Introduction
The quality of mounting structures in industrial shed solar installations directly impacts performance, safety, and return on investment (ROI).
These structures form the backbone of any rooftop solar plant, where both structural load and waterproofing are critical factors. Mounting structures not only hold the solar panels in place but also ensure the integrity of the industrial shed’s roof. Poor-quality systems can lead to issues like leakage, corrosion, misaligned panels, and lower power generation—ultimately impacting the life and ROI of your solar plant.
This blog explores the key specifications, essential components, installation practices, common pitfalls, and a checklist for buyers to ensure a high-quality and durable mounting system.
🔧 Key Components
Support Rails (Aluminum or Galvanized Steel)
- Why Aluminum: Lightweight, rust-free, reduces shed load and structural stress.
Material: Extruded Aluminum (High strength alloys like AL 6063 T6).
Types:
▶⃣ Short Rail – Directly fixed on trapezoidal roofs.
▶⃣ Long Rail – Spanning across multiple roof points, used with clamps.
IS Codes: IS 733, IS 1285.
Quality Specs: Minimum 10-micron anodizing, wall thickness > 1.5mm, load bearing capacity testing.
Fasteners & Clamps
Types:
▶⃣ Mid Clamp: Secures panels between two modules.
▶⃣ End Clamp: Locks the last panel at the edge.
▶⃣ Rail Clamp: Fixes rails to the roof or structure.
Material: Stainless Steel (SS 304/316).
IS Code: IS 1363, IS 1367.
Quality Check: Rustproof, precise threading, torque test passed.
Base Plates & Anchor Bolts
IS Code: IS 2062, IS 800.
Spec: Powder-coated, M10-M16 bolts, waterproof washers.
✅ Preventing Water Leakage
⚠️ Improper waterproofing can lead to rusting and leakage of the industrial shed.
✅ Always use EPDM gaskets or butyl tape between clamps and roof.
✅ Penetration points must be sealed with UV-resistant silicone sealant.
🤩 Earthing of Solar Panels
Proper earthing is a must for industrial rooftops to prevent lightning or surge damage.
✅ Methods:
Copper-bonded earthing rods (IS 3043 compliant).
Equipotential bonding of panels with copper wire.
Earth continuity testing for all metal parts.
⚠️ Risks of Poor-Quality Mounting Structures
🚫 Loose panel movement due to low-grade fasteners.
🚫 Roof damage from rusting clamps or improper anchoring.
🚫 Frequent maintenance leading to increased operational costs.
🚫 Long-term ROI loss due to reduced energy generation.
🏛️ Budget Vendors: Common Shortcuts
❌ Use of thin aluminum rails (<1.2mm wall thickness).
❌ Switching to mild steel fasteners to cut costs
❌ Poor galvanization or painting instead of HDG.
❌ Panel to panel earthing not done.
❌ Poor galvanization or painting instead of HDG.
❌ No waterproofing layers on roof contact points.
👨💼 Installer’s Role in Project Success
In industrial sheds, every roof type and load distribution matters. A good installer ensures:
🔹 Correct torqueing of all fasteners.
🔹 Accurate panel alignment across large spans.
🔹 No damage or bending of the roof sheet.
🔹 Proper waterproofing and drainage slope consideration.
🔹 Fully tested electrical earthing and surge protection.
❌ Common Installer Mistakes
❌ Ignoring load calculations on fragile sheds.
❌ Skipping waterproofing to save time.
❌ No torqueing or over-tightening fasteners.
❌ Misaligned rails leading to energy loss.
❌ Incomplete or unsafe earthing.
Conclusion
For industrial solar installations, mounting structures are not just technical hardware—they are strategic components that ensure energy performance, roof longevity, and investment protection. Choose certified materials, demand quality checks, and hire trained installers who understand industrial roof nuances.
