Solar Racking: The Best Solution for Mounting Solar Panels

Solar racking is a mounting system used to firmly fix solar panels on different surfaces such as roofs, grounds, or a pole. The main importance of solar racking in a solar panel system includes ensuring safety and stability, optimal positioning, maximizing energy outputs, easing airflow, a straightforward maintenance process, and protection against harsh environmental conditions by providing resistance in high wind areas.

Let’s find out the working process of solar racking, the components involved, types, benefits, and challenges. Most importantly, to select the top brands at a reasonable cost, there are certain important factors to be considered so that you can understand how the solar module racking can be adjusted after installation.

What is Solar Racking? How Does It Work?

Solar racking is the framed structure to mount solar panels as the framework ensures that the modules are fixed in the proper place and controlled by sudden fluctuations in weather conditions.

The working procedure starts right away by setting up the panels with a racking system on the rooftop or ground, which is later connected to the power grid. The energy production can be increased to its highest level based on factors such as direction, angle, and geographical location. Mainly, the solar panels are oriented at a 30-degree angle to gain maximum exposure to sunlight by facing either south or southwest to facilitate maximum energy generation and enhanced efficiency.

What Are the Components of Solar Racking?

Flashings, mounts, rails, and clamps are the most important components of solar racking discussed below in detail:

1. Flashings: Typically, Flashings are the materials that prevent water leakage through a roof covered with thin and rectangular aluminum sheets. The flashings are positioned underneath shingles on a traditional asphalt-based tile roof. Suppose the roofs are constructed with tiles, metal, rubber, or wood, the designed flashings are specifically used to suit the exact shape of your roofing material.
   
2. Mounts: The solar panel systems connected to your roof with mounts are referred to as feet. The entire system is assembled by attaching your roof with a bolt that is linked through flashing and a rafter. Several types of mounts are used in racking systems. To ensure the rafters are completely functional and properly spaced, solar installers should have an initial visit to your site to position the mounts for your solar panel system.
   
3. Rails: Mounts are attached to the long aluminum tracks known as rails installed either vertically or horizontally on your roof. The rack rails are made of aluminum to provide a strong base for solar panels by increasing their durability and strength. The main advantage of adding rails is that considerable space is provided to run the wiring of your solar panel system which helps to minimize clutter and improve reliability and aesthetic appeal of your installation.
   
4. Clamps: Installers use clamps to connect solar modules and rails. Most often, mid-clamps and end-clamps are used for installation. The main difference is that the mid-clamps are situated between the solar panels on both sides, whereas the large-sized end-clamps are located at the rear side of the entire system.
   

Types of Solar Racking

These are the most commonly used solar racking systems types explained below with their design, uses, and benefits:

1. Ground Mounted Racking:

• Design: Installed on the ground using concrete or metal to support the panels.
• Uses: Large-scale solar farms, commercial installations, and properties with huge land space.
• Benefits: Accommodates higher capacity, no modifications required, and simple to install the tracking systems.

2. Roof Mounted Racking:

• Design: Installed directly on a flat roof.
• Uses: Suitable for solar farms, and residential and commercial installations.
• Benefits: Easier maintenance, lower installation costs, and provides roof protection.

3. Tracking Racking Systems:

• Design: Tracking technology such as motors and sensors are used to adjust the angle of panels throughout the day. Designed with one-axis (sun’s movement from east to west) and two-axis trackers (sun’s routine and seasonal path).
• Uses: Utility-scale installations and areas with higher solar irradiance.
• Benefits: Maximum electricity generation during peak hours, optimizes the possibility of limited space, and avoids shading to increase efficiency.

4. Carport Mounting Structures:

• Design: Similar to ground-mounted structures that are installed above ground level to allow spaces such as car parking.
• Uses: Residential and commercial buildings.
• Benefits: Easier maintenance, dual functionality of energy generation, and providing shade.

5. Shed Mounting Structures:

• Design: Mounted on metal sheds or sheet roofings.
• Uses: Residential, commercial, and industrial sectors.
• Benefits: Reasonable installation costs, easy maintenance, and converts underutilized space into energy generation areas.

Benefits of Solar Racking

These are the benefits of using the right solar racking system:

1. Enhanced Energy Production: To obtain peak solar efficiency, the panels must be aligned in the best possible way according to the sun’s position to maximize the generated energy throughout the lifespan of a panel.
2. Durability and Protection: The racking system provides high-quality support by protecting panels against harsh environmental conditions. Extending the service life increases the robustness and reduces the wear and tear of the system by ensuring its durability.
3. Maintenance and Easy Installation: A properly designed racking system makes the cleaning and maintenance process simpler to guarantee the highest performance.
4. Increased Property Value: Solar racking systems can increase property value by making it an attractive option for potential buyers to save energy and reduce electricity bills on a long-term basis.

Challenges in Solar Racking

The common challenges faced in solar racking include:

1. Load Distribution:

• Issues: Causes overloading and structural damages due to improper design of the attachment points.
• Solutions: Experienced solar structural engineers should be hired for rooftop solar installations to ensure equal load distribution across the building’s framework to maintain stability.

2. Compatibility with existing roof:

• Issues: It is a sensitive task to balance the load-bearing capacity of the existing structure.
• Solutions: Requires careful planning of building design, layout, and materials. In addition, engineers must plan for upcoming challenges to achieve beneficial construction that doesn’t affect the structural stability of commercial buildings.

3. Roof Penetrations and Water Ceiling:

• Issues: Threats for water leakages.
• Solutions: Implement effective waterproofing measures to maintain the building’s roofing rigidity. Make sure that the entry points are completely sealed to prevent water leakages and protect the interior elements.

4. Theft and Crimes of Vandalism:

• Issues: Since these panels are easily accessible at ground level, they are vulnerable to damage and theft.
• Solutions: Security measures must be implemented such as locking systems, alarms, and surveillance cameras.

5. Site Preparation and Ground Alteration:

• Issues: Frequent construction work is required at ground level that includes processes such as trenching, foundations, and concrete.
• Solutions: Ground Alteration should be avoided at massive level by carefully planning the site preparation to reduce damages.

What Factors Should Be Considered Before Buying A Solar Racking?

The factors to be considered before installing a solar racking system include:

1. Type of Racking: Different types of racking solutions are suitable for various mounting systems including:

• Roof-mounted: Suitable for residential and commercial buildings.
• Ground-mounted: Ideal for larger installations such as solar farms and commercial properties.
• Pole-mounted systems: Used to elevate solar panels above ground level if there isn’t any roof space.

Here is detailed comparison of rooftop solar mounts and ground solar mounts.

2. Material: Solar racking systems are made up of various materials such as:

• Steel Racking: Used in industry and large-scale installations.
• Aluminum: Best for areas near the seaside or having higher humidity.
• Carbon Fiber Composites: Appropriate for upscaled applications where weight reduction is important.

3. Site Assessment: Evaluating the site’s sunlight availability, shading issues, and panel orientation in the best possible direction.

4. Wind/Snow Load: The guidelines provided by the American Society of Civil Engineers (ASCE) explain calculating the loads to guarantee structural integrity and safety by considering the mechanical design of the photovoltaic systems for loads due to wind and snow.

5. Compatibility with Panels: The racking system should be compatible with the size and weight of your solar panels.

6. Aesthetics: Select a design that complies with your architectural requirements and suits your property.

7. Leak Protection: Racking systems with integrated flashing and sealing ensure watertight installations that protect from leakage.

8. Roof Shape: The roof shape and type such as flat, pitched, tile, and metal will alter the selection of the racking system.

9. Warranties: A longer warranty provided by the racking system manufacturer increases confidence in the product and covers defects in materials and workmanship. Here, I have mentioned everything about solar warranties.

10. Regulatory Compliance: The racking system should comply with local building regulations that involve obtaining necessary permits and following strict standards for structural safety.

11. Future Expansion: While choosing a racking system check the possibilities for future expansion, to ensure scalability and flexibility for future needs.

What is the Cost of Solar Racking?

The typical cost of solar racking for residential systems is $0.10 per watt and commercial solar racking varies between $0.10 to $0.22 per watt based on the measures of wind and snow loading capacity. It means that the total cost of the solar racking system ranges between $1500 to $7000 or even more based on the solar panel brand, location, and number of panels. Let’s consider the overall cost of three main types of solar racking systems tabulated below in detail:

Type	Per Panel Cost	Overall Cost
Ground-Mounted Racking Systems	$100 to $200	$2,000 to $4,000 (for 20 panels)
Roof-Mounted Racking System	$50 to $150	$1,000 to $3,000 (for 20 panels)
Tracking Racking System	500 to $1000	$50,000 to $100,000

Typically, solar racking systems cost 3% to 10% of the overall system value. This is because the price fluctuates depending upon the type of installation (rooftop, ground, poles, or canopy). In addition, the environmental conditions, permit, and inspection fees, budget limitations, and aesthetic value are the various factors that determine the cost.

For example, a 10 kW system costs $28,000 approximately before applying any incentives, the racking equipment cost ranges from $840 to $2,800 (calculated based on 3% to 10% costs of the total system).

Top Solar Racking Brands

These are the top solar racking brands in the USA you need to know about what they offer and their unique aspects:

1. IronRidge: A wide range of solar racking solutions such as flat roofs, pitched roofs, and ground mounts are used for both residential and commercial installations. The robust design enhances the simple installation process and reduces overall costs. Mainly the solar panel racking systems come with a 25-year warranty and are listed under UL2703, which is a measure for estimating the effectiveness of the mounting systems related to electrical and mechanical interconnections.

2. K2 Systems: The K2 Systems provides different solar racking products that include roof mounts, ground mounts, and tracking systems. The online design tool assists customers in developing their solar panel racking system for projects, and you can contact the staff to plan for the next installation process. Furthermore, the racking system enables portrait and landscape configurations by increasing the rooftop space for best performance.

3. SnapNrack: A snap-in system makes the installation process easier by attaching the rails for smooth integration that aligns according to the panel’s orientation for enhancing energy generation. Although few users prefer a streamlined structure, the user-friendly and adaptable design makes it suitable to accommodate various module sizes.

4. Unirac: Ranked as the leading manufacturer of racking systems, Unirac offers the best solutions for ground mounts and roofs that are flat and pitched. One of its unique features includes the strong racking systems that make it suitable in highly windy or snowy areas.

What are the long-term maintenance requirements for solar racking systems?

These are the long-term maintenance tips you should follow for solar racking systems:

1. Inspection: It is important to frequently check the racking system and mounts to find traces of damages including dislodged clamps, bent rails, or malfunctioned components.
2. Cleaning: To ensure the proper energy flow, you need to ensure the cleanliness of solar panels and racking system. It is essential to remove the dirt or debris accumulated on the panels that block the sunlight. By following the manufacturer’s instructions, you can clean the panels using proper methods as well as avoid rough materials that leave a scratch on the panels.
3. Tightening the Connection: The stability of the racking system can be maintained by tightening any loose connections including clamps or brackets. At the same time, you need to take caution by not overtightening which might damage the panels or components.
4. Consulting professional: Make arrangements for professionals to visit your location so that they can perform regular inspections and maintenance to guarantee that your solar panel racking and mounts are in the best condition.

What is the best type of solar racking for high-wind areas?

A Ballasted rooftop solar racking system is suitable for installation in high-wind areas and prevents the problem of wind lifts. Mainly, the ballasts‘ weight firmly fixes the system in one place during strong winds. Also, there is less risk of leakage or structural damage because the system is easier to install compared to the traditional ones that don’t require drilling or bolting into the roof or ground.

Can solar racking be adjusted after installation?

Yes, Solar racking can be adjusted after installation to change the panel orientation to enhance capturing the energy. Overall, the flexibility is beneficial for ground-mounted and roof-mounted systems that have adaptable mounting brackets or clamps to ensure that panels get full exposure to sunlight.