10 Popular Steel Structure Designs for PV Panel Projects

Here are the 10 most popular steel structure types for PV panel projects:

1. Fixed Tilt Ground

2. Single-Axis Tracker

3. Dual-Axis Tracker

4. Ballasted Roof

5. Flush Roof

6. Carport

7. Canopy

8. Pergola

9. Facade

10. BIPV Structure

Each Steel Structure for PV Panel project offers unique features, advantages, and ideal applications. The table below highlights recent global installation statistics for these mounting systems.

Key Takeaways

• Fixed tilt and flush roof steel structures offer low-cost, easy installation options ideal for projects with tight budgets and simple site conditions.

• Single-axis and dual-axis trackers increase solar energy output but require higher investment, more maintenance, and expert installation.

• Carports, canopies, and pergolas add value by combining solar power with functional outdoor spaces, enhancing property appeal and usability.

• Ballasted roof systems protect roof integrity by avoiding penetrations, making them suitable for flat commercial roofs with careful engineering for wind and seismic loads.

• Choosing the right steel structure depends on site conditions, climate, panel specs, budget, and aesthetics to ensure durability, efficiency, and visual harmony.

1. Fixed Tilt Ground

Overview

Fixed tilt ground systems use steel frames to support solar panels at a constant angle. These structures anchor directly into the ground. They do not move or track the sun. Many large-scale solar farms choose this design for its simplicity and reliability.

Features

• Simple design: Fixed tilt systems have fewer moving parts than trackers.

• Adjustable tilt angle: Installers can set the angle to match the site’s latitude for optimal sunlight.

• Durable materials: Most frames use galvanized steel for corrosion resistance.

• Low maintenance: The lack of motors or moving joints reduces upkeep needs.

Pros

1. Cost-effective: Fixed tilt systems often cost less to install than tracking systems.

2. Reliable: The sturdy design withstands harsh weather and requires little maintenance.

3. Quick installation: Crews can assemble these structures faster than more complex systems.

4. Predictable output: Energy production remains steady throughout the year.

Tip: Fixed tilt ground systems work well in areas with high land availability and consistent sunlight.

Cons

• Lower energy yield: Panels do not follow the sun, so they capture less energy than trackers.

• Land use: These systems need more space to avoid shading between rows.

• Limited flexibility: Once installed, changing the tilt angle requires significant effort.

Applications

• Utility-scale solar farms

• Rural or open land installations

• Projects with limited budgets

• Sites with minimal shading and flat terrain

A fixed tilt ground Steel Structure for PV Panel projects offers a balance between simplicity and performance. Many developers select this option for its proven track record and ease of deployment.

2. Single-Axis Tracker

Overview

A single-axis tracker rotates solar panels along one axis, usually from east to west. This movement allows panels to follow the sun’s path during the day. Many utility-scale solar farms use this system to increase energy production. The design uses a Steel Structure for PV Panel projects that supports both the panels and the tracking mechanism.

Features

• Motorized rotation: The system uses motors or actuators to move the panels.

• East-west tracking: Panels tilt to follow the sun’s movement across the sky.

• Modular design: Installers can expand the system by adding more rows.

• Weather sensors: Some trackers include sensors to adjust for wind or storms.

Pros

1. Higher energy yield: Panels capture more sunlight throughout the day.

2. Efficient land use: Rows can be spaced closer together than fixed systems.

3. Automated operation: The system adjusts itself without manual input.

4. Scalable: Suitable for both medium and large installations.

Note: Single-axis trackers can boost energy output by 15–25% compared to fixed tilt systems.

Cons

• Higher upfront cost: The tracking mechanism increases installation expenses.

• More maintenance: Moving parts require regular inspection and servicing.

• Complex installation: The system needs precise alignment and calibration.

• Potential for mechanical failure: Motors and gears may wear out over time.

Applications

• Utility-scale solar farms

• Commercial solar fields

• Projects aiming for maximum energy output

• Sites with flat or gently sloped terrain

Single-axis trackers offer a strong balance between increased energy production and manageable complexity. Many developers choose this design when they want to maximize returns without the added cost of dual-axis systems.

3. Dual-Axis Tracker

Overview

A dual-axis tracker moves solar panels along two axes. The system tilts panels both horizontally and vertically. This design allows panels to follow the sun’s path across the sky throughout the day and year. Many large-scale solar projects use this advanced system to maximize energy capture.

Features

• Full sun tracking: The tracker adjusts both tilt and rotation for optimal sunlight exposure.

• Automated controls: Sensors and motors manage movement based on the sun’s position.

• Robust steel frame: The structure supports the weight and movement of multiple panels.

• Weather adaptation: Some systems include wind stow features to protect panels during storms.

Pros

1. Maximum energy yield: Panels can generate up to 35% more electricity than fixed systems.

2. Efficient land use: The system reduces shading and increases output per square foot.

3. Advanced technology: Automated tracking ensures panels always face the sun.

4. Ideal for high-value sites: Best suited for locations where land or energy prices are high.

Tip: Dual-axis trackers work best in areas with high direct sunlight and minimal obstructions.

Cons

• High upfront cost: Dual-axis tracker kits often cost about $26,000, which is higher than single-axis systems.

• Expensive per panel: Tracking equipment can add over $1,000 per panel, with at least $500 extra investment per solar PV panel.

• Complex installation: Expert installation is required due to the system’s complexity.

• Ongoing maintenance: Movable parts wear out faster than PV panels, leading to higher maintenance and replacement costs.

Applications

• Utility-scale solar farms seeking maximum output

• Research facilities testing advanced solar technologies

• High-value commercial sites with limited space

• Projects where energy yield justifies higher investment in a Steel Structure for PV Panel

4. Ballasted Roof

Overview

Ballasted roof systems use weighted supports to secure PV panels on flat or low-slope roofs. These structures do not require roof penetrations. Instead, installers place concrete blocks or other heavy materials to hold the steel frame in place. Many commercial buildings with flat roofs choose this method to avoid damaging the roof membrane.

Features

• No need for roof penetrations, which helps preserve waterproofing.

• Quick installation process, as crews can place ballast and racks directly on the roof.

• Modular design allows for flexible panel layouts.

• Suitable for roofs with a pitch of 5% or less.

• Steel frames often use corrosion-resistant coatings for long-term durability.

Pros

1. Protects roof integrity by avoiding holes or fasteners.

2. Reduces installation time and labor costs.

3. Allows for easy removal or repositioning of panels.

4. Works well for leased buildings or sites with strict roofing warranties.

5. Minimizes risk of leaks compared to attached systems.

Tip: Ballasted systems offer a non-invasive solution for solar on flat commercial roofs.

Cons

• Adds significant weight to the roof, which may limit use on lightweight structures.

• Not suitable for steeply pitched roofs.

• Requires careful engineering to address wind uplift and seismic risks.

• May need additional ballast or attachments in high-wind or earthquake zones.

• Can complicate roof drainage if not properly designed.

Applications

• Commercial and industrial flat roofs

• Older buildings with strong steel truss structures

• Sites where roof penetrations are not allowed

• Temporary or leased property installations

Structural load requirements for ballasted roof systems depend on several factors:

• Site-specific engineering evaluations consider roof age, framing, and local codes.

• Older steel truss roofs often support more weight than newer lightweight designs.

• Roof pitch affects suitability; ballast works best on roofs with 5% pitch or less.

• Parapets and roof edges influence wind loads and ballast placement.

• Seismic zones may require attachments or buffer zones to prevent movement.

• Standard mechanical load tests may not reflect real-world conditions, so extra analysis is needed.

• Each project needs a building engineer to assess framing, drainage, and wind uplift.

• Software tools and site surveys help optimize ballast and layout for safety.

Note: Industry experts continue to refine standards for ballasted PV systems, especially in areas with high wind or seismic activity.

5. Flush Roof

Overview

Flush roof mounting systems attach solar panels directly to pitched roofs. The panels sit close to the roof surface, creating a low-profile look. Many residential and small commercial buildings use this design. Installers secure the steel rails or brackets to the roof structure, usually following the roof’s slope.

Features

• Panels align parallel to the roof, reducing wind resistance.

• Steel rails or brackets provide strong support.

• Systems work with most roofing materials, including shingles, tiles, and metal.

• Flashing and waterproof seals protect against leaks.

• Lightweight design minimizes added load on the roof.

Tip: Flush roof systems blend well with existing architecture and often meet local building codes.

Pros

1. Aesthetic appeal: Panels remain less visible from the ground.

2. Lower wind load: The close fit reduces the risk of wind damage.

3. Cost savings: Fewer materials and less labor lower installation costs.

4. Efficient use of space: No extra land or structures needed.

5. Quick installation: Crews can mount panels rapidly on most roof types.

Cons

• Limited tilt adjustment: Panels follow the roof angle, which may not be optimal for sunlight.

• Potential for roof leaks: Poor installation can lead to water intrusion.

• Difficult maintenance: Accessing panels or roof areas can be challenging.

• Not ideal for flat roofs: Flush systems require a pitched surface.

Applications

• Residential homes with pitched roofs

• Small commercial buildings

• Urban areas with limited ground space

• Projects prioritizing aesthetics and cost efficiency

Note: Flush roof steel structures suit homeowners who want reliable solar power without altering the building’s appearance.

6. Carport

Overview

Carport steel structures combine vehicle protection with solar energy generation. These systems use robust steel or aluminum frames to support PV panels above parking spaces. Many commercial and residential properties choose carports to maximize space and add value. Carports shield vehicles from sun, rain, and snow while producing clean electricity.

Features

• Dual-purpose design: provides covered parking and solar power.

• Modular construction: allows for single or multiple parking bays.

• Adjustable tilt angle: optimizes solar panel performance.

• High wind and snow load resistance: ensures safety in harsh climates.

• Corrosion-resistant materials: extend lifespan and reduce maintenance.

Pros

1. Efficient use of parking areas for energy production.

2. Reduces vehicle exposure to weather, lowering maintenance costs.

3. Enhances property value and visual appeal.

4. Supports high wind and snow loads for safety.

5. Flexible design fits various site layouts.

Tip: Carport systems often qualify for renewable energy incentives and can improve a property's sustainability profile.

Cons

• Higher initial investment compared to ground or roof mounts.

• Requires sufficient open space for installation.

• May need permits or zoning approval in some regions.

• Installation can disrupt parking during construction.

Applications

• Commercial parking lots at malls, offices, and hospitals.

• Residential complexes and private homes.

• Schools and universities seeking sustainable infrastructure.

• Public transport hubs and municipal facilities.

Carport steel structures offer a practical solution for sites that need both parking and solar power. Their robust design and customizable features make them a popular choice for modern PV panel projects.

7. Canopy

Overview

Canopy steel structures support PV panels above open spaces, such as walkways, playgrounds, or outdoor seating areas. These systems create shaded zones while generating solar power. Many schools, parks, and commercial sites use canopies to combine energy production with functional outdoor coverage. The design often features elevated steel frames that allow people and vehicles to move freely underneath.

Features

• Elevated Design: Canopies lift solar panels above ground level, providing shelter below.

• Flexible Sizing: Installers can customize the length, width, and height to fit different spaces.

• Durable Materials: Most canopies use galvanized or powder-coated steel for long-lasting performance.

• Integrated Drainage: Many systems include built-in gutters to manage rainwater.

• Aesthetic Options: Designers can choose from various shapes and finishes to match site needs.

Canopy structures often include lighting or signage, making them multi-purpose additions to public spaces.

Pros

1. Dual Functionality: Canopies offer both shade and renewable energy.

2. Space Efficiency: They use existing open areas without taking up extra land.

3. Enhanced Comfort: Shaded zones improve comfort for people using outdoor spaces.

4. Customizable Appearance: Owners can select styles that blend with surroundings.

5. Added Value: Canopies can increase property appeal and support sustainability goals.

Cons

• Higher Cost: Canopy systems usually cost more than ground or roof mounts.

• Complex Engineering: The elevated design requires careful structural planning.

• Longer Installation: Building large canopies may take more time and coordination.

• Maintenance Needs: Exposed steel frames and drainage systems need regular checks.

Applications

• Schoolyards and university campuses

• Parks and recreational facilities

• Outdoor seating at restaurants or malls

• Transit stops and pedestrian walkways

• Event venues seeking shade and solar power

Note: Canopy steel structures for PV panels help organizations turn unused outdoor areas into productive, comfortable, and sustainable spaces.

8. Pergola

Overview

A pergola steel structure for PV panels creates a shaded outdoor area while generating solar power. Homeowners and designers often select pergolas for patios, gardens, or poolside spaces. The steel frame supports solar panels above, blending renewable energy with outdoor living. Many residential projects use pergolas to combine comfort, style, and sustainability.

Features

• Strong, weather-resistant steel frames

• Customizable size, shape, and color options

• Modern, minimalistic design that fits various home styles

• Engineered for durability and safety by architects and engineers

• Supports both solar panels and climbing plants

• Low-maintenance materials such as galvanized steel or aluminum

Pergolas often outlast the solar panels they support, offering long-term value.

Pros

• Provides durable and safe support for solar panels

• Enhances outdoor living spaces by adding shade and defining areas

• Increases property value and curb appeal

• Reduces electricity bills through on-site solar generation

• Offers eligibility for federal and state tax incentives, including a 30% tax credit

• Complements modern architecture with an industrial aesthetic

• Allows for easy customization to match homeowner preferences

Cons

• Higher initial investment compared to basic ground or roof mounts

• Requires professional design and installation for safety and aesthetics

• May need local permits or approvals before construction

• Limited to areas with enough outdoor space for installation

Applications

• Residential patios, decks, and gardens

• Outdoor dining or lounge areas

• Poolside shade structures

• Community parks and shared green spaces

Homeowners choose steel pergola PV structures to enjoy both renewable energy and improved outdoor comfort. These systems turn ordinary yards into functional, attractive, and energy-efficient spaces.

9. Facade

Overview

Facade steel structures mount PV panels directly onto the exterior walls of buildings. These systems transform vertical surfaces into energy-generating assets. Many architects and engineers use facade installations to maximize solar potential in urban environments. Facade PV systems often serve both functional and aesthetic purposes.

Features

• Vertical Mounting: Panels attach to steel frames fixed on building facades.

• Customizable Layouts: Designers can arrange panels in patterns or grids.

• Integrated Design: Systems blend with architectural elements for a seamless look.

• Ventilated Gap: Most facades include a gap between the wall and panels for airflow.

• Durable Materials: Galvanized or stainless steel frames resist corrosion.

Note: Facade PV structures can double as shading devices, reducing heat gain inside buildings.

Pros

1. Efficient Use of Space: Facades generate solar power without occupying roofs or land.

2. Aesthetic Enhancement: Panels can create modern, attractive building exteriors.

3. Thermal Benefits: Systems provide extra insulation and reduce cooling costs.

4. Urban Suitability: Ideal for high-rise or dense city locations.

5. Flexible Orientation: Panels can face any direction, capturing sunlight on multiple sides.

Cons

• Lower Yield: Vertical panels capture less sunlight than tilted systems.

• Complex Installation: Mounting on facades requires skilled labor and careful planning.

• Higher Cost: Custom frames and integration increase project expenses.

• Maintenance Access: Cleaning and repairs can be challenging on tall buildings.

Tip: Facade PV systems work best on south-facing walls in the northern hemisphere.

Applications

• Office towers and commercial buildings

• Apartment complexes in urban areas

• Schools and public facilities with large wall surfaces

• Renovation projects seeking energy upgrades

• Buildings aiming for green certifications

Facade steel structures for PV panels help cities harness solar energy while improving building performance and appearance. These systems offer a smart solution for sites with limited roof space or high architectural standards.

10. BIPV Structure

Overview

BIPV (Building-Integrated Photovoltaic) structures combine solar panels with building elements. These systems replace traditional materials in roofs, facades, or skylights. The steel frame supports both the PV panels and the building envelope. Architects often use BIPV to create energy-efficient and visually appealing buildings.

Features

• Integration with roofs, walls, or windows

• Custom steel frames designed for structural and weather protection

• Dual function as both power generator and building material

• Wide range of shapes, sizes, and finishes

• Compatibility with modern and traditional architecture

BIPV structures often blend seamlessly with the building, making solar panels almost invisible.

Pros

1. Saves space by combining solar generation with building surfaces

2. Improves building aesthetics and value

3. Reduces energy bills and carbon footprint

4. Enhances insulation and weather resistance

5. Qualifies for many green building incentives

Cons

• Higher initial cost than standard PV systems

• Complex design and installation process

• Limited retrofit options for existing buildings

• Requires coordination between solar and construction teams

• May have lower efficiency due to less optimal orientation

Applications

• Commercial office buildings with glass facades

• Residential homes with solar roofs or skylights

• Schools and public buildings seeking LEED certification

• Urban projects with limited roof or ground space

• Renovations aiming for net-zero energy performance

Common standards for BIPV projects include:

• IEEE 1547 (interconnection of distributed resources)

• UL 1703 (flat-plate photovoltaic modules and panels)

• UL 1741 (inverters and interconnection equipment)

• NEC Article 690.12 (solar provisions in electrical code)

No unique certifications exist for BIPV steel structures, but these general PV standards ensure safety and performance.

Types of Steel Structure for PV Panel

Steel frames form the backbone of most PV panel installations. Different frame types suit various project needs and site conditions. Here are the main steel frame types used in solar projects:

• Portal Frames:

  • These frames use I beam sections, either rolled or fabricated.

  • Rolled I beams come from standard profiles and offer simple design choices.

  • Fabricated I sections use steel plates, allowing more flexibility in design.

  • Fully fabricated tapered frames change depth along their length, reducing weight and material use.

  • Portal frames work best for industrial or commercial buildings with PV panels on the roof.

• Truss Frames:

  • Truss designs use interconnected triangles for strength and stability.

  • They support large spans and heavy loads, making them ideal for wide-roof buildings or carports.

• Grid Frames:

  • Grid frames create a network of steel beams.

  • These frames distribute weight evenly and suit large ground-mounted solar arrays.

• C Type Frames:

  • C-shaped steel sections provide lightweight support.

  • They often appear in rooftop and small-scale solar projects.

Portal frames, especially tapered designs, save up to 11% in steel weight compared to rolled frames. This efficiency helps reduce both material costs and environmental impact.

Steel material choice affects both durability and cost. The table below compares common options:

Steel Structure for PV Panel projects often use galvanized or cold-formed steel for cost savings and durability. Stainless steel suits harsh environments where corrosion is a concern. Protective coatings and proper design further extend the lifespan of these structures.

Comparison Table

Selecting the right Steel Structure for PV Panel projects depends on several factors. The table below compares the ten most popular designs by key attributes. This overview helps readers quickly identify which structure fits their needs.

Tip: Fixed tilt ground and flush roof systems offer the lowest cost and easiest installation. Dual-axis trackers and BIPV structures provide the highest energy yield and aesthetics but require higher investment and expertise.

Key Points to Consider:

• Fixed tilt and flush roof designs suit projects with tight budgets.

• Carports, canopies, and pergolas add value and functionality to properties.

• Ballasted roof systems avoid roof penetrations, protecting building integrity.

• Facade and BIPV structures maximize solar use in urban or architecturally demanding projects.

Each Steel Structure for PV Panel project brings unique strengths. The table above helps project owners match their priorities—cost, durability, appearance, or space efficiency—to the best structure type.

Choosing the Right Structure

Selecting the best steel structure for a PV panel project involves careful evaluation of several important factors. Each site presents unique challenges and opportunities. Project owners should review the following key considerations:

• Site Conditions

  • Soil characteristics, such as acidity, density, and groundwater presence, affect foundation choices.

  • The ability to excavate the site determines if ballast mounts or helical piles are suitable.

  • Terrain complexity and topography influence the length and type of foundation piles.

  • Weather risks, including hurricanes, storms, and heavy snowfall, require strong structural designs.

• Panel Specifications

  • The need for tilt angle adjustment or tracking features impacts the selection of mounting systems.

  • Compatibility with panel size and weight ensures proper support and safety.

• Local Climate

  • Sunshine levels, wind speeds, and snow loads shape the requirements for structural integrity.

  • Some mounting types offer better resistance to harsh weather or allow for orientation changes.

• Maintenance and Cost

  • Simpler structures often require less maintenance and have lower upfront costs.

  • Complex systems may offer higher energy yields but demand more frequent inspections.

• Aesthetics

  • The visual impact of the installation can influence the choice, especially for residential or public sites.

Tip: Ballast mounts work well for sites where excavation is not possible, while ground screws suit rocky or clay-heavy soils.

To match the right structure to project needs, consider these practical steps:

1. Assess the site’s soil and terrain before selecting a foundation type.

2. Choose a Steel Structure for PV Panel that matches the local climate and expected weather conditions.

3. Review panel specifications to ensure compatibility with the mounting system.

4. Balance installation and maintenance costs with long-term energy goals.

5. Factor in the desired appearance and how the structure will blend with its surroundings.

A thoughtful approach helps ensure the PV system remains durable, efficient, and visually appealing for years.

• Each steel structure type offers unique benefits. Fixed tilt and flush roof systems provide cost savings and easy installation. Trackers increase energy yield but require more investment. Carports, canopies, and pergolas add value and function to properties.

• Readers should consider site conditions, budget, and long-term goals before choosing a Steel Structure for PV Panel.

• Professional services, such as ESTEL’s pre-engineered modular solutions, ensure compliance with engineering standards and adapt to harsh climates.

• Site assessments, proper training, and regular maintenance help maximize safety and performance.

FAQ

What is the most cost-effective steel structure for PV panels?

Fixed tilt ground and flush roof systems usually offer the lowest upfront costs. These designs use simple frames and require less labor. Many project owners choose them for budget-friendly solar installations.

How does local climate affect steel structure selection?

Local climate impacts material choice and design. High wind or snow loads require stronger frames. Galvanized or stainless steel resists corrosion in humid or coastal areas. Engineers recommend matching the structure to weather risks for long-term durability.

Can steel structures support both residential and commercial PV projects?

Yes. Steel structures adapt to many project sizes. Carports, canopies, and pergolas fit homes and businesses. Larger frames like ground mounts or trackers suit commercial and utility-scale sites.

Do ballasted roof systems damage the building?

Ballasted roof systems avoid roof penetrations. They use weights to hold frames in place. This method protects the roof membrane and reduces leak risks. Engineers still check roof strength before installation.

Are permits required for installing steel PV structures?

Most regions require permits for solar installations. Local codes may set rules for structure type, wind resistance, and electrical safety. Project owners should consult local authorities before starting construction.