kit. The kit features S-5!’s signature zero-penetration fixation technology, requiring no drilling into the metal roof to securely install solar modules, fundamentally eliminating the risk of roof leaks caused by installation.

PV Kit 2.0 features significant improvements in installation convenience: the entire system can be installed with just one tool, and pre-assembled MidGrab or EdgeGrab clamps greatly simplify on-site construction. For electrical safety, the kit adopts more aggressive grounding teeth to ensure more reliable system grounding, while significantly reducing the number of lugs and copper wire used for inter-module connections, further lowering system BOS costs. Additionally, the kit leaves a 1-inch gap between modules, effectively reducing wind load impact on the system.

Magerack: Innovative Breakthrough with a Rail-Less Design

In August of the same year, Magerack launched the MageBracket CL rail-less mounting kit specifically for corrugated metal roofs. The kit features an innovative rail-less design, consisting of only two main components – mid-clamp kits and end-clamp kits – greatly reducing the number of parts. The mid-clamps integrate electrical connection functionality, completing electrical connections between adjacent modules while clamping them. The universal end-clamps are compatible with all framed solar modules. All bolts use a uniform specification, requiring only one socket for all fastening operations. Installers can easily tighten the clamps from the top or outside, significantly improving on-site installation efficiency.

PV-ezRack SolarRoof: Durability Choice with Anodized Finish

Clenergy’s PV-ezRack SolarRoof™ system introduced a Tin Roof Interface metal roof mounting interface kit with a black anodized finish, designed specifically for solar module installation on metal roofs. The kit uses high-strength AL6005-T5 aluminum alloy, equipped with EPDM pre-installed gaskets and SUS304 stainless steel fasteners. The black anodized surface finish enhances corrosion resistance while blending seamlessly with the roof appearance. The kit includes roof interfaces, roof screws, and Z-shaped modules, compatible with metal or wood purlins, offering flexible installation options for different roof structures.

Risen Energy “Super Top”: New Heights in BIPV Integration

In March, Risen Energy released its ultra-low carbon BIPV product “Super Top”, which adopts an innovative integration of modules and steel panels, seamlessly integrating with color steel tiles as a building material within the building system. The product features a new frameless dual-glass module technology using 210 cells, paired with a 360° standing seam 740瓦型 (740 profile), providing excellent waterproofing. The shadow-free design can increase power generation by an additional 1.5%. “Super Top” is easy and quick to install – a single person can complete the job. Its excellent corrosion-resistant design, wind resistance, and fire performance greatly reduce the frequency of later maintenance.

Schletter ProLine: Efficiency Revolution through Material Optimization

At Intersolar 2022, Schletter Group, a world-leading solar mounting manufacturer, showcased its latest ProLine pitched roof system, with the core concept of “achieving the same or even higher load-bearing capacity using less material.” The new profile geometry significantly reduces material usage compared to previous standard profiles while withstanding higher loads. ProLine profiles can be installed without tools using a single internal connector, saving installation time and cost. Additionally, Schletter launched lightweight EcoA and RapidA aluminum roof hooks, offering more options for optimizing projects and reducing installation costs.

Antai Energy “Taiyang Ding”: Flagship All-Aluminum BIPV Solution

In July, Antai Energy prominently exhibited its new product “Taiyang Ding” all-aluminum BIPV solution at the 17th China (Jinan) Solar Energy Utilization Conference. The product uses Antai’s self-developed high-performance aluminum alloy, with all material properties exceeding Chinese national standards by over 20% (yield strength nearly 60% higher), offering lightweight construction, high strength, super corrosion resistance, and long life. In terms of waterproofing, “Taiyang Ding” adopts a philosophy of “external drainage and internal redirection.” With six waterproof components working closely together, it achieves 100% waterproofing. In actual installations, it can increase efficiency by about 50% and reduce material and labor costs by 20%.

03 Technical Depth: Core Techniques and Innovations in Metal-Roof PV Installation

Three Main Installation Methods

According to the three-part white paper series “Solar and Metal Roofing” (jointly completed by S-5! and the Metal Building Association (MCA) in 2022), there are three primary methods for metal-roof PV installation. Flush-mounted systems are currently the most widely used solution, with modules leaving about 4 inches of clearance from the roof surface to allow air circulation and module cooling, and can be installed on metal roofs with slopes as low as 2°. Rail-mounted systems use aluminum rails to mount modules above the roof, adding 7 to 9 inches of space above the rails, providing ample room for optimizers and rapid shutdown devices. Direct-fixation systems mount modules directly onto the metal roof’s ribs or rails without additional rails, resulting in fewer system components and faster installation. Choosing the appropriate installation method requires a comprehensive assessment based on the specific roof type, metal roof panel profile, and actual roof conditions.

Clamps and Rails: Core Components for Metal-Roof PV

Aluminum alloy clamps are key connecting components in metal-roof PV mounting systems. Their main function is to clamp onto the ridges of color steel sheets and support the aluminum rails installed on the roof. Jiangyin Juxin Energy’s aluminum alloy clamps, made of aluminum alloy with stainless steel accessories, require no drilling through the color steel tile roof, fundamentally eliminating water leakage caused by module installation. Such clamps securely lock the color steel tiles and aluminum rails, offering durability, aesthetics, easy assembly, and quick installation, and are widely applicable in roof PV mounting systems.

Color steel tile pitched roof PV mounting systems use a unique extruded aluminum alloy support, tilt mounting clips, and various clamps, mainly consisting of rails, rail connectors, mid-clamps, end-clamps, and clamps. All accessories are highly pre-assembled before delivery, making installation simple and fast. Solar First’s adjustable metal leg system offers a versatile mounting solution for all common metal roof profiles, including standing seam, corrugated, trapezoidal, and arc designs, with customizable tilt ranges to improve solar output by optimizing panel orientation.

“No-Tear-Off” Technique: A Disruptive Innovation in Installation Philosophy

In 2022, the “no-tear-off” BIPV system installation technique innovatively developed by State Grid Zhoushan Power Supply Company became a major technical highlight in the field of metal-roof PV installation. Traditional roof PV systems require concrete piers to fix the mounting structure, with an average weight of about 400 kg per 10 square meters, placing significant pressure on the load-bearing capacity of color steel tile roofs. Additionally, the cost of removing color steel tiles can be as high as one million yuan per thousand square meters. Zhoushan Power Supply Company used L-shaped brackets and self-tapping screws to penetrate the color steel tiles, firmly connecting the PV panel mounting structure to the roof’s steel framework. This approach reduces roof load pressure while saving the cost of color steel tile removal, reducing installation costs for roof PV projects by an average of nearly 30%. Furthermore, the “no-tear-off” technique increases usable roof area by over 70%, significantly improving installed capacity. For rainwater protection, Zhoushan Power Supply Company proposed a “full-coverage” installation scheme, establishing a three-layer waterproofing system: surface layer, structural layer, and base layer.

04 Standards, Codes, and Industry Certifications: Ensuring Installation Quality and Safety

In 2022, the metal-roof PV installation field made important progress in the development of standards and codes.

In July, Zhejiang Province released local standard DBJ33/T1282-2022, “Technical Specification for Integration of Crystalline Silicon Photovoltaic Systems with Profiled Metal Sheet Roofs,” providing a unified technical basis for the design, construction, and acceptance of integrated systems.

In June, the China Construction Metal Structure Association organized a technology evaluation meeting in Huaibei City, Anhui Province, for the “Photovoltaic Building Integration (BIPV) Applied Technology for Steel Structure Roofs with Structural Waterproofing.” This achievement, completed jointly by Jiangsu Baijia New Energy Technology Co., Ltd. and others, reached an internationally advanced level overall according to the expert panel. The innovation includes integrating PV design from the early planning stage of the building, and using overlapping waterproof frames, drainage beams, and auxiliary waterproof covers to enhance waterproofing and eliminate roof leakage risks, significantly extending service life.

In terms of product certification, mainstream metal-roof mounting kits in 2022 generally passed international certifications such as UL 2703. Materials are primarily AL6005-T5 aluminum alloy and SUS304 stainless steel with anodized surface treatment, offering 10-year warranties and 20–25 year service lives. Wind resistance generally exceeds 60 m/s, meeting safety requirements under various climatic conditions, including typhoon-prone areas.

05 Large-Scale Project Applications: Metal-Roof PV Moves from Concept to Scale Practice

In 2022, several large-scale metal-roof PV projects were successfully completed, fully validating the engineering feasibility and economic value of metal-roof solar mounting kits.

Huizhou Nangang Steel 3.5MW BIPV Project

In September, Kseng Solar adopted a BIPV integrated photovoltaic building solution for the deteriorated roof of Nangang Steel’s industrial facility, launching a 3.5MW renovation project. Given the acidic/alkaline emissions in the steel plant environment, the project used high-quality aluminum alloy BIPV products with stable corrosion resistance. The lightweight, modular design facilitated later operation and maintenance, achieving overall cost reduction and efficiency improvement for the rooftop power station.

Xiamen 21MW Metal-Roof PV Project

In November, Mibetsolar’s 21MW metal-roof PV mounting project in Xiamen, China, was successfully completed and grid-connected. The project installed aluminum rails onto clamps, further strengthening the overall structure and ensuring the fundamental stability of the solar mounting framework.

Zhoushan “No-Tear-Off” PV Projects

Since the implementation of Zhejiang Province’s “Doubling Wind and Solar Plan” in June 2021, Zhoushan Power Supply Company has signed contracts for 69 PV projects with a total capacity exceeding 80,000 kW. Of these, 68 projects totaling approximately 78,000 kW have been commissioned and grid-connected. It is estimated that these projects will save the involved companies an average of about 20% on annual electricity costs, reduce raw coal consumption by approximately 31,512 tons, and cut CO2 emissions by nearly 61,775 tons. For just four roof PV projects at companies including Wanbang Heavy Industry, East Coast, and Changhong International, the company helped the enterprises save over RMB 100 million in investment.

Longteng Special Steel BIPV Project

As one of the largest-span photovoltaic building integration projects in China to date, the Longteng Special Steel BIPV project uses a three-span double-layer cylindrical latticed shell steel structure roof. The 68,000 monocrystalline PV panels laid on the roof cover an area of 176,000 square meters – equivalent to 25 football fields. The maximum span of the large structure is 223.7 meters, and the maximum roof height is 58 meters. The project saves nearly 10,000 tons of standard coal annually, reducing SO2 emissions by 77.4 tons, NOx emissions by 82.6 tons, and CO2 emissions by 25,000 tons.