A drone-captured image of a large solar farm in Kingston, Canada, surrounded by snow.

How to Calculate Mounting Structure for Solar System

Calculating the mounting structure for a solar system is a key engineering step in solar project design. A properly calculated solar mounting system ensures structural safety, long-term durability, and stable power generation under different environmental conditions.

This guide explains how to calculate a solar mounting structure using practical, engineering-based logic commonly applied in commercial and utility-scale solar installations.

Step 1: Define Basic Design Parameters

Before starting any calculation, it is essential to define the basic project parameters:

  • Solar panel dimensions and weight
  • Number of panels per row or table
  • Installation type (roof-mounted or ground-mounted)
  • Tilt angle of the solar panels
  • Installation height from ground or roof
  • Project location and climate conditions

These parameters directly influence wind load, snow load, and structural spacing.

Example:
A ground-mounted solar system installed in a coastal or high-wind area requires stronger mounting structures than a rooftop system in a low-wind urban region.

Step 2: Calculate Dead Load of the Solar Mounting Structure

Dead load refers to the permanent static load acting on the mounting system.

Dead load includes:

  • Weight of solar panels
  • Weight of mounting rails and beams
  • Weight of posts, clamps, and fasteners

Dead Load Formula (simplified):

Dead Load = Total weight of modules and mounting components per square meter

Dead load calculation helps determine suitable material thickness and profile strength.

Step 3: Calculate Wind Load on Solar Mounting System

Wind load is often the most critical factor in solar mounting structure design.

Key factors affecting wind load:

  • Local design wind speed
  • Panel tilt angle
  • Installation height
  • Terrain category (open field, suburban, coastal)

Basic wind pressure calculation:

Wind Pressure = 0.5 × Air Density × Wind Speed²

In real projects, wind load calculations follow international standards such as:

  • ASCE 7
  • EN 1991 (Eurocode)
  • AS/NZS standards

Higher tilt angles and elevated installations significantly increase wind uplift forces on the solar mounting structure.

Step 4: Calculate Snow Load (If Required)

For regions with snowfall, snow load must be included in the structural calculation.

Snow load depends on:

  • Local ground snow load values
  • Tilt angle of solar panels
  • Roof or ground installation type

Snow load affects rail span, beam size, and post spacing, especially for large solar arrays in cold climates.

Step 5: Determine Post Spacing and Rail Span

After combining dead load, wind load, and snow load, the next step is to determine:

  • Post spacing
  • Rail span
  • Beam cross-section size

The design objective is to:

  • Prevent excessive deflection
  • Avoid material yielding
  • Maintain long-term structural stability

Reducing post spacing increases structural strength but also increases material and installation costs. A balanced design is essential.

Step 6: Select Suitable Materials for Solar Mounting Structure

Common materials used in solar mounting systems include:

  • Aluminum alloy (6005-T5, 6063-T5)
  • Hot-dip galvanized steel
  • Stainless steel fasteners

Material selection depends on load requirements, corrosion environment, and project budget.

Coastal and high-humidity areas typically require higher corrosion resistance.

Step 7: Apply Safety Factor and Final Verification

Safety factors are applied to ensure the mounting structure remains safe under extreme conditions.

Typical safety factors:

  • 1.5 to 2.0 for structural components
  • Higher safety margins for wind uplift-critical projects

Final verification usually includes structural checks, engineering drawings, and compliance with local building codes.

Why Accurate Solar Mounting Structure Calculation Is Important

Accurate calculation of a solar mounting structure helps to:

  • Prevent structural failure
  • Extend system service life beyond 25 years
  • Reduce maintenance and repair costs
  • Meet international and local certification requirements

A properly designed solar mounting system improves both safety and overall project return on investment.

Frequently Asked Questions

What standards are used for solar mounting structure calculation?

Commonly used standards include ASCE 7, Eurocode EN 1991, and local building codes depending on the project location.

Can solar mounting structures be customized?

Yes. Professional manufacturers can provide customized mounting solutions based on site conditions, load requirements, and project specifications.

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