Solar structure fabrication

Products Manufacturing

Solar structure fabrication is the industrial process of designing and manufacturing the “skeleton” (racks and mounts) that holds solar panels in place.1 Because these structures must last 25+ years in harsh outdoor environments, the fabrication process involves heavy-duty metallurgy and precision engineering.

1. Common Materials & Treatments2

The choice of material depends on the environment (coastal vs. desert) and the scale of the project.3

  • Galvanized Steel (Most Common): Carbon steel is coated with a layer of zinc via Hot-Dip Galvanization.4 This is the industry standard for ground-mounted solar farms because it is strong and cost-effective.

  • Anodized Aluminum: Preferred for rooftop systems due to its light weight and natural resistance to corrosion.5 It doesn’t add excessive load to building structures.

  • Zinc-Magnesium-Aluminum (ZAM) Coating: A newer high-performance coating for 2026 that offers superior self-healing properties on cut edges, making it ideal for high-salinity coastal areas.

2. The Fabrication Process

The journey from raw metal to a finished solar rack involves several specialized steps:

Step Process Detail
Design & Engineering CAD & Wind Analysis Engineers calculate the “Wind Load” and “Snow Load” to determine the thickness of the metal needed.
Cutting & Punching CNC Laser/Plasma Computer-controlled machines cut the steel sections and punch holes for bolts with sub-millimeter precision.
Cold Roll Forming Profile Shaping Long strips of metal are passed through rollers to create “C,” “U,” or “Sigma” profiles, which provide maximum strength with minimum weight.
Welding Robotic MIG/TIG High-precision robotic arms perform the welding to ensure uniform strength across thousands of units.
Surface Treatment Hot-Dip Galvanizing The fabricated parts are dipped in molten zinc at 450°C to create a permanent, rust-proof bond.

3. Types of Structures being Fabricated

  • Fixed-Tilt: The simplest and most durable. The panels are locked at a specific angle (e.g., 30°) facing the equator.

  • Seasonal Tilt: Fabricated with adjustable “telescopic” legs that allow manual adjustment of the angle twice a year to capture more sun.

  • Single-Axis Trackers: These involve complex fabrication of moving parts, including torque tubes and bearing housings, allowing panels to follow the sun from East to West.6

  • Carport / Canopy: Heavy-duty, long-span structures fabricated to support panels while allowing vehicles to park safely underneath.

4. Key Quality Checks

Because a structural failure can destroy millions of dollars in solar panels, fabrication plants use strict testing:

  1. Pull-out Test: Testing the force required to pull a foundation pile out of the ground.

  2. Zinc Coating Thickness: Measured in microns to ensure it meets the 25-year lifespan requirement.

  3. Salt Spray Testing: Subjecting samples to high-salt environments to simulate decades of coastal wear.

Would you like to see a specific bill of materials (BOM) for a standard 10kW ground-mount structure, or are you interested in the latest “self-healing” coatings used in 2026?