What Is Galvanized Steel? Why Solar Projects Use It
Galvanized steel is a cornerstone material in countless industries, prized for its ability to withstand the elements. But what exactly is it, and why does it matter—especially for solar energy projects? Let’s break it down.
What Is Galvanized Steel?
Galvanized steel is regular steel coated with a protective zinc layer to prevent rust and corrosion. The most common method is hot-dip galvanizing: steel is dipped into molten zinc (over 450°C), forming a durable bond. This process creates two lines of defense:
- The zinc acts as a “sacrificial anode,” corroding itself before the steel does.
- A zinc-iron alloy layer forms between the zinc and steel, boosting adhesion and longevity.
Galvanizing Methods: Hot-Dip vs. Electrogalvanizing
Not all galvanizing is equal. Two common methods exist:
- Hot-Dip Galvanizing: Steel is immersed in molten zinc, forming a thick, uniform coating (20–100μm). This is what Wanhos uses for their solar frames—ideal for outdoor durability, as the thick layer resists scratching and environmental attack.
- Electrogalvanizing: A thin zinc layer (5–10μm) is applied via electricity. Cheaper but less durable; unsuitable for heavy-corrosion areas like solar farms.
Key Advantages of Galvanized Steel
Why choose galvanized steel over other materials? Its benefits make it ideal for outdoor applications like solar farms:
- Corrosion Resistance: Zinc-coated steel resists moisture, salt, and chemicals far better than uncoated steel. In harsh environments (e.g., coastal areas or snowy regions), it can last 20–50 years—critical for long-term solar investments.
- Cost-Effective Durability: While stainless steel offers superior corrosion resistance, it’s far more expensive. Galvanized steel strikes a balance: lower upfront costs + minimal maintenance (no repainting or recoating).
Adaptability for Solar Projects
Its strength and malleability make it perfect for custom structures. For example, Wanhos’ C-Steel Ground Mount Solar Frames (made with galvanized steel tubes) support 2–8 PV panels in modular arrays, adapting to diverse project scales.
The Science of Corrosion Resistance
Galvanized steel leverages galvanic corrosion—but in a good way. Zinc has a more “active” (negative) electrode potential than steel. When exposed to moisture, zinc acts as the anode (sacrificially corroding), while steel becomes the cathode (protected).
Wanhos’ frames take this further: combining this material (for structural strength) with anodized aluminum (for lightweight components). Anodizing forms a hard oxide layer on aluminum, boosting its corrosion resistance—perfect for parts like clamps or connectors. Together, these materials create a “dual-defense” system against rust.
Total Cost of Ownership
While it costs ~15–30% more upfront than painted steel, its lifespan (20+ years) and zero maintenance (no repainting) create long-term savings. For a 5MW solar farm:
- Painted Steel: Initial cost + annual repainting = Higher total cost over 20 years.
- Galvanized Steel: 1.2x initial cost + $0 maintenance = 20% lower total cost over 20 years.
Wanhos’ 10-year warranty on their galvanized frames adds confidence—you’re not just buying steel, but a decades-long guarantee.
Galvanized Steel in Solar Energy
Solar projects demand materials that survive decades outdoors. Galvanized steel shines here:
1. Ground-Mount Solar Structures
In large-scale ground-mounted systems, galvanized steel frames (like Wanhos’ product) endure extreme conditions:
- Withstand winds up to 60 m/s and snow loads of 1.4 kN/m² (tested to standards like AS/NZS 1170).
- Optional foundation flexibility: Bolt to concrete or use earth-driven rods for cost savings.
- Low-profile design blends into sensitive areas (e.g., near buildings or protected land), easing planning permissions.
2. Beyond Ground Mounts: Diverse Solar Applications
Galvanized steel’s versatility shines across solar projects:
- Agri-PV Systems: Wanhos’ low-profile frames (10°–60° tilt) work well in farmland, letting sunlight reach crops beneath while generating power. The galvanized coating resists fertilizer runoff and soil moisture.
- Roof-Mounted Arrays: Though Wanhos specializes in ground mounts, galvanized steel is also used in roof structures. Its light weight (vs. concrete) reduces roof load, while corrosion resistance handles rain and humidity.
3. Meeting Global Standards
Solar projects face strict engineering codes. Wanhos’ frames adhere to:
- AS/NZS 1170: Australian/New Zealand standards for wind loads—critical in cyclone-prone regions.
- DIN 1055: German code for structural safety, ensuring frames survive snow loads up to 1.4 kN/m² (equivalent to 140 kg of snow per square meter).
These certifications mean developers can trust the frames in diverse climates, from desert heat to Nordic winters.
4. Modular Design: Speed and Scalability
Large solar projects demand fast deployment. Wanhos’ galvanized steel frames are pre-engineered in 2-panel modules, which can be extended to 8 panels per row. This modularity:
- Cuts on-site labor by 30–40% (no welding or custom cutting).
- Allows easy expansion (add modules as project scales).
- Simplifies logistics—frames ship flat-pack, reducing transport costs.
How It Compares to Alternatives
| Material | Pros | Cons vs. Galvanized Steel |
|---|---|---|
| Stainless Steel | Max corrosion resistance | 3–5x more expensive |
| Painted Steel | Lower upfront cost | Requires frequent repainting |
Final Thoughts
Galvanized steel’s blend of durability, cost-effectiveness, and adaptability makes it a workhorse for solar infrastructure. When paired with engineering like Wanhos’ ground-mount frames—with their modular design, dual-material corrosion defense, and global certifications—it ensures solar projects thrive—even in the harshest climates.
For developers and installers, choosing galvanized steel means investing in longevity. And in solar, longevity equals ROI.
Want to see galvanized steel in action? Explore Wanhos’ C-Steel Ground Mount Solar Frames—built to last 20+ years with galvanized durability.
