Case study

How Zimmermann achieved 80% faster design processes with PVcase Ground Mount

Zimmermann logo
80%
faster design processes
2weeks
for new team members to work independently
50%
decrease in execution time

Summary

Zimmermann PV-Tracker, a division of the Zimmermann PV-Steel Group, has established itself as a leader in innovative substructures for ground-mount solar power plants. Their expertise spans fixed-tilt systems, electric trackers, floating PV solutions, and Agro PV systems, with a standout position in floating PV systems across Europe.

However, as demand for solar projects surged, Zimmermann PV-Tracker faced challenges that called for a shift in their design processes. To overcome these challenges, they adopted PVcase Ground Mount, highly improving their processes and unlocking impressive outcomes.

Wondering how they made it happen? Keep reading to learn about the challenges they tackled, the cutting-edge solutions PVcase delivered, and the outstanding results that followed.

Challenges

Before adopting PVcase, Zimmermann PV-Tracker's engineering team relied heavily on manual design workflows in AutoCAD. This approach led to several hurdles:

1. Time-consuming manual tasks

Engineers spent excessive time calculating pole lengths and creating layouts, slowing down the design process and delaying project timelines.

2. Difficulties with undulating terrain

Accounting for complex terrains manually resulted in mismatched pole lengths and stability issues during construction, compromising the safety and efficiency of installations.

3. Delayed client response times

Repetitive design tasks hindered the team's ability to provide fast feedback and adapt to evolving project requirements.

Client experience

“We pushed PVcase to develop a garden plant for our tracker to ensure all strings face the sun in the same direction, even on varying slopes. This feature was implemented recently and allows our clients to benefit from improved product functionality.”

Zimmermann logo

Hannes Elsen

Product Engineering Team Lead

Solution

Hannes and his team at Zimmermann PV-Tracker decided to give PVcase a try to tackle their setbacks and make their design process smoother. Once they started using PVcase, they saw some big improvements:

More precision in design

PVcase automated pole length calculations and terrain analysis, providing accurate ramming depths for thousands of piles. This was key for safely accommodating varied slopes and terrain conditions.

Automated workflows

Getting rid of repetitive tasks halved the design time, which led to quicker project iterations and faster client responses.

Innovative features

Zimmermann collaborated with PVcase to develop a custom garden plant feature for tracker systems, aligning solar modules across uneven terrains and improving performance.

Improved client interaction

Tools like slope checks, framing presets, and collision analysis finally allowed engineers to validate designs efficiently and deliver preliminary layouts and material tables to clients more quickly.

Responsive support

PVcase's support team hugely helped with implementation, addressing software bugs promptly and incorporating user feedback into future updates.

Results

The adoption of PVcase has yielded significant benefits for the Zimmermann PV-Tracker:

80% faster design processes

Automating pole length calculations and terrain analysis helped cut design time by around 80% enabling Zimmermann PV-Tracker to complete projects more efficiently.

Greater accuracy on tricky terrains

With automated terrain analysis, the team could calculate exact pole lengths right from the start. This minimized the need for on-site adjustments and guaranteed solar installations were stable and secure, even on uneven ground.

Stronger client collaboration

Faster preliminary layouts and clearer material tables made communication smoother. Clients got the insights they needed upfront, helping Zimmermann speed up project approvals while building trust and confidence in their work.

Product innovation

The garden plant feature for trackers gave Zimmermann a competitive edge by allowing clients to maintain optimal solar alignment on uneven terrain.

Training simplified

New team members could start working independently within two weeks, thanks to P/case's user-friendly interface and swift support.

Client experience

“PVcase supported us and helped us speed up the design processes. It provided precise information for every single pile on undulating terrain, ensuring correct ramming depth, which is crucial for safety and efficiency.”

Zimmermann logo

Hannes Elsen

Product Engineering Team Lead

About Zimmermann

Since 2017, Zimmermann PV-Tracker has provided high-quality substructures far ground-mounted solar projects across 10 countries, delivering over 500 Mp of solar energy. Their expertise in mounting solutions, terrain analysis, and tracker systems continues to drive innovation in renewable energy.

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