The impact of steel quality on solar panel durability

The solar energy sector is undergoing transformative innovations, including flexible solar panels, solar paint, and space-based solutions, which are propelling the world toward cleaner energy solutions. India has emerged as a key player in this global transition, ranking 4th in solar capacity worldwide, with its solar power capacity surging from 21,651 MW in 2018 to 70,096 MW in 2023. By 2030, the country aims to achieve 500 GW of renewable energy capacity and generate 50% of its energy needs from renewables. Initiatives like the Production Linked Incentive (PLI) scheme, Solar Park Scheme, and PM-KUSUM are fostering domestic manufacturing, job creation, and decentralized energy production. Cutting-edge developments, such as tandem cells and organic semiconductors, are advancing solar efficiency and sustainability. 

Why steel is the backbone of solar panel structures 

Among the types of steel used in solar structures, galvanised steel is the most common due to its ability to resist corrosion. Its zinc coating provides a protective barrier, ensuring the structure remains strong and rust-free, even in coastal or high-humidity areas. For projects that require extra durability, high-strength steel is another popular choice. It offers enhanced load-bearing capacity while being lightweight, making it easier to transport and install. 

Galvanised steel (GI): coated with zinc, it protects against corrosion, with coatings ranging from 80GSM to 550GSM. It is widely used in rooftop installations and ground-mount projects, depending on environmental conditions and desired durability. 

Galvalume steel (GL): a mix of aluminium, zinc, and silicon, offers enhanced corrosion resistance, especially in humid or coastal regions. It reflects sunlight, reduces heat absorption, and is lighter, providing cost benefits in large-scale projects. 

Factors that define steel quality for solar applications 

• Corrosion resistance 

Rust weakens the steel’s structural integrity, leading to potential safety hazards and reduced durability. To address this, treatments like galvanisation are crucial. Galvanised steel is coated with a layer of zinc, which acts as a protective barrier, preventing rust and extending the structure's lifespan. In more demanding environments, such as coastal regions with high salinity, powder coating is often applied as an additional layer of protection. This ensures the steel maintains its strength and appearance even under severe conditions, reducing maintenance costs and improving long-term reliability. 

• Strength and load-bearing capacity 

High-quality steel ensures the structure can bear the weight of solar panels, maintain alignment, and remain stable during strong winds or other environmental stresses. Substandard steel, with lower tensile strength or inconsistent material properties, can compromise the structural safety of solar installations, leading to deformation, misalignment, or even collapse. High-strength steel alloys are often used to achieve the necessary load-bearing capacity while keeping the material lightweight, which is advantageous for transportation and installation. 

• Fabrication quality 

Precision cutting ensures all components fit accurately, avoiding stress points that can weaken the structure. Welding quality is equally critical; poor welds can create weak joints prone to failure under load or environmental stress. Automated fabrication techniques, like laser cutting and robotic welding, offer greater precision and consistency, improving the alignment and stability of the solar panel structure. 

India’s 2047 vision focuses on achieving 90% renewable energy and energy independence through green technologies, creating millions of jobs and attracting global investments estimated at $350-400 billion annually. This ambitious path not only combats climate change and reduces pollution but also offers lucrative opportunities for investors to contribute to and benefit from India’s growing clean energy sector.