The PV Profile 80×40 is a heavy-duty aluminum solar mounting rail designed for photovoltaic installations where standard 40 mm profile heights are insufficient to meet structural requirements. By doubling the profile height to 80 mm while maintaining the 40 mm width, this mounting rail achieves a significantly higher moment of inertia — the structural property that governs bending resistance under load. This translates directly into longer allowable spans between support points, fewer roof hooks or brackets per rail run, and a simplified substructure that reduces both material costs and installation labour. Extruded from EN AW-6060 T6 aluminum alloy, the PV Profile 80×40 is the profile of choice for ground-mount solar farms, large commercial rooftop arrays, carport structures, and any installation in high wind or high snow load zones across Europe. ULAMEX supplies this profile at B2B wholesale conditions with European-wide delivery.
Technical Specifications
The PV Profile 80×40 is manufactured by hot extrusion from EN AW-6060 T6 (AlMgSi alloy, material number 3.3206, T6 temper condition). The alloy and temper are identical to the 40×40 profiles in the ULAMEX range, ensuring consistent material quality across all PV mounting rails:
- External dimensions: 80 mm (height) × 40 mm (width)
- Minimum tensile strength: 190 MPa
- Minimum yield strength (Rp0.2): 150 MPa
- Minimum elongation: 8%
- Weight per metre: approximately 1.50–1.70 kg/m
- Moment of inertia (Iy): approximately 4.5–5.0 cm⁴ (roughly 4× that of the 40×40 profile)
- Channel type: T-slot channel (upper) with sliding inlet and ball retention capability
- Upper channel fastening: M8 T-bolts (hammer-head), M8 sliding inlets with ball retention, M8 socket head cap screws (DIN 912)
- Base fastening: M10 hex bolts per DIN 933 with DIN 6923 flange nuts
- Surface finish: Mill finish (natural silver aluminum)
The critical structural advantage of the 80×40 profile is its moment of inertia, which is approximately four times higher than the standard 40×40 profile. The moment of inertia (I) determines a beam’s resistance to bending: a higher value means less deflection under the same load, or the ability to span greater distances between support points while staying within allowable deflection limits. For structural engineers designing PV mounting systems, this means the 80×40 profile enables support spacings of up to 2,000 mm or more (depending on the specific load case), compared to the typical 1,200–1,400 mm limit for 40×40 profiles.
Dimensional tolerances conform to EN 755-9.
Available Lengths and Sizes
The PV Profile 80×40 is stocked in two standard lengths optimized for large-scale installation layouts:
| Length (mm) | Length (m) | Approx. Weight (kg) | Typical Application |
|---|---|---|---|
| 4,300 | 4.30 | ~6.9 | Commercial rooftop arrays, carport structures, mid-span ground-mount sections |
| 6,210 | 6.21 | ~10.0 | Ground-mount solar farms, industrial flat roofs, long-span commercial arrays |
Both lengths are designed for commercial and utility-scale applications where shorter rails would create unnecessary splice joints. The 6,210 mm length is particularly suited for ground-mount solar farms where maximizing continuous rail length reduces the number of splice connectors, improves structural continuity, and speeds up installation across large arrays. The 4,300 mm length serves commercial rooftop segments, carport constructions, and projects with transport length restrictions.
Custom cutting to intermediate lengths is available on request. For installations requiring rails longer than 6,210 mm, ULAMEX supplies rail splice connectors rated for the higher bending loads of the 80×40 profile. Note that the 80×40 profile weighs approximately twice as much per metre as the 40×40 — a 6,210 mm rail weighs approximately 10 kg, which typically requires two-person handling on elevated installations.
Channel System and Fastener Compatibility
The PV Profile 80×40 features a T-slot upper channel designed for hammer-head bolts and sliding inlets with ball retention — the same rapid-assembly system used in the Hammer PV Profile 40×40. This means installers working with the heavy-duty 80×40 benefit from the same tool-free fastener insertion and slide-anywhere positioning that reduces mounting time on large-scale projects.
Compatible hardware for the upper T-slot channel:
- M8 T-bolts (hammer-head bolts) — inserted at any point along the rail, rotated 90° to engage
- M8 sliding inlets with ball retention — spring-loaded captive mechanism for hands-free positioning
- M8 socket head cap screws (DIN 912) — where head dimensions are compatible with the T-slot opening
For base attachment:
- M10 hex bolts (DIN 933) with M10 flange nuts (DIN 6923) — for connection to ground-mount foundations, roof hooks, or heavy-duty mounting brackets
The 80×40 profile is compatible with all ULAMEX aluminum mid-clamps and end-clamps as well as clamp systems from other manufacturers designed for 40 mm wide rails. The clamp engagement width (40 mm) is identical to the 40×40 profiles, ensuring full cross-compatibility of clamp hardware across the ULAMEX range.
Installation Applications
The 80×40 mm PV mounting rail is specified for solar installation types where structural demands exceed the capacity of standard 40×40 profiles:
- Ground-mount solar farms — the primary application for the 80×40 profile. Open-field solar installations are exposed to full wind loads without the shielding effect of a building. The high moment of inertia of the 80×40 allows support spacings of 1,800–2,000+ mm between foundation posts, reducing the total number of posts, foundations, and connection points across the array. On a 1 MWp ground-mount project, this simplification can save significant foundation and labour costs.
- Large commercial and industrial rooftops — warehouse, logistics centre, and factory roofs with extended roof areas and potentially high wind exposure. The 80×40 profile handles the higher structural requirements while maintaining the same clamp and module attachment system as standard installations.
- Carport and canopy structures — solar carports require profiles that span unsupported distances between carport columns while supporting module weight, wind uplift, and potential snow accumulation. The 80×40 profile’s bending resistance is well-suited for typical carport beam spacings of 1,500–2,500 mm.
- High wind and snow load zones — installations in wind zone 4, coastal areas, or mountain regions with snow loads above 1.0 kN/m². The 80×40 allows the use of standard support spacings while staying within allowable deflection and stress limits under extreme loading.
- Flat roof systems with raised substructures — on flat roofs where tilt triangles or raised ballast systems create elevated module arrays, the 80×40 profile provides the stiffness needed to control vibration and maintain module alignment under dynamic wind loading.
- Bridging obstacles — on rooftops with mechanical equipment, vents, skylights, or other penetrations, the 80×40 profile can bridge larger gaps between support points without exceeding deflection limits, enabling continuous module rows across obstructed zones.
Why This Profile
The PV Profile 80×40 exists for one purpose: to extend the structural envelope of PV rail systems beyond what 40 mm profiles can achieve. When a project’s structural calculation shows that 40×40 profiles would require support points every 1,200 mm — resulting in excessive roof hooks, brackets, or foundation posts — the 80×40 allows the same installation to proceed with support points at 1,800–2,000+ mm intervals. Fewer support points mean:
- Fewer roof penetrations (pitched roof) or fewer ballast trays (flat roof)
- Less hardware and connection material
- Faster substructure installation
- Lower total system cost despite the higher per-metre profile price
The 80×40 is approximately twice the weight per metre and carries a higher per-metre cost than the 40×40. But on projects where it is structurally warranted, the reduced support infrastructure more than compensates for the higher profile cost. The break-even point depends on the specific project parameters — your structural engineer’s calculation will determine whether 40×40 or 80×40 delivers the most economical overall system.
Within the ULAMEX range, the 80×40 complements the four 40×40 variants (standard, anodized, hammer, anodized hammer) by serving the heavy-duty segment that 40 mm profiles cannot address.
Standards and Quality
The PV Profile 80×40 is manufactured under the same quality framework as all ULAMEX aluminum PV profiles:
- EN AW-6060 T6 — aluminum alloy per EN 573-3 (chemical composition) and EN 755-2 (mechanical properties)
- EN 755-9 — dimensional and form tolerances for extruded profiles
- CE marking — European Construction Products Regulation (EU) No 305/2011
- EN 1090 — ULAMEX is EN 1090 certified for structural aluminum components
- ISO 3834-2 — quality management system certification
- ISO 3834 — quality requirements for fusion welding of metallic materials
Material test certificates (EN 10204 type 3.1) are available on request. The higher structural demands placed on the 80×40 profile make material documentation particularly important for projects requiring engineering sign-off — ULAMEX provides full batch traceability and mill certificates for every delivery.
Why Choose ULAMEX
With over 38 years in the European steel and aluminum trade, ULAMEX is a trusted B2B wholesale supplier for photovoltaic mounting systems. Our heavy-duty 80×40 profile is supplied alongside the complete ecosystem of standard and specialist PV mounting components: all profile variants, clamps, roof hooks, fasteners and connectors, ballast systems, and tilt triangles. Single-source your complete PV mounting kit at wholesale pricing with European delivery and full documentation. Request a quote for your ground-mount, carport, or commercial rooftop project.
Frequently Asked Questions
What is the maximum span between support points for the PV Profile 80×40?
Under typical European wind and snow loads, the PV Profile 80×40 supports spans of approximately 1,800–2,000 mm or more between support points, compared to the 1,200–1,400 mm typical for 40×40 profiles. The exact allowable span depends on the specific project’s wind zone, snow load zone, module weight, module orientation, and the maximum permissible deflection criterion specified by the structural engineer. Always base span decisions on the project-specific structural calculation.
Is the PV Profile 80×40 compatible with the same clamps as the 40×40 profiles?
Yes. The clamp engagement width of the 80×40 profile is 40 mm — identical to all 40×40 variants in the ULAMEX range. All ULAMEX aluminum mid-clamps and end-clamps are fully compatible. Third-party clamp systems designed for 40 mm wide rails are also compatible. The difference is in the vertical height of the profile (80 mm vs 40 mm), which does not affect clamp engagement.
When should I choose the 80×40 profile over the 40×40?
Choose the PV Profile 80×40 when your structural calculation indicates that 40×40 profiles would require support spacings below 1,200 mm, when the installation is in a high wind or snow load zone (wind zone 3–4, snow loads above 0.75 kN/m²), when the project involves ground-mount or carport construction with large support spacings, or when bridging obstacles on the roof requires long unsupported spans. If the 40×40 profile meets the structural requirements of your project, it remains the more economical choice per metre.
Can the 80×40 profile be used with PV tilt triangles for flat-roof installations?
Yes. The PV Profile 80×40 integrates with ULAMEX PV tilt triangles for angled flat-roof installations. The higher bending resistance of the 80×40 is particularly beneficial in east-west flat-roof configurations where the elevated module position increases wind exposure. The T-slot upper channel enables rapid clamp and triangle attachment using the same M8 T-bolts or sliding inlets used across the entire ULAMEX profile range.