Best practices for fabricating solar panel frames using galvanised steel

Solar panel frames serve as the backbone of photovoltaic (PV) installations, ensuring durability and structural integrity. Galvanised steel is the preferred material for these frames due to its corrosion resistance, strength, and cost-effectiveness. With the Indian solar market experiencing rapid growth, adhering to best practices in fabricating solar panel frames using galvanised steel is essential.  

According to the International Energy Agency (IEA, 2023), India added 18.1 GW of solar capacity in 2023 alone, underscoring the increasing demand for robust and long-lasting solar panel mounting structures.  

Best practices for fabricating galvanised steel solar panel frames  

1. Choosing the right galvanised steel grade 

Selecting the appropriate steel grade is crucial for fabricating solar panel frames that withstand environmental stresses. Hot-dip galvanised steel (HDG) is the most suitable option, providing a zinc coating thickness of 70-85 microns, which enhances corrosion protection for up to 30 years. According to the Indian Steel Association (ISA, 2023), HDG steel is up to 40% more corrosion-resistant than pre-galvanised alternatives.  

2. Optimising frame design for structural integrity  

A well-engineered frame design enhances load distribution and wind resistance. To achieve optimal performance:  

• Use C-channel and square tube profiles for maximum rigidity. 

• Ensure minimum steel thickness of 1.5-2 mm for durability. 

• Incorporate cross-bracing and reinforcement to withstand high wind loads, especially in coastal regions. 

 3. Precision cutting and welding techniques 

 To maintain the integrity of galvanised coatings during fabrication:  

• Use laser cutting or CNC plasma cutting to ensure precision without compromising the protective zinc layer. 

• Employ low-heat welding techniques (e.g., MIG welding) to reduce zinc evaporation, preventing weak points in the frame structure. 

 4. Anti-corrosion treatment post-fabrication  

Even though galvanised steel is naturally corrosion-resistant, additional protective treatments enhance longevity:  

• Apply zinc-rich paint or cold galvanising spray on cut and welded areas to restore corrosion protection. 

• Use polyurethane or epoxy coatings in regions with high humidity or salinity. 

 5. Ensuring proper mounting and installation  

A solar panel frame's performance depends on proper installation:  

• Secure frames with stainless steel fasteners to prevent rusting. 

• Align panels with aerodynamic positioning to minimise wind uplift forces. 

• Conduct pre-installation load testing to ensure compliance with IS 875 (Indian Wind Load Code). 

 
Advantages of Using Galvanised Steel for Solar Frames  

1. Cost-effective and readily available  

Steel is significantly cheaper than aluminium, making it a cost-effective choice for large-scale solar installations. The Ministry of New and Renewable Energy (MNRE, 2023) reports that galvanised steel frames cost 25-30% less than aluminium alternatives while offering similar durability.  

2. Superior corrosion resistance  

Galvanisation forms a protective zinc layer, preventing rust and degradation. According to the World Steel Association (2023), hot-dip galvanised steel extends service life by up to 50% compared to non-galvanised steel in outdoor conditions.  

3. High load-bearing capacity  

Galvanised steel provides the necessary strength-to-weight ratio, allowing frames to support high-capacity PV modules without deformation over time.  

Future trends in solar frame fabrication  

With India's goal of reaching 280 GW of solar capacity by 2030, advancements in solar panel frame fabrication are expected to focus on:  

• Hybrid steel-aluminium structures for reduced weight without compromising strength. 

• Smart coatings with self-healing properties to enhance corrosion resistance. 

• Modular, prefabricated frame designs to simplify on-site installation.