Utility Scale Solar Mounting System Mass Production Supply

PINJIE Hot Dip Galvanized PV Mounting Brackets are engineered for solar power generation systems, utilizing Q235B/Q355B high-quality structural steel as base material, achieving comprehensive corrosion protection through hot-dip galvanizing process. Manufactured in strict compliance with GB/T 13912-2020 and ASTM A123 standards, our products ensure a design service life of over 25 years in various harsh environments. As the core supporting structure of photovoltaic power plants, this series features excellent mechanical properties and corrosion resistance, capable of withstanding wind loads of Beaufort scale 12-14, suitable for coastal, high-humidity, saline-alkali and other complex working conditions, providing reliable guarantee for long-term stable operation of PV systems.

Superior Corrosion Protection

The metallurgically bonded zinc layer formed by hot-dip galvanizing provides dual protection of sacrificial anode and physical barrier. Zinc coating forms metallurgical bond with steel substrate with strong adhesion, ensuring no detachment. Under normal atmospheric conditions, zinc corrosion rate is less than 1μm per year, 85μm coating thickness ensures over 30 years of corrosion protection life. During corrosion process, zinc forms dense basic zinc carbonate protective film, further slowing down corrosion rate.

Excellent Mechanical Performance

Manufactured with high-quality carbon structural steel, tensile strength exceeds 550MPa with stable yield strength. Precision cold-formed profiles feature high section moment of inertia with excellent bending and torsion resistance. Bracket system optimized through finite element analysis with reasonable structure, capable of withstanding extreme loads such as strong wind, snow accumulation and seismic activities. All connecting components adopt same material hot-dip galvanizing treatment, ensuring overall structural strength consistency.

Rigorous Process Control

Fully automated galvanizing process with temperature precision controlled within ±5°C, dipping time accurately calculated based on workpiece thickness. Multi-stage pickling and activation process ensures perfect bonding between zinc coating and substrate. Zinc bath composition strictly controlled with proper aluminum and nickel alloying elements, optimizing coating crystalline structure and improving glossiness and corrosion resistance. Each production batch undergoes thickness measurement and adhesion testing to ensure consistent quality.

Efficient Installation

Standardized modular design with hole position accuracy controlled within ±0.5mm, no on-site drilling required. Matching hot-dip galvanized bolts with universal installation tools. Wide adjustment range for flexible adaptation to different terrains and mounting angles. All components are pre-fabricated, requiring only bolted connections on site, significantly reducing construction period.

Coastal High-Salt Atmosphere

Coastal areas contain high chloride ion content in air, causing pitting corrosion and stress corrosion cracking on ordinary steel. Our products with 85μm+ heavy zinc coating effectively resist chloride attack, passing 1000 hours neutral salt spray test without red rust, particularly suitable for PV power plant construction on islands and tidal flats.

Saline-Alkali Soil & High Humidity

Saline-alkali soil features abnormal pH value and high groundwater level, causing severe corrosion to bracket foundation and lower structure. Hot-dip galvanized coating demonstrates excellent corrosion resistance in both alkaline and acidic soils. With proper foundation design, ensures long-term stable operation of PV power plants in saline-alkali regions.

High Altitude Strong UV Radiation

High altitude areas feature strong ultraviolet radiation and large temperature difference between day and night, causing aging and cracking on ordinary organic coatings. Hot-dip galvanized zinc coating is inorganic metallic coating with excellent UV aging resistance and good thermal cycling stability, no chalking or peeling phenomena.

Utility-Scale Ground Mount PV Plants

Suitable for MW-class utility-scale ground mount PV power plants. Customizable C-channel, U-channel, square tube and other bracket profiles according to project requirements. Standardized mass production with stable supply capacity, meeting concentrated delivery requirements for large-scale projects.

Substrate Preparation

1. Cutting & Forming: CNC cutting according to drawings, cold roll forming ensuring dimensional accuracy

2. Deburring: Removing cutting edge burrs to prevent zinc dross during galvanizing

3. Welding: GMAW welding ensuring smooth welds without porosity

4. Rigging Assembly: Specialized racks ensuring proper hanging angle for optimal zinc drainage

Surface Preparation

1. Alkaline Degreasing: 60°C hot alkaline immersion for 15-30 minutes to remove surface oils

2. Acid Pickling: 15% hydrochloric acid immersion at room temperature, removing mill scale and rust

3. Rinsing: Multi-stage countercurrent rinsing to remove residual acid solution

4. Flux Treatment: 45°C zinc ammonium chloride immersion, forming activation protective film

Hot Dip Galvanizing

1. Zinc Bath Heating: Zinc temperature controlled at 455±5°C with induction heating

2. Preheating: Workpieces preheated to 100-150°C before immersion to prevent zinc explosion

3. Galvanizing Immersion: Uniform immersion for 3-8 minutes (adjusted by material thickness)

4. Centrifuging: Immediate centrifugation after withdrawal to remove excess zinc

5. Water Cooling: 40-60°C warm water cooling to prevent distortion and stabilize coating

Post-Treatment & Inspection

1. Passivation: Optional chromate or chromium-free passivation for enhanced corrosion resistance

2. Visual Inspection: Checking for uncoated areas, zinc nodules, flaking defects

3. Thickness Measurement: Magnetic gauge multi-point testing with average thickness recorded

4. Adhesion Testing: Hammer test or bend test for coating adhesion verification

5. Marking & Packaging: Product identification and categorized packaging

Q1: What are the differences between HDG, electro-galvanized and painted brackets?

A: HDG coating thickness is 10-20 times that of electro-galvanizing, with 5 times longer service life. Compared to painting, HDG provides metallurgical bond with far superior adhesion than organic coatings, no大面积 peeling. The sacrificial anode protection of HDG is unique, preventing accelerated corrosion even with local damage.

Q2: How to select appropriate zinc coating thickness for different regions?

A: Standard 65μm for inland rural areas; 85μm+ recommended for industrial and suburban regions; coastal, high humidity and saline areas require minimum 85μm, 100μm+ specified for critical projects. Refer to ISO 14713 corrosion environment classification for specific selection.

Q3: What causes white rust on HDG brackets and does it affect performance?

A: White rust is basic zinc carbonate formed under humid confined conditions, normal phenomenon not affecting corrosion protection. White rust forms stable protective film actually slowing further corrosion. Severe white rust can be wiped off, not affecting product service life.

Q4: Is maintenance required after bracket installation?

A: HDG brackets require no special maintenance under normal operating conditions. Visual inspection recommended every 3-5 years, zinc-rich paint repair available for extensive mechanical damage. No overall replacement required within 25 years of normal service.

Q5: What international standards can you provide?

A: We supply HDG products conforming to ASTM A123, EN ISO 1461, BS EN 10240 standards. Third-party inspection reports available upon request, including SGS, BV, TUV certifications.

Packaging Methods

Vertical Packaging: For profiles over 6 meters, fixed on specialized vertical racks, 10-15 pieces per bundle, 3 steel straps, end cap protection.

Horizontal Packaging: For short profiles and accessories, stacked on wooden pallets, EPE foam separation between layers to prevent scratching, overall PE stretch wrapping for waterproofing.

Container Loading Plans

20'GP Container:

- Loading capacity: Approximately 18-22 metric tons

- Loading method: Wooden skids on floor, profiles placed parallel, layered loading with wooden spacers

- Securing method: 4 wire rope tighteners, end wooden stops to prevent shifting

40'GP/HQ Container:

- Loading capacity: Approximately 25-28 metric tons

- Loading method: Mixed sizes acceptable, long materials along sides, short materials filling center

- Space optimization: Vertical packaging improves space utilization by 20%, suitable for high-volume lightweight products

Ocean Freight Protection Measures

1. Moisture Protection: Desiccant included in all packaging, 200g per cubic meter

2. Rust Prevention: Rust preventive oil on metal contact surfaces, VCI paper on ends

3. Container Inspection: Container integrity checked before loading, damaged seals replaced

4. Cargo Securing: All voids filled with air dunnage bags to prevent movement and collision

5. Marking: Clear labeling of center of gravity, lifting points, moisture and fragile indicators

6. Loading Documentation: Full process photo documentation, packing list and photos provided