Hebei Yehui Metal Materials Co., Ltd.

The Application of Galvalume Steel in Photovoltaic Mounting Systems: An In-Depth Analysis of Its Excellent Weather Resistance and Outstanding Affordability

The Application of Galvalume Steel in Photovoltaic Mounting Systems: An In-Depth Analysis of Its Excellent Weather Resistance and Outstanding Affordability

With the rapid development of the global photovoltaic industry, the long-term reliability and return on investment (ROI) of photovoltaic power plants have become key concerns for investors and operators. As the backbone of a photovoltaic power plant, the selection of mounting systems is crucial. Among various materials, galvalume steel, due to its unique advantages, is gradually becoming the mainstream choice for photovoltaic mounting systems. This article will analyze in depth why galvalume steel stands out from the crowd, focusing on two core dimensions: weather resistance and affordability.

I. Solid as a Rock: The Excellent Weather Resistance of Galvalume Steel Photovoltaic Mounting Systems

Photovoltaic power plants are often built outdoors, even in harsh environments such as coastal areas, plateaus, and deserts. They are constantly exposed to wind, sun, rain, salt spray, and significant temperature fluctuations. Therefore, the corrosion resistance of the mounting system directly determines the plant's service life of 25 years or even longer.

Galvalume steel is a high-performance composite material composed of an alloy of 55% aluminum, 43.4% zinc, and 1.6% silicon, plated on a high-quality steel substrate. Its weather resistance far exceeds that of traditional galvanized steel. The secret lies in its multiple protective mechanisms:

1. Dual "Shielding" and "Sacrificial" Protection Mechanisms:

Aluminum Barrier Protection: Aluminum quickly forms a dense and stable aluminum oxide (Al₂O₃) protective film on the surface of the coating. This film is extremely inert, effectively isolating moisture, oxygen, and corrosive substances (such as chloride ions and sulfides) from the steel substrate, providing excellent physical barrier protection.

Zinc Electrochemical Sacrificial Protection: When the coating is scratched or cut, exposing the steel substrate, the zinc acts as a sacrificial anode and corrodes preferentially, protecting the steel substrate from rust. This is the principle of "cathodic protection" in electrochemistry.

2. Excellent High-Temperature Oxidation Resistance:

Aluminum's high melting point allows galvanized steel to maintain coating stability even in high-temperature environments (such as summer sun exposure). Its heat resistance can reach 315°C (600°F), far exceeding that of galvanized steel. This is crucial for photovoltaic mounting systems used in hot regions.

3. Uniform Corrosion, Longer Lifespan:

In actual atmospheric corrosion tests, the corrosion rate of galvanized steel sheets is much lower than that of galvanized steel sheets. At the same coating thickness (e.g., AZ150, which has a coating weight of 150 grams per square meter), its corrosion lifespan is typically 2-4 times that of ordinary galvanized steel sheets. This means that galvanized steel photovoltaic mounting brackets can easily withstand C1-C4 (moderate) corrosion environments, ensuring that the main structure of the power station is maintenance-free and replacement-free throughout its lifespan.

II. Cost-Effectiveness: The Outstanding Cost-Effectiveness of galvanized steel mounting brackets

Investing in a photovoltaic power station is a long-term undertaking. Cost accounting should not only focus on the initial investment but also on the comprehensive cost over the entire lifespan. Galvanized steel sheets offer excellent cost-effectiveness, primarily in the following aspects:

1. Longer Service Life, Lower Amortized Costs:
As mentioned previously, their exceptionally long corrosion lifespan means that virtually no maintenance or replacement of the mounting brackets is required over the entire 25-30-year operational lifespan of the power station. This saves significant costs for ongoing maintenance, material replacement, and labor, spreading the initial purchase cost over a longer lifespan, resulting in a highly competitive annual cost.

2. Reduced material thickness allows for lightweighting and cost reductions while maintaining a comparable lifespan:
Due to its excellent corrosion resistance, galvanized steel, with a thicker coating but a thinner base plate, can be used to achieve the same design lifespan as galvanized steel brackets. This directly reduces steel usage and achieves lightweighting. This lightweighting not only lowers material costs but also reduces energy consumption and expenses during transportation and installation.

3. Excellent material utilization and processability:
Galvanized steel exhibits excellent flexibility, ductility, and weldability. When producing galvanized steel bracket profiles, stamping and cold-forming are easy, resulting in high yields and minimal scrap, further reducing production costs.

4. Higher Lifecycle Value (LTV):
For an asset that needs to operate stably for decades, reliability is the ultimate economic benefit. Choosing galvanized steel brackets significantly reduces the risk of component damage, power outages, and even structural damage due to bracket corrosion failure, ensuring sustained power generation revenue for the power plant and enhancing the overall asset lifecycle value.

Conclusion and Recommendations
Overall, the application of galvanized steel in photovoltaic brackets perfectly balances the seemingly conflicting demands of weather resistance and affordability. Rather than simply being "more expensive" or "cheaper," it delivers both peace of mind and value through its superior long-term performance.