Steel Fixing Structures in Solar Panel Installations: Corrosion Challenges and Alternative Materials

06 Feb 2025

Steel Fixing Structures in Solar Panel Installations: Corrosion Challenges and Alternative Materials

Key Takeaways
The Corrosion Challenge in Steel Structures
Alternative Materials to Steel
Lifecycle and Sustainability Considerations
Conclusion
Frequently Asked Questions (FAQs)

Key Takeaways

Corrosion is a Critical Issue: Steel fixing structures for solar panels face significant corrosion challenges in outdoor environments.
Economic & Safety Impacts: Corrosion increases maintenance costs, poses safety risks, and shortens the lifespan of installations.
Exploring Alternatives: Materials such as stainless steel, aluminum, and composite materials such as Fiberglass Reinforced Plastic offer improved corrosion resistance and longer service life.
Sustainability Benefits: Adopting alternative materials can enhance the sustainability and cost-effectiveness of solar panel installations.

Solar panel installations are on the rise worldwide as the demand for renewable energy grows. A critical yet often overlooked component of these systems is the fixing structure—the metal framework that secures the panels. Traditionally, steel is favored for its strength and cost-effectiveness. However, when exposed to outdoor elements, steel is highly prone to corrosion, which can compromise both the integrity and safety of the installation over time.

In this article, we delve into the corrosion challenges inherent in steel-based fixing structures for solar panels and explore alternative materials that offer enhanced durability and sustainability.

The Corrosion Challenge in Steel Structures

High Rise Building Rooftop Solar Panel Structure Rusted Real Life Example, Corroded Mounting Structure, Corroded Structure Base Steel, while robust and versatile, is inherently susceptible to corrosion when exposed to environmental elements such as moisture, salt, and varying temperatures. In solar panel installations, factors like high humidity, coastal salt spray, and temperature fluctuations accelerate the corrosion process. Over time, this degradation can lead to:

Structural Weakening: Reduced load-bearing capacity and compromised integrity.
Increased Maintenance: Frequent repairs and replacements add to the lifecycle cost.
Safety Risks: Structural failures may lead to accidents or panel detachment.

The challenges extend beyond structural deterioration and economic costs; they can also have severe safety implications. For instance, a broken/fallen-off solar ground wire—resulting from corrosion or structural failure—can create potentially hazardous situations. Without a proper grounding path, the electrical system is at significant risk: High Rise Building Rooftop Solar Panel Structure Rusted Real Life Example Solar Ground Wire Detached Close Up

Electrical Shock Risk: Fault currents can travel through a person touching the system, causing severe electric shocks.
Equipment Damage: Electrical surges, such as those from lightning strikes or internal faults, may damage critical components in the solar array.
System Malfunction: A compromised ground wire can disrupt the electrical system, leading to malfunctions or even a complete shutdown.

In large-scale solar farms, the impact of corrosion on ground wires and fixing structures is magnified, increasing the likelihood of downtime, safety hazards, and costly repairs. The need for continuous maintenance—such as recoating or replacing corroded parts—not only escalates operational costs but also reduces the overall efficiency of the system.

Addressing these issues requires a proactive approach during the design and material selection phases. Environmental conditions should be carefully assessed, and protective measures like advanced coatings or alternative materials with higher corrosion resistance should be prioritized. This holistic strategy ensures the long-term safety, reliability, and efficiency of solar panel installations, minimizing both operational disruptions and risks to personnel.

Understanding these issues is critical for stakeholders who want to ensure long-term reliability and cost efficiency in their solar installations.

Alternative Materials to Steel

Given the inherent challenges of using steel in corrosive environments, several alternative materials have emerged as potential solutions:

Alternative Material Comparison Table

Material

Advantages

Limitations

Stainless Steel

High corrosion resistance due to alloying elements like chromium.
Excellent durability and low maintenance requirements.

Higher material cost compared to conventional carbon steel.
May require specialized fabrication techniques.

Aluminum

Naturally forms a protective oxide layer, offering good corrosion resistance.
Lightweight and easy to fabricate.

Generally lower strength compared to steel.
May not be suitable for all load-bearing applications without proper design.

Fiberglass Reinforced Plastic (FRP)

Superior corrosion resistance, especially in harsh environments (e.g., saltwater, chemicals).
Lightweight with a high strength-to-weight ratio.
Low maintenance and long service life, reducing lifecycle costs.
Non-conductive and fire-retardant options are available, ideal for solar panel applications.

Higher initial costs compared to aluminum or regular carbon steel.
Requires trained personnel for installation and repairs.
Limited recyclability, although sustainable over a long product life.

HMF Pultruded Profile, I-beam, C-Channel, Square Hollow, Solid Rod, L-Angle

Key Takeaways for FRP as a Manufacturer:

FRP’s corrosion resistance is unmatched, making it ideal for solar panel structures in highly corrosive environments like coastal areas.
While initial costs may seem higher, FRP’s long service life and minimal maintenance deliver superior value over time.
As a non-conductive material, FRP is particularly safe for electrical installations, adding to its appeal in renewable energy projects like solar infrastructure.

Lifecycle and Sustainability Considerations

When selecting a material for solar panel fixing structures, it is essential to consider not only the upfront costs but also the long-term lifecycle and sustainability. While traditional steel structures may appear cost-effective initially, the expenses associated with frequent maintenance and eventual replacement can be significant. In contrast, alternative materials like stainless steel, aluminum, and composites often offer:

Extended Service Life: Reduced frequency of repairs and replacements.
Lower Environmental Impact: Improved recyclability and reduced need for chemical treatments.
Enhanced Safety: More resilient structures that can better withstand harsh conditions.

Conclusion

Corrosion poses a significant challenge to steel fixing structures in solar panel installations, impacting both safety and cost-effectiveness. By exploring and adopting alternative materials—such as stainless steel, aluminum, or composite materials—industry professionals can mitigate these risks while enhancing sustainability and long-term performance.

As the renewable energy sector continues to grow, investing in corrosion-resistant solutions will be key to maintaining reliable and efficient solar installations. In our next article, we delve into one such innovative approach: FRP lamination as a corrosion barrier for solar panel structures.

Frequently Asked Questions (FAQs)

Why is steel prone to corrosion in solar panel structures?

Steel corrodes when exposed to moisture, salt, and temperature fluctuations, leading to structural degradation and increased maintenance needs.

What are the main alternatives to steel for solar panel fixing structures?

Alternatives include stainless steel for enhanced corrosion resistance, aluminum for lightweight applications, and composite materials for high durability and low maintenance.

How do alternative materials improve sustainability?

They often offer longer service life, require less maintenance, and reduce the overall environmental impact through better recyclability and resource efficiency.

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