The PV Profile 40×40 is the most widely installed aluminum solar mounting rail in European photovoltaic construction. Extruded from EN AW-6060 T6 aluminum alloy, this 40×40 mm cross-section profile serves as the primary horizontal structural member in pitched roof, flat roof, ground-mount, and carport solar installations. Whether you are an installer fitting residential rooftop systems or a project developer specifying materials for a 500 kWp commercial array, this solar mounting rail delivers the structural performance, dimensional consistency, and universal fastener compatibility that professional photovoltaic projects demand. ULAMEX supplies this profile at B2B wholesale conditions with European-wide delivery, full material documentation, and the backing of over 38 years in the steel and aluminum trade.
Technical Specifications
The PV Profile 40×40 is manufactured by hot extrusion from EN AW-6060 T6 (AlMgSi alloy, material number 3.3206, T6 temper condition). This alloy specification guarantees a minimum tensile strength of 190 MPa, a minimum yield strength (Rp0.2) of 150 MPa, and a minimum elongation of 8%. The T6 heat treatment — solution heat treated and artificially aged — ensures optimum hardness and dimensional stability throughout the service life of the profile.
Key cross-section properties:
- External dimensions: 40 mm × 40 mm
- Wall thickness: approximately 1.2–1.5 mm (varies by section geometry)
- Weight per metre: approximately 0.80–0.90 kg/m
- Moment of inertia (Iy): approximately 1.2 cm⁴
- Channel type: Hex channel (upper) — accepts standard hex bolts inserted from the rail end
- Upper channel fastening: M8 bolts per DIN 912 (socket head cap screw), DIN 557 (square nut), DIN 934 (hex nut)
- Base fastening: M10 hex bolts per DIN 933 with DIN 6923 flange nuts for connection to roof hooks and substructure brackets
- Surface finish: Mill finish (natural silver aluminum)
Dimensional tolerances conform to EN 755-9 (extruded profiles — tolerances on dimensions and form). The dual-channel design — hex channel on top, open base channel below — enables secure two-axis load transfer between the solar modules above and the supporting substructure below, ensuring that both gravity loads and uplift forces from wind suction are reliably transmitted through the mounting system.
Available Lengths and Sizes
ULAMEX stocks the PV Profile 40×40 in six standard lengths, covering every common installation scenario from compact residential rooftops to extended commercial arrays:
| Length (mm) | Length (m) | Approx. Weight (kg) | Typical Application |
|---|---|---|---|
| 2,220 | 2.22 | ~1.8 | Short residential roof spans, dormers |
| 2,500 | 2.50 | ~2.0 | Standard residential 2-panel rows |
| 3,300 | 3.30 | ~2.7 | Residential 3-panel landscape rows |
| 4,400 | 4.40 | ~3.5 | Commercial roof segments |
| 6,210 | 6.21 | ~5.0 | Large commercial and ground-mount arrays |
| 6,600 | 6.60 | ~5.3 | Maximum standard length — minimizes splice joints |
Custom cutting to project-specific lengths is available on request. For installations requiring rails longer than 6,600 mm, ULAMEX supplies compatible rail splice connectors that maintain structural continuity across joined sections. Shorter lengths (2,220 mm and 2,500 mm) are particularly suited for pitched rooftops where handling space is limited, while the 6,210 mm and 6,600 mm lengths reduce the number of splice joints on large flat-roof and ground-mount systems, improving both structural integrity and installation speed.
Channel System and Fastener Compatibility
The PV Profile 40×40 uses a hex channel system in the upper rail slot. Fasteners — typically M8 hex bolts, square nuts, or socket head cap screws — are inserted from the open end of the rail and slid along the channel to the desired position. This system is universally compatible with the majority of European solar clamp manufacturers and has been the industry standard for over a decade.
The hex channel accepts the following standard hardware:
- M8 × 25 / M8 × 30 socket head cap screws (DIN 912) — the most common fastener for mid-clamp and end-clamp attachment
- M8 square nuts (DIN 557) — slide freely within the hex channel for positioning
- M8 hex nuts (DIN 934) — alternative to square nuts where channel geometry permits
For base attachment to roof hooks, mounting brackets, or ground-mount foundations, the lower channel accommodates:
- M10 hex bolts (DIN 933) with M10 flange nuts (DIN 6923) — providing high clamping force and vibration resistance
If your project requires tool-free T-bolt insertion at any point along the rail (rather than end-fed hex bolts), consider the Hammer PV Profile 40×40 variant, which shares identical external dimensions but features a T-slot channel optimized for sliding inlets with ball retention.
Installation Applications
The 40×40 mm PV mounting rail is the default choice for the following solar installation types:
- Pitched roof installations (tile, slate, metal) — the profile is mounted horizontally on roof hooks or hanger bolts, with solar panels secured using mid-clamps and end-clamps. The 40×40 cross-section handles typical residential wind and snow loads at standard support spacings of 1,200–1,400 mm.
- Flat roof systems — profiles are mounted on ballast trays or tilt triangles for south-facing or east-west configurations. The lightweight aluminum construction minimizes additional dead load on the roof membrane.
- Ground-mount arrays — long rails (6,210 mm or 6,600 mm) span between steel foundation posts for open-field solar farms. The 40×40 profile is suitable for standard module configurations where wind exposure is moderate.
- Carport and canopy structures — integrated into aluminum carport frames, the profile serves as both the module mounting rail and a structural element of the canopy roof.
- Facade-mounted systems — vertical or angled facade installations where the profile is fixed to wall-mounted brackets.
For installations in high wind zones (above wind zone 3), high snow load areas, or projects requiring support spans exceeding 1,400 mm, ULAMEX recommends the PV Profile 80×40, which offers approximately double the moment of inertia.
Why This Profile
The PV Profile 40×40 is the most specified solar mounting rail in Europe for good reason. Its 40×40 mm cross-section represents the optimal balance between structural capacity and material efficiency for the vast majority of residential and light commercial photovoltaic installations. The profile is light enough for a single installer to handle on a pitched roof, yet strong enough to meet the structural requirements of standard wind and snow load calculations per Eurocode 1 (EN 1991).
Compared to the Anodized PV Profile 40×40, the mill-finish version offers lower material cost while providing the same structural performance and natural corrosion resistance inherent to aluminum EN AW-6060 T6. Compared to the Hammer PV Profile 40×40, the hex channel version is compatible with a wider range of existing fastener inventories. For projects where neither enhanced aesthetics nor T-bolt speed is a primary requirement, this standard profile is the economically optimal choice.
Standards and Quality
All ULAMEX PV mounting rails are manufactured in compliance with the following standards and quality frameworks:
- EN AW-6060 T6 — aluminum alloy specification per EN 573-3 (chemical composition) and EN 755-2 (mechanical properties for extruded profiles)
- EN 755-9 — tolerances on dimensions and form for extruded profiles
- CE marking — conformity with the European Construction Products Regulation (EU) No 305/2011
- EN 1090 — execution of steel and aluminum structures (ULAMEX is EN 1090 certified)
- ISO 3834-2 — quality management system certification
Material test certificates (EN 10204 type 3.1) are available on request for all deliveries. Full traceability from extrusion batch to delivered product is maintained throughout our supply chain.
Why Choose ULAMEX
ULAMEX has been supplying steel and aluminum products to professional buyers across Europe for over 38 years. As a dedicated B2B wholesale distributor, we combine large stock volumes with competitive pricing, fast logistics, and the technical support that installers and project developers need. Our PV profile range is complemented by a full ecosystem of clamps, roof hooks, fasteners, ballasts, and triangles — enabling single-source procurement for your complete PV mounting hardware. Contact us for a wholesale quotation tailored to your project volume.
Frequently Asked Questions
What is the maximum span between support points for the PV Profile 40×40?
For a standard 40×40 mm profile under typical European wind and snow loads, the recommended maximum span between support points (roof hooks or brackets) is approximately 1,200–1,400 mm. The exact allowable span depends on the specific wind zone, snow load zone, module weight, and mounting orientation (portrait or landscape) of your project. Always refer to the structural calculation for your specific installation.
Is the PV Profile 40×40 compatible with all solar panel clamps?
The hex channel dimensions of the ULAMEX PV Profile 40×40 conform to industry-standard specifications and are compatible with the vast majority of European mid-clamp and end-clamp systems designed for 40 mm rails. Our own aluminum clamps are specifically designed and tested for optimal fit with this profile. If you are using third-party clamps, verify that they are rated for a 40 mm hex-channel rail.
What is the difference between the standard PV Profile and the Hammer PV Profile?
Both profiles share the same 40×40 mm external dimensions and EN AW-6060 T6 material. The difference is the channel geometry: the standard profile uses a hex channel where bolts are inserted from the rail end and slid to position, while the Hammer profile features a T-slot channel that allows T-bolts and sliding inlets to be inserted at any point along the rail with a 90° rotation. The hammer variant enables faster on-roof assembly, particularly on large-scale projects.
Can this profile be used for ground-mount solar installations?
Yes, the PV Profile 40×40 is used in ground-mount arrays, particularly in the longer lengths (6,210 mm and 6,600 mm). However, for ground-mount systems in exposed locations with high wind loads or large support spans, the PV Profile 80×40 is recommended due to its significantly higher bending resistance. Consult the structural engineer responsible for your ground-mount project to determine the appropriate profile section.