Mounting solutions for photovoltaic panels: European guide to mounting structures, brackets, and profiles

Every efficient photovoltaic system starts from a solid foundation: the mounting system.
This structure, often invisible but fundamental, ensures stability, security, and durability over time, keeping the modules well anchored and oriented to capture sunlight effectively.

In Europe, the design of the mounts follows strict standards to withstand wind, snow, and thermal variations, ensuring consistent performance for over 25 years.
Whether it’s flat roofs, sloped installations, ground mounts, or canopies, choosing the right mounting system means protecting the investment and maximizing energy yield.

Design Principles: Wind and Snow Loads According to Eurocodes

Designing a mounting system for solar panels means much more than just fixing modules onto a surface. It is an engineering job that must consider static and dynamic forces, thermal variations, and extreme weather conditions. In Europe, the main references are contained in the Eurocodes EN 1991 (Actions on Structures) and EN 1993/EN 1090 (Steel and Aluminum Structures).

Dimensioning and Environmental Actions

Wind load represents one of the most critical forces. In coastal or mountainous regions, gusts can generate stresses exceeding 1,000 N/m². Therefore, the mounting system must be able to withstand uplift and shear forces that tend to displace or rotate the modules.
The Eurocodes provide parameters to calculate these loads based on:

• building height or installation ground;

• wind exposure (open, urban, or sheltered);

• roof pitch and shape;

• air density and local turbulence.

Similarly, snow load can vary from a few kilograms per square meter in Mediterranean regions to over 200 kg/m² in Scandinavian or alpine countries. For this reason, the structure must be verified not only for tension but also for bending and concentrated loads.

Thermal Expansion and Vibrations

Metal materials, such as steel and aluminum, undergo expansions with temperature variations. A careful design must include expansion joints and anchoring systems that allow slight movements without compromising stability or causing stresses on the modules.
Even vibrations caused by wind or minor seismic events can loosen connections over time: for this reason, serrated washers, controlled torque and adequately rated bolts are used.

Corrosion and Aggressive Environments

In coastal, industrial, or particularly humid areas, corrosion can drastically reduce the lifespan of mounts. The standards EN ISO 12944 classify levels of environmental corrosivity from C1 (very low) to CX (extremely high), defining the necessary surface treatments to ensure a useful life of 25 or 50 years.

In summary, the structural design of a mounting system is not limited to mechanical aspects but is a complex process that integrates calculation, materials, environment, and maintenance over time.

Types of Mounts for Flat Roofs: Ballasted and Anchored Structures

Flat roofs represent one of the most common surfaces for installing photovoltaic systems, especially in commercial, industrial, or multi-family buildings. Here, ballasted or anchored systems are primarily used, designed to avoid puncturing the roof cover and ensure maximum waterproofing.

Ballasted Systems

Ballasted structures rely on tilt-adjustable metal frames stabilized with concrete blocks or gravel, avoiding perforations of the roof membrane.
The main advantages are:

• quick and non-invasive installation;

• absence of risks for waterproofing;

• ease of adjusting pitch and orientation.

However, the ballasting must be dimensioned based on wind load and the cover’s resistance: excess weight can compromise roof stability, while under-dimensioning can cause module uplift in strong gusts.

Anchored Systems

Alternatively, anchored systems use mechanical fixing points directly connected to the load-bearing structure of the roof (e.g., beams or corrugated sheets).
While requiring greater attention during installation, they provide superior wind resistance and less need for ballast. They are recommended in windy areas or on buildings with limited structural loads.

Pit Optimization

On flat roofs, the pitch of the panels is set between 10° and 30°, depending on latitude and yield objectives. Modern structures also allow “sail” or “dual slope” configurations that reduce mutual shading and improve output.

In any case, mounts must be made of anodized aluminum or galvanized steel, with components resistant to corrosion and EPDM seals to ensure insulation over time.

Mounts for Sloped Roofs: Under-tile Hooks, Adjustable Brackets, and Aluminum Profiles

Sloped roofs are typical of European residential buildings. Here, the mounting system must adapt to a wide range of coverings: tiles, pantiles, corrugated sheets, or sandwich panels.

Main Components

A standard mounting system for sloped roofs consists of:

• under-tile or under-pan hooks, anchored to the roof beams;

• aluminum profiles on which the modules are fixed;

• adjustable brackets that compensate for irregularities in the covering;

• central and end clamps to secure the panels.

The goal is to ensure a solid mechanical connection without compromising the roof's water tightness. For this reason, each hole must be sealed with certified seals and waterproof membranes.

Compatibility and Safety

Each type of covering requires dedicated solutions. For tiles, for example, hooks must follow the curvature profile; for corrugated roofs, clamps or self-tapping screws with integrated seals are used.
The quality of materials and precision in installation are crucial to avoid leaks, slipping, or abnormal stresses.

Advantages of Aluminum

Anodized aluminum is the most commonly used material for profiles due to its lightweight and corrosion resistance. In addition to reducing the overall weight on the roof, it allows for quick and modular installation, with pre-assembled systems that cut assembly times by up to 40%.

Sloped roof structures must conform to the EN 1090 standard, which defines the requirements for execution and CE marking of metal structures.

Ground Mounting Structures: Concrete Bases, Foundation Screws, and Anchors

For large-scale installations – agricultural, industrial, or solar parks – the most efficient solution is often ground mounting. In these cases, ground mounting systems provide maximum orientation and maintenance flexibility.

Fixed Systems and Trackers

Fixed structures are the most economical and reliable choice. The panels are mounted in parallel rows with optimized tilt according to latitude.
Solar trackers, on the other hand, allow the modules to move to follow the sun throughout the day, increasing production by up to 25%. However, they require a more complex structure, motorized and with more frequent maintenance.

Types of Foundations

The type of foundation depends on the nature of the ground:

• foundation screws: suitable for compact or gravelly soils, allow rapid installation without digging;

• concrete bases: ideal for unstable grounds or long-lasting installations;

• direct anchors: used in rocky or sandy soils, where screws are not suitable.

The load-bearing structure must be designed in hot-dip galvanized steel or structural aluminum, with stainless steel joints to prevent galvanic corrosion.

Space Optimization

One often underestimated aspect is the inter-module spacing, or the distance between rows of modules. It must be calculated to avoid shading, allow technicians to pass, and comply with national fire safety regulations.
Ground mounts are subject to greater wind forces than roofs, so the sizing of profiles and anchors is crucial for overall stability.

Canopies and Photovoltaic Carports: Architectural Integration and Load Resistance

canopies and photovoltaic carports represent one of the most versatile applications of mounting systems. They combine functionality and design, offering protection for vehicles and people, while also producing renewable energy.

In recent years, more and more companies and private individuals in Europe are choosing such solutions for corporate parking lots, condominiums, or public areas. Unlike traditional rooftop installations, here the mounting structure is not just a technical support: it becomes an integral part of the architecture.

Structural Design and Loads

The design of a photovoltaic canopy requires the same engineering attention as a small building structure.
It must withstand the weight of the modules, wind pressure, and snow accumulation, but also the accidental load from maintenance personnel or cleaning systems.
The main beams are generally made of galvanized steel or extruded aluminum, with bolted or welded joints conforming to the EN 1090.

In areas subject to strong winds or heavy snow, calculations must account for complex load combinations. In many cases, diagonal bracing and oversized columns are used to avoid torsional instability.

Aesthetic and Functional Integration

A modern photovoltaic carport is not only efficient but also aesthetically pleasing. Slim profiles, integrated coverings, and anodized finishes allow for harmonious integration with the surrounding environment.
Many models also include drainage systems for rainwater management, preventing unwanted leaks or accumulations.

In addition to its support function, the structure can host electric vehicle charging systems (EV charger), LED lighting, or smart sensors.
This increasingly widespread approach transforms the carport into a micro-energy infrastructure, efficient and autonomous.

Materials for Mounting Systems: Anodized Aluminum, Galvanized Steel, and Stainless Steel

The choice of materials directly affects the durability and safety of the mounting system. In Europe, the most commonly used materials are anodized aluminum, hot-dip galvanized steel, and stainless steel.

Anodized Aluminum

Aluminum is lightweight, strong, and easily worked. Anodization increases its corrosion resistance and ensures a uniform aesthetic finish.
It is ideal for flat and sloped roofs, where its light weight reduces the load on the covering.
Among the main advantages:

• ease of cutting and drilling;

• resistance to weather conditions;

• complete recyclability, in line with European sustainability goals.

However, aluminum has lower rigidity than steel: in large structures, it may be necessary to increase sections to avoid deformation.

Hot-Dip Galvanized Steel

Galvanized steel is a robust and cost-effective solution. Hot-dip galvanizing (EN ISO 1461) creates a protection against corrosion through a coating of molten zinc.
It is the preferred choice for ground installations or large canopies, where mechanical strength is a priority.
Average durability exceeds 25 years, with minimal maintenance.

The only limitation is the weight, making site handling less convenient. However, modern prefabrication techniques and modular assembly significantly reduce installation times.

Stainless Steel

For highly corrosive environments – such as coastal areas, ports, or industrial sites – stainless steel (AISI 304 or 316) represents the best choice.
It offers exceptional resistance to rain, saltwater, and thermal variations, ensuring a useful life exceeding 30 years.
Although more expensive, its use pays off over time due to reduced maintenance needs.

New Materials and Coatings

Research is leading to the introduction of composite alloys and nanotechnology coatings that improve adhesion and resistance to weather conditions.
The use of fasteners with passivating treatments (zinc-nickel, Dacromet, Geomet) also helps increase the useful life of mechanical connections.

Mechanical and Electrical Compatibility with Photovoltaic Modules

An often-overlooked aspect is the compatibility between mounts and modules. The mounting system must comply with the dimensional tolerances of the panel frames and ensure proper electrical contact for grounding.

Clamps and Profiles

The central and end clamps must fit the thickness of the module frame, typically between 30 and 40 mm.
They must ensure an even load distribution, avoiding excessive pressure on the glass.
The profiles must then provide a continuous and stable support, with expansion joints to compensate for thermal spikes.

Electrical Connections

In many European countries, regulations require equipotential grounding of metal frames to prevent shock or electrical arc risks.
The clamps must be conductive and compliant with the IEC 62548 standards, which specify the requirements for the electrical installation of photovoltaic systems.

Poor electrical contact can generate leakage resistances or stray currents, reducing system efficiency. It is therefore essential to use certified components that are compatible with each other.

Regulations and Markings: EN 1090, CE Requirements, and National Guidelines

Every mounting system installed in Europe must comply with a series of harmonized technical standards and have the CE marking.

EN 1090 – Steel and Aluminum Structures

This European standard establishes the requirements for the design, production, and inspection of metal structures.
All bearing components must be traceable, produced by certified companies, and accompanied by a Declaration of Performance (DoP).
Without EN 1090 compliance, a structure cannot be legally marketed in the European Union.

EN 1991 – Eurocode 1

Defines wind actions, snow, and accidental loads. It is the reference for calculating the mechanical resistance of the mounting system in any European climatic zone.
Each member state may introduce additional national parameters (e.g., safety coefficients or wind maps).

EN ISO 12944 – Corrosion Protection

Establishes the design, painting, and maintenance criteria to ensure the desired lifespan based on exposure class (from C1 to CX).
The goal is to ensure that the system maintains its integrity throughout the useful life of the installation, generally 25–30 years.

Complementary Certifications

Besides adhering to European standards, some countries adopt additional standards, such as the German DIN or the French NF, which establish stricter testing requirements.
A reliable manufacturer must be able to provide all compliance documents, including test certificates, technical data sheets, and inspection reports.

Selection Criteria: Cost, Efficiency, and Return on Investment

Choosing the right mounting system means finding the right balance between initial cost, mechanical performance, and long-term durability.
An inexpensive mount may seem advantageous at first, but if it is not certified or suitable for the environmental context, it can generate high maintenance costs or, worse, damage to the modules.

Technical Assessment

Before selection, it is necessary to analyze:

• type of surface and pitch;

• local wind and snow loads;

• environmental conditions (humidity, salinity, thermal variations);

• ease of installation and accessibility for maintenance.
  
  
  

Economic Analysis (TCO)

The Total Cost of Ownership considers the entire lifecycle of the system: purchase, installation, maintenance, and longevity.
A stainless steel system, for example, may cost 20–30% more upfront but require less maintenance and offer double the lifespan compared to a galvanized steel one.

Efficiency and Productivity

The mounting system also affects energy yield. An optimal tilt or precise orientation of the modules can increase annual production by up to 10%.
A well-designed mount also reduces dirt accumulation and facilitates rainwater runoff.

Best Practices for Installation and Maintenance

The effectiveness of a mounting system depends as much on the quality of materials as on the installer’s expertise.
Here are some best practices recommended throughout Europe:

• Always use CE certified components.

• Apply the torque values indicated by the manufacturer.

• Avoid direct contact between different metals to prevent galvanic corrosion.

• Seal every penetration point with EPDM or neutral silicone seals.

• Conduct periodic visual inspections to identify loosening or corrosion.

After severe weather events (hail, strong wind, snowfalls), a technical review is advised to check the stability and alignment of structures.

Innovation in Mounting Systems: Modularity and Sustainability

The photovoltaic mounting sector is in constant evolution.
The latest trends focus on pre-assembled systems, aerodynamic designs, and sustainable materials.

Pre-assembled modules reduce installation times by 50%, while aerodynamic profiles decrease wind resistance, allowing the use of less ballast.
The use of recycled aluminum and low-carbon steel further improves the project’s environmental footprint, in line with European targets for climate neutrality by 2050.

Also, Building Integrated Photovoltaics (BIPV) — integrating panels directly into building elements — is revolutionizing the way mounting is understood, making the structure no longer an accessory, but an integral part of architecture.

European Criteria for a Safe, Efficient, and Durable Mounting System

A photovoltaic system is as efficient as the structure supporting it.
A mounting system designed according to European standards, built with certified materials, and installed with technical precision guarantees safety, efficiency, and sustainability for decades.

From the choice of materials to periodic maintenance, every detail matters.
Following best practices and relying on qualified manufacturers and installers is the key to achieving a durable, secure investment that meets European standards.

In a Europe that is decisively moving towards energy transition, mounts for photovoltaic panels represent not only a technical element but a pillar of the new architecture of clean energy.