Beyond the Clamp: Engineering a Complete Attachment Environment for Solar on Structural Steel

The S-5-CP^TM clamp (“CP” for carport) is engineered to fit both Cee and Zee purlin-framed structures, delivering a secure, non-penetrating attachment for solar applications. Its design offers faster installation, superior strength and long-term reliability, while protecting against corrosion by eliminating the need for drilled holes.

By Fiona Maguire-O’Shea, METALCON staff writer

As solar continues to be integrated into carports, canopies and ground mount structures, greater attention is being paid to how photovoltaic systems are attached to structural steel. From retail fuel stations to large-scale ground mount installations, contractors and engineers are seeking solar mounting solutions that protect the integrity of the steel — resisting corrosion, maintaining material compatibility and delivering reliable, long-term structural performance in demanding environments.

Ricardo Barroso, Head of Engineering at S-5!, has spent years helping guide the development of solutions designed specifically for these evolving needs. In this conversation, he shares how the S-5-CP^TM clamp for carports came to market, what differentiates it and where he sees the industry heading next.

Built in Response to Real-World Demand

The story of the CP clamp begins not in a lab, but in the field.

“We were seeing an increase in solar over carports — at convenience stores, office buildings, gas stations and shopping centers — many in regions with demanding environmental conditions,” Barroso says. “We knew we could bring meaningful savings and performance improvements to those projects.”

In high-wind regions such as Florida, engineered structural performance is non-negotiable. Many of these carport structures rely on Cee or Zee purlins, and attaching solar modules to those members has historically required complexities.

“One effective method for those structures is a racking system,” Barroso explains. “But traditional approaches created challenges that made it clear a better solution was needed.”

Contractors typically relied on two primary methods: perforating the purlin with screws or fastening substructures with bolts and nuts. Both approaches introduced concerns.

“Perforation with screws was common. The other option was using bolts and nuts to secure the solar system,” he says. “Both presented long-term corrosion risks, escalated costs and potential corrosion issues. Material compatibility is crucial in these environments.”

The breakthrough came after S-5!’s international team brought forward several project opportunities, including gas station canopy applications.

“They came to us with real projects that required a purpose-built solution,” Barroso recalls. “At that point, it was clear the market didn’t need a small improvement — it needed something designed specifically for the application.”

The result was a non-penetrating clamp engineered to fit Cee and Zee purlins while improving installation speed and long-term durability.

“The S-5-CP clamp does not perforate the purlin,” he emphasizes. “Instead of fastening through the steel, the clamp secures to the purlin using S-5!’s proprietary setscrews, which are engineered for compatibility with the base material and designed to resist corrosion over the life of the structure.”

The clamp pairs seamlessly with S-5!’s PVKIT® solar mounting solution for a rail-less solar panel installation, minimizing parts and labor costs.

Designing for Strength, Compatibility and Longevity

From an engineering standpoint, defining the dimensional range of commonly used Cee purlins was foundational.

“There is a wide variation in purlin dimensions across markets,” Barroso explains. “One of the most important inputs was understanding the most common profiles so we could design a product that would fit the majority of applications.”

Rather than tailoring the product to niche variations, the team focused on developing a solution that addresses the most prevalent structural configurations without sacrificing strength and while streamlining installation.

High wind resistance was also central to the design brief.

“We needed a solution suitable for high-velocity wind zones,” he says. “Reliability in those environments was critical.”

But performance wasn’t the only consideration. Aesthetic consistency and cable management were also part of the equation.

“When you’re talking about direct attachment on carports, you don’t want wires hanging randomly.” Barroso notes. “With the CP clamp, we developed a complete environment solution that includes wire management and accessories.”

Water management was another factor in certain applications.

“In many cases, reducing water intrusion under the carports is important, such as in the Port of Bilbao in Spain, where perishable food has been unloaded from cargo ships and loaded on trucks for local distribution in the North of Spain. We incorporated features to address that as well.”

As with other S-5! product launches, the engineering team surveyed our global sales team to gather market intelligence about regional applications and structural trends.

“That input helps us design for real-world conditions. It is what we call ‘listening to the voice of our customers and the industry,’” he says.

The full engineering package, which easily incorporates either traditional rail systems or the S-5! PVKIT. 

More Than a Clamp

While the clamp itself solves a specific attachment challenge, Barroso believes the broader value lies in the complete system and support behind it.

“What makes it different is not just the clamp,” he says. “It’s the full engineering package, which easily incorporates either traditional rail systems or the S-5! PVKIT.”

The product is engineered and tested to meet rigorous standards, including Florida Product Approval for the clamp and UL 2703 compliance for the PVKIT system.

Equally important, Barroso says, is the company’s engineering support.

“We have application engineers who answer questions around the clock and go to the field to train and support installations. Customers value that support — it often helps win projects.”

Expanding Beyond the Original Vision

Although initially developed for carports and canopies, the CP clamp has proven adaptable.

“When we developed it, the focus was carports and canopies,” Barroso says. “Ground mount was not initially in sight. Now we’re seeing strong opportunities there.”

A recent ground mount solar farm in the South used more than 20,000 CP clamps — a signal that the product’s applicability extends beyond its original intent.

Any contractor working in solar carports, canopies or compatible ground mount structures can benefit.

Where Does It Create the Greatest Impact?

“Speed and labor efficiency matter, of course,” Barroso says. “But the real impact is long-term reliability.”

He explains that the value goes beyond faster installation.

“When you eliminate penetration, address material compatibility and engineer for corrosion resistance, you’re protecting the structure for its entire service life. That’s where owners see the real return — in durability and performance that doesn’t degrade over time.

“It’s about compatibility and holding strength that lasts for the lifetime of the structure. No maintenance. No corrosion.”

Shifting Expectations in Solar Mounting

Barroso sees the CP clamp as part of a broader industry shift.

“The main shift is toward reliability,” he says. “The industry is demanding products that don’t degrade in performance over time.”

As project owners increasingly evaluate systems based on multi-decade performance, attachment systems must align with that expectation.

S-5! is continuing to pursue additional certifications, including submission for International Code Council (ICC) listing, further reinforcing its commitment to engineering rigor and compliance.

Looking ahead, Barroso does not expect major changes in the way steel support structures are built.

“Carports, canopies and many ground mount systems use structural forms that have been standard for a long time,” he explains. “The opportunity is in improving the attachment, simplifying installation and enhancing long-term reliability.”

For S-5!, that means continued focus on practical innovation.

“We’re always looking at what we can do better,” Barroso says. “It’s about improving the customer experience and finding better ways to serve evolving applications.”

Bottom Line

As solar deployment accelerates across diverse project types and geographies, solutions like the CP clamp underscore a simple yet powerful principle: when small components are engineered with precision and purpose, they can make a lasting impact on the performance and longevity of the entire system.

About S-5!®

Founded by a veteran metal roof expert, S-5! has been the leading authority on metal roof attachment solutions since 1992. S-5!’s zero-penetration clamps and lifetime brackets attach virtually anything to most metal roof types, while maintaining roof integrity and warranties. Made in the U.S.A., S-5! solutions are engineered for a variety of roof-mounted applications and are now installed on more than 3.0 million metal roofs worldwide, including more than 9 GW of roof-mounted solar, providing strength and longevity never before seen. For more information, visit s-5.com.