How to Prevent Corrosion in Solar Mounting Structures?

Corrosion is one of the most critical factors affecting the longevity and safety of solar mounting systems. As solar projects are expected to operate for over 25 years, selecting the right anti-corrosion strategy is essential for both structural integrity and long-term return on investment.

In this article, we’ll explore the causes of corrosion, material selection, surface treatments, and best practices to prevent corrosion in solar mounting structures.

What Causes Corrosion in Solar Mounts?

Solar mounting structures are often exposed to harsh environments—UV radiation, humidity, acid rain, coastal salt spray, and industrial pollution can all accelerate corrosion. The most common corrosion types include:

.Galvanic corrosion (when dissimilar metals contact in the presence of an electrolyte)

.Atmospheric corrosion (from moisture and air pollutants)

.Crevice corrosion (in areas where moisture is trapped)

Strategies to Prevent Corrosion

1. Choose the Right Material

Aluminum Alloys: Lightweight, naturally corrosion-resistant due to the oxide layer. Common for rooftop systems.

Hot-Dip Galvanized Steel (HDG): Coated with zinc for strong corrosion protection, especially in ground-mounted systems.

Zinc-Aluminum-Magnesium Coated Steel (ZAM): Offers 2–5x better corrosion resistance than HDG steel, ideal for coastal or industrial zones.

Stainless Steel (304 or 316): Highly corrosion-resistant but more expensive, often used for bolts, fasteners, and critical joints.

2. Surface Treatment

Anodizing (for Aluminum): Enhances the oxide layer to increase resistance and surface hardness.

Powder Coating: Adds a protective barrier, often used for aesthetic and added corrosion resistance.

HDG Standards Compliance: Ensure steel parts meet ISO 1461 or ASTM A123 coating thickness standards.

3. Avoid Dissimilar Metals

To prevent galvanic corrosion, do not directly connect dissimilar metals like aluminum and copper. Use insulation pads, washers, or compatible coatings to separate them.

4. Smart Design for Drainage and Ventilation

Avoid areas where water can accumulate. Proper slope, vented profiles, and sealed joints help minimize moisture retention and reduce the risk of crevice corrosion.

5. Routine Inspection & Maintenance

Although solar panel mounting systems are low-maintenance, annual checks can identify early signs of rust or wear, especially in high-risk environments (coastal, tropical).

Special Considerations for Coastal or Tropical Installations

For systems within 5 km of the sea, or in regions with year-round humidity, we recommend:

ZAM or stainless steel material

Marine-grade anodizing

Fully sealed fasteners and cable trays

Extra-thick galvanization (≥ 85 μm)

Conclusion

Corrosion protection is not an afterthought—it's a foundational element of reliable solar mounting system design. From material selection to installation techniques, every decision plays a role in extending the system's lifespan and safeguarding investment.

At Xiamen TopFence, we offer a full range of corrosion-resistant solar mounting solutions tailored to your project’s environment. Whether you’re installing in tropical Thailand, coastal Vietnam, or inland Malaysia, our systems are engineered for long-term durability.