Flat Roof PV Mounting System Manufacturers

From design to operation and maintenance: technical points of the whole process of flat roof PV mounting system

Structural features of flat roof PV mountings
Flat roof PV mountings usually refer to structural systems installed on roof surfaces without obvious inclination to support photovoltaic modules. Its core structure includes components such as base, beams, vertical supports, rails and clamps, forming an overall stable and easy-to-maintain load-bearing system.
Unlike pitched roof mountings, the main features of flat roof systems are adjustable inclination design and compatibility with roof protection. In system design, Dongsheng New Energy uses a combination of modular structure and standardized components to make the mounting not only adapt to different types of components, but also adjust the inclination according to local conditions to optimize power generation efficiency.

Classification of mounting installation methods

1. Non-penetration installation (ballast type)
This method uses counterweight blocks to achieve system stability without drilling holes in the roof. It is often used on roofs where the waterproof layer cannot be damaged. Ballast materials usually use concrete blocks or metal counterweight blocks. The layout needs to be considered in combination with on-site wind force, roof load capacity and drainage conditions.
2. Penetration installation (chemical anchor/expansion bolt fixing)
When the roof structure allows penetration, the mounting system can be reinforced by anchoring to further enhance wind resistance. It is suitable for concrete roofs and factory roofs with strong structural bearing capacity, but waterproof sealing should be focused on to prevent water seepage.
3. Adjustable inclination installation
In order to adapt to the optimal power generation angle in different latitudes, some flat roof mountings of Dongsheng New Energy adopt adjustable support leg design, so that the angle of the component can be flexibly set within the range of 10°-30°, improving the average annual power generation efficiency.

Material selection and anti-corrosion treatment requirements
PV mountings are exposed to outdoor environments for a long time and must have good weather resistance, corrosion resistance and mechanical strength. The mainstream materials in the industry include:
* Aluminum alloy (common model 6063-T5): light weight, strong corrosion resistance, suitable for projects sensitive to roof loads.
* Hot-dip galvanized carbon steel: high cost performance, stable structure, suitable for environments with large wind loads.
* Stainless steel fasteners: used for component fixing parts to avoid loosening due to metal contact corrosion.
The flat roof mounting products provided by Taizhou Dongsheng New Energy have all passed ISO quality management system certification. Some core components adopt independent patented structural design, and the surface treatment adopts hot-dip galvanizing (≥80μm) or anodizing processes to effectively extend the service life.

Wind load and system stability design
Flat roof PV mountings are often exposed to the front of the wind due to the inclination design, and wind resistance becomes a key indicator in the design. The system design needs to calculate the wind load according to the "Building Structure Load Code" of the project location.
Dongsheng New Energy uses a combination of structural simulation and on-site data evaluation to perform finite element analysis on the stress points of the mounting system to ensure the overall stability of the system in a strong wind environment. For the ballasted installation system, Dongsheng's design team further improves the system's wind resistance by optimizing the counterweight arrangement and adopting a windshield design.

Compatibility of photovoltaic modules and mountings
Photovoltaic modules from different manufacturers differ in size, thickness, and weight, and flat roof PV mounting systems need to have good compatibility. Dongsheng New Energy set up a variety of guide rail grooves and adjustable clamps during the R&D stage, so that the mounting system can adapt to the mainstream 166/182/210 series components, which is conducive to customers' flexible decision-making in component procurement and project progress.
The coordination of the mounting system and the inverter wiring path is also part of the system integration. Dongsheng comprehensively considered the component arrangement, inverter layout and cable direction during the project design stage to improve the overall construction efficiency of the system.

Maintenance convenience and system life cycle
The operating life of the flat roof system is usually designed to be more than 25 years. During this period, the durability of the structure, maintenance convenience and component cleaning ability become key factors affecting the stability of power generation.
Taizhou Dongsheng New Energy incorporates convenient connectors, quick-install guide rails and other structural designs into product design, and sets sufficient channel width to facilitate daily inspection and cleaning by operation and maintenance personnel. Some mounting systems are equipped with water collection and drainage grooves and ground wire routing slots to improve the standardization of on-site wiring.

As the core supporting structure of the photovoltaic system, the flat roof PV mounting plays a key role in system stability, power generation efficiency and operation and maintenance management. Relying on continuous technical research and development capabilities and mature project delivery experience, Taizhou Dongsheng New Energy has formed an integrated service system covering design, manufacturing, installation and maintenance, providing highly reliable and adaptable flat roof support solutions for the global distributed photovoltaic market.

Photovoltaic system support foundation: Systematic analysis of flat roof PV mounting

System structure of flat roof PV mounting
Flat roof PV mountings are generally used to be installed on roofs without obvious inclination angles. Their function is to stably carry photovoltaic modules and ensure their safe operation under various climatic conditions. According to different installation methods, flat roof PV mountings can be roughly divided into several types, such as ballast type, penetration type and adjustable angle type.
The ballast type structure uses counterweights to keep the system stable and is suitable for roofs that do not allow drilling, such as some commercial roofs; the penetration type structure is fixed to the roof concrete structure through anchors and is suitable for areas with large wind loads; and the adjustable inclination type structure adjusts the orientation of the components according to the local sunshine angle to improve power generation efficiency. Taizhou Dongsheng New Energy Technology Co., Ltd. In actual projects, the appropriate mounting solution will be selected and the structure will be optimized based on factors such as roof structure, geographical location, wind speed level and load capacity.

The impact of installation method on structural safety
The installation method of flat roof PV mountings is closely related to the roof structure. Choosing a reasonable installation method not only helps to improve construction efficiency, but also affects the service life and risk resistance of the system.
*Ballast installation method: This method does not damage the roof structure and is often used in buildings where drilling is not allowed on the roof, such as commercial buildings or factory roofs with thin waterproof layers. The ballast block is generally made of concrete or prefabricated metal counterweights, and the load is evenly distributed with the guide rail system. When Taizhou Dongsheng New Energy Technology Co., Ltd. applies this solution, it will be combined with anti-slip mats and gutter designs to reduce the impact on the roof waterproof layer.
*Penetration fixing method: Suitable for roofs with high structural strength, such as reinforced concrete roofs. The mounting is fixed in the structural layer by expansion bolts or chemical anchors to improve the overall stability. This method has strong resistance to wind loads, but sealing and waterproofing measures must be taken to prevent water seepage from the roof.
*Adjustable inclination structure: Used to optimize the angle between the component and solar radiation, it is common in low and medium latitudes. In the mounting system designed by Taizhou Dongsheng New Energy Technology Co., Ltd., the inclination can be adjusted from 10° to 30°, taking into account both installation convenience and power generation efficiency.

Material selection and anti-corrosion technology
PV mountings that operate for a long time under various climatic conditions must have good corrosion resistance and structural stability. Common materials include hot-dip galvanized steel, aluminum alloy, stainless steel, etc.
*Hot-dip galvanized steel mounting: high strength, suitable for large span and high wind pressure environment, the surface galvanized layer thickness is usually above 80 microns, which effectively prevents corrosion. Taizhou Dongsheng New Energy Technology Co., Ltd. strictly controls the thickness of the galvanized layer during product manufacturing to ensure that the service life of the mounting reaches more than 25 years.
*Aluminum alloy mounting: light weight, easy installation, suitable for roofs with limited bearing capacity, widely used in rooftop photovoltaic projects. The company selects 6063-T5 industrial aluminum profiles and enhances its weather resistance through anodizing.
*Stainless steel fasteners: used for connectors and rail pressure blocks, which can avoid metal potential difference corrosion and improve the overall durability of the system.
Taizhou Dongsheng New Energy Technology Co., Ltd. combines the characteristics of different engineering projects to provide customers with a variety of material selection solutions, and cooperates with product testing and third-party testing to ensure reliable operation of the system.

Wind load and structural stress analysis
Wind load is an important factor in the design of flat roof photovoltaic systems, especially in coastal and high wind speed areas. Reasonable wind resistance design directly affects the safety and long-term stability of the system.
The design team of Taizhou Dongsheng New Energy Technology Co., Ltd. uses structural software to perform finite element analysis and simulate the stress points of the system. According to the "Building Structure Load Code" in different regions, consider parameters such as wind direction, building height, roof friction coefficient in advance during the system layout stage, design reasonable ballast distribution and mounting spacing to ensure the structural safety of the system under the design wind speed. During the on-site installation of the project, the company's technicians will evaluate the on-site wind conditions and make adjustments based on meteorological data and the actual situation of the roof.

PV module layout and space utilization
In the design of flat roof systems, the arrangement of components affects the overall power generation efficiency, ventilation effect and maintenance channel reservation. Common arrangements include single-row arrangement in the north-south direction, double-row back-to-back arrangement, east-west double-tilt arrangement, etc.
Taizhou Dongsheng New Energy Technology Co., Ltd. optimizes the utilization of roof space while ensuring the reasonable orientation of components through the integrated design of components and mounting systems. For roofs with obstacles (such as vents and water tanks), the company will design personalized mounting wiring and layout solutions to improve the overall efficiency of the project. The setting of maintenance channels is also a key content in the company's plan. Usually, a space of about 600mm is reserved between each group of components to facilitate later cleaning and maintenance.

System maintenance and post-management
Although the flat roof mounting system is a static structure, it still needs regular inspection and maintenance to extend the service life of the system and ensure the safe operation of the components. Taizhou Dongsheng New Energy Technology Co., Ltd. formulates a regular inspection plan for each project, including fastening of connectors, inspection of rust, and monitoring of foundation displacement.
For ballasted structures, it is also necessary to regularly check the displacement or loosening of the counterweight block and make timely adjustments; for penetrating structures, pay attention to whether the anchor point is loose and whether the waterproof layer is aging. The company provides customers with maintenance manuals and technical support to help them establish system operation ledgers.