Mounting panels with unistrut

[Hedges]

The threading let me extend a little more than 10ft upward in a few cases using a coupler + additional 2" pipe and let me use 2" galvanized flanges to hold the base within the concrete footers - https://www.lowes.com/pd/Mueller-Proline-2-in-dia-Galvanized-Floor-Flange-Fittings/4330338 - so the pole wouldn't slip downward.

I considered those, but they need multiple anchor bolts, and small ones.
Instead, I put a coupling on the bottom and screwed one of these in.

https://www.supplyhouse.com/Everflow-GMBU2002-2-x-1-2-Galvanized-Malleable-Hex-Bushing

Or rather, I used a large anchor bolt to secure the bushing to concrete. Then use a coupling to connect 2" conduit to it.

 

[Robkh]

I used IronRidge Top Caps - https://realgoods.com/ironridge-ground-mount-system-top-cap - which are made for this purpose.
They have options for 2" and 3" vertical pipe. Not pushing the specific link/company above - just the 1st one that popped up for google search.
View attachment 176630

I used the 2" version because my verticals are 2" x 10ft (threaded) galvanized pipe from Home Depot - https://www.homedepot.com/p/Southland-2-in-x-10-ft-Galvanized-Steel-Pipe-568-1200HC/100565809

The threading let me extend a little more than 10ft upward in a few cases using a coupler + additional 2" pipe and let me use 2" galvanized flanges to hold the base within the concrete footers - https://www.lowes.com/pd/Mueller-Proline-2-in-dia-Galvanized-Floor-Flange-Fittings/4330338 - so the pole wouldn't slip downward.

Thank you…you did a great build

 

[OffGridInTheCity]

I considered those, but they need multiple anchor bolts, and small ones.
Instead, I put a coupling on the bottom and screwed one of these in.

https://www.supplyhouse.com/Everflow-GMBU2002-2-x-1-2-Galvanized-Malleable-Hex-Bushing

View attachment 176637

Or rather, I used a large anchor bolt to secure the bushing to concrete. Then use a coupling to connect 2" conduit to it.

I didn't bolt the flange to the concrete but embedded it in the concrete a couple of inches above the bottom of the pour - the flange ensures the pole won't move vertically within the concrete footer.

I could have drilled holes in the vertical pipe and used horizontal re-bar for a similar purpose but flanges seemed easier for me at the time

 

[Hedges]

You did say "within the concrete footers"
In that case it also provides torsional rigidity (within strength limits of the conduit.)
More convenient when erecting (not flopping around) so long as in the right position.
I suppose you installed top caps and cross pipes before pouring?

In concrete, anything including coupling or pipe cap should be sufficient to prevent pull-out.

I just slapped mine on the surface of existing patio.
One anchor bolt didn't bite, but the others did.
Was 18 Sharp 165W panels, I've extended the array wider (20') for 24, will make wider still (21') with diagonal supports when I replace them with SunPower 327W panels (like in background). Those are 50% more efficient, more power in the same area.

 

[42OhmsPA]

Looking for feedback on my latest idea. I want to expand the ground mount to hold 2 additional panels....
What are your thoughts on a 26" max open air cantilever on each side of the ground mount? 12 gauge superstrut.
I would add the 'extensions' to the center of the mount so the outer sections of strut were full 10' sticks.
I haven't came up with a way to add support gusset without interfering with the tilt angle... I suppose I could add angle brackets to reduce the cantilever to ~20".

Feedback please? Is it worth a potential 740w gain?

Here's what I used for my ground mount array. Worked great, my only complaint is the width of the mid clamps. I'd find narrower ones next time.

I picked up stainless 1/4-20 bolts from the local Amish supply store.

1/4"-20 Cone Nuts, Strut Channel Nuts with Zinc Electroplate Finish, Twirl Nuts for Use with Strut Channel (10 Pack) (1/4"-20) https://a.co/d/eHkgdPf

The included clamp nuts don't work with standard strut, that's why I bought the cone nuts above.
Solar Panel Mid Clamps 1.06 Inch Solar Panel Bracket Aluminum Solar Mid Clam with Solar Mounting Brackets 32-50 mm Panel Clamps Adjustable End Clamps Panel Clamps (56 Pieces) https://a.co/d/eK48elg

 

[Hedges]

Looking for feedback on my latest idea. I want to expand the ground mount to hold 2 additional panels....
What are your thoughts on a 26" max open air cantilever on each side of the ground mount? 12 gauge superstrut.
I would add the 'extensions' to the center of the mount so the outer sections of strut were full 10' sticks.
I haven't came up with a way to add support gusset without interfering with the tilt angle... I suppose I could add angle brackets to reduce the cantilever to ~20".

Feedback please? Is it worth a potential 740w gain?
View attachment 180270

I think you could extend rails, add end piece, and add a truss to support end.

An inverted triangle, with vertical in the middle resembling this roof framing.
The vertical ties to edge of existing panel and is under tension, two diagonals are under compression.
One of these in middle of upper row of panels, one in middle of lower row. That should allow tilt without hitting posts.

 

[chilly2]

Here's what I used for my ground mount array. Worked great, my only complaint is the width of the mid clamps. I'd find narrower ones next time.

I picked up stainless 1/4-20 bolts from the local Amish supply store.

1/4"-20 Cone Nuts, Strut Channel Nuts with Zinc Electroplate Finish, Twirl Nuts for Use with Strut Channel (10 Pack) (1/4"-20) https://a.co/d/eHkgdPf

The included clamp nuts don't work with standard strut, that's why I bought the cone nuts above.
Solar Panel Mid Clamps 1.06 Inch Solar Panel Bracket Aluminum Solar Mid Clam with Solar Mounting Brackets 32-50 mm Panel Clamps Adjustable End Clamps Panel Clamps (56 Pieces) https://a.co/d/eK48elg

Ah that wonderful open view for the panels in the first pic!