Optimization of Photovoltaic Mounting Structures: Material and Cost Savings

Thesan, an Italian company specializing in the design, manufacture, and distribution of mounting structures for photovoltaic plants, was faced with the challenge of optimizing the mounting structure of a medium-sized PV field with a power of 5 MW. The field consisted of 1700 arrays, each mounted on two poles, with each individual assembled structure weighing about 60 kg. The total weight of the mounted structures on the field was 204 tons of steel, with material costs of about 170,000 Euro. A weight reduction of only 5 kg per structure would lead to significant savings in material and cost. The structure was composed of two main parts, a steel driven pile and an aluminum rafter, with the weight reduction of the more costly aluminum parts being crucial. Another significant factor for cost savings was transportation, as PV fields are often built in remote areas with poor infrastructure. Lighter structures would not only mean less material costs in production, but also lower transportation efforts and costs. However, the new, lighter weight structures still had to be able to carry all occurring loads from natural causes such as wind or snow and the dead load of the structure, ensuring perfect quality, consistent stability and the requested stiffness of the structures.

Thesan is an Italian company based in Chiusa di San Michele that designs, manufactures, and distributes mounting structures for photovoltaic plants. In addition, the company also develops, constructs, and operates renewable energy power plants, including photovoltaic and mini-hydroelectric power plants. Thesan was founded in 2008 and operates as a subsidiary of Savio Spa, a global manufacturer and foremost specialist in hardware for aluminum windows and doors, with factories in Italy, China, and India. Drawing on the Savio Group’s competence in the design of steel and aluminum structures and thanks to a team of over 40 engineers, Thesan is able to satisfy every construction requirement of photovoltaic power plants at all altitude and climatic conditions, using any specific fixation requirements. The company provides the technical expertise and the corresponding experience to follow all phases of the production chain; from project development to construction, management to maintenance of the power plant.