PV Hardware USA (PVH USA), a global provider of solar tracking and foundation solutions, is expanding its original Houston manufacturing facility, increasing domestic production capacity to meet growing demand for its solar tracking systems and its factory pre-assembly approach that moves installation work from the jobsite into a controlled factory environment.
The expansion adds approximately 34,200 square feet of manufacturing space and increases the company’s overall Houston store capacity by 42%. The additional capacity is expected to enable a 35% increase in production of pre-assembled components, allowing the company to support more solar projects while maintaining the quality, consistency, and production control central to its U.S. manufacturing strategy.
The investment represents the latest step in the manufacturer’s broader effort to bring more of the solar installation process into the factory. By completing more assembly before equipment reaches a project site, the company helps customers reduce field complexity, improve installation predictability, and make more efficient use of increasingly constrained construction labor.
“We are investing in additional domestic manufacturing capacity because our customers are asking us to do more,” said Alfonso Queipo, CEO of PVH USA. “But this is not simply about manufacturing more products. It is about finding ways to make solar installation more efficient. Pre-assembly has become an important part of that strategy because it allows us to move complexity out of the field and into an environment where we have greater control over quality, productivity and consistency. This expansion gives us the capacity to bring that approach to more customers and more projects while maintaining the standards they expect from PVH USA.”
Bringing factory precision to the jobsite
Since 2023, the company has refined its pre-assembly approach to shift complex construction processes from the jobsite into a controlled manufacturing environment. Rather than shipping numerous individual components to a project site and requiring field crews to complete extensive assembly, technicians perform a greater portion of the work in Houston facilities before equipment leaves the factory. The result is a streamlined installation process designed to reduce components managed in the field:
- Up to 70% fewer on-site components: Reduces the number of individual parts crews must receive, organize, and assemble.
- Up to 44% faster installation rates: Helps accelerate project construction timelines.
- Reduced field labor requirements: Allows crews to focus on installation rather than extensive component assembly.
- More predictable field execution: Completes key assembly processes under controlled factory conditions.
- Greater agility for field crews: Minimizes exposure to challenging conditions and expedites construction during extreme weather.
“Solar EPCs face mounting pressure regarding labor availability, strict timelines and total project costs,” said Rodolfo Bitar, Vice President of Business Development for PVH USA. “Traditionally, manufacturers pushed the assembly burden onto the jobsite. We ask a different question: what work can be done more efficiently before the equipment ever leaves the factory? By managing the assembly of 188 loose parts per row in our controlled manufacturing environment, we remove field complexity and make installation highly predictable.”
Manufacturing innovation becomes installation innovation
The expansion reflects a broader shift in how the organization approaches manufacturing. Rather than viewing manufacturing and installation as separate stages of a solar project, the company uses its factory capabilities to address challenges that traditionally emerge in the field, including labor shortages, compressed schedules, and site conditions.
A commitment to sustainable manufacturing
The Houston expansion also aligns with PVH’s broader sustainability objectives by expanding domestic manufacturing and shortening supply chains. Localizing production in Texas cuts transportation emissions while increasing domestic content. Furthermore, steel accounts for more than 98% of the tracker weight, keeping systems highly recyclable at the end of their operational lifespan.