(July 2025, Georgia) – Successfully commissioning a 620kW ground-mounted solar plant requires a support structure that’s cost-effective, incredibly durable, and quick to install – especially in varied environments. This project in Georgia perfectly showcased how the winning combination of Zn-Al-Mg coated steel for the superstructure and ground screw foundations delivered on all fronts, setting a new benchmark for economic and operational efficiency.

Project Challenge: Balancing Cost, Durability & Speed

The client needed a robust solution for their significant 620kW investment. Key priorities were:

  Minimizing Lifetime Cost: Avoiding high maintenance and early replacement expenses.

  Ensuring Long-Term Reliability: Withstanding local environmental conditions for decades.

  Expediting Installation: Reducing labor time and complexity to meet tight deadlines.

  Optimizing Foundation Solution: Adapting to the site soil conditions efficiently.

The Optimal Solution: Synergy of Advanced Materials & Foundation

Our engineering team prescribed a system leveraging the core strengths of two key technologies:

1.  Superstructure: Zn-Al-Mg Coated Steel Racking

*Unrivaled Corrosion Resistance: Zn-Al-Mg coating provides a protective layer 5 times more effective than standard hot-dip galvanization (HDG) under the same conditions. It withstands over 3000 hours in salt spray tests, guaranteeing decades of service life (30+ years) without the “red rust” that plagues conventional options. This drastically reduces maintenance needs and replacement costs .

*Self-Healing Properties: A unique advantage of Zn-Al-Mg is its ability to protect cut edges and minor scratches. Magnesium migrates to damaged areas, forming protective oxides, eliminating the need for post-cutting treatments and ensuring longevity even after handling and installation .

*Cost Efficiency Champion: While the initial material cost is marginally higher (10-20%) than standard HDG, Zn-Al-Mg delivers significant lifetime cost savings (typically 15%+). This comes from its extreme durability (no early replacement), minimal maintenance requirements, and the elimination of post-fabrication galvanizing steps (making it more environmentally friendly too) .

*Design & Weight Advantages: The superior corrosion protection allows for optimized, potentially lighter section designs without sacrificing strength, contributing to material savings and easier handling .

      Environmental Compliance: Produced using eco-friendly, often chromium-free processes, aligning with sustainable project goals .

2.  Foundation: Ground Screw System

*Rapid, Low-Impact Installation: Ground screws were driven directly into the soil using specialized machinery, eliminating the need for digging, concrete pouring, and curing time. This resulted in a dramatically faster foundation installation (approximately 30% quicker than concrete) .

*Immediate Load-Bearing: Once installed to the specified depth and torque, the screws offer immediate structural support, allowing racking installation to commence without delay .

*Versatility & Strength: Engineered to perform reliably in various soil types encountered in Georgia, providing high pull-out resistance and stability for the structure .

*Reduced Environmental Footprint: No concrete means minimal site disturbance and no waste materials left behind .

Implementation & Results: Efficiency Realized

Deploying the Zn-Al-Mg coated racking onto the ground screw foundations proved exceptionally smooth:

*Streamlined Logistics: The pre-fabricated Zn-Al-Mg components and ground screws arrived ready for assembly.

*Accelerated Installation: The lack of concrete curing and the simplicity of attaching the racking to the screw heads significantly compressed the construction schedule. Crews reported notably faster progress compared to traditional concrete-based systems.

*Seamless Integration: The design compatibility between the ground screw heads and the Zn-Al-Mg mounting rails/clamps ensured a secure and straightforward connection process.

*Confidence in Longevity: The combination of the below-ground durability of the galvanized screws and the above-ground superiority of Zn-Al-Mg coating gives the asset owner unparalleled confidence in the system's lifespan with minimal operational headaches.

Ready to build smarter, faster, and more durable solar mounting system? Kseng provides cutting-edge Zn-Al-Mg coated solar mounting solutions with compatible ground screw foundations for projects worldwide. Contact us today for a quote and see the difference premium materials and intelligent design make!