From Steel to Aluminium: Choosing the Right Materials for Reliable Solar Mounting Systems

Two primary materials dominate the solar mounting industry: steel and aluminium. Each comes with its own set of advantages and is suited for specific applications. Understanding the unique properties of these materials and their suitability for various environments is essential for designing systems that are both efficient and long-lasting.

April 15, 2025. By News Bureau

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MTE Structures Limited

Solar energy

Solar panels

Solar mounting systems

Tejas Patel

sustainable material

Solar energy projects

Solar installations

In the solar energy sector, the importance of reliable mounting systems cannot be overstated. While solar panels are often the focus of attention for their energy-generating capabilities, the mounting structures that support these panels play a crucial role in determining the efficiency and durability of the overall system. Selecting the right materials for these mounting systems is a decision that can significantly impact performance, cost, and sustainability.

Two primary materials dominate the solar mounting industry: steel and aluminium. Each comes with its own set of advantages and is suited for specific applications. Understanding the unique properties of these materials and their suitability for various environments is essential for designing systems that are both efficient and long-lasting.

The Strength and Versatility of Steel
Steel has been a trusted material across industries for decades, and its role in solar mounting systems is no different. Known for its strength and durability, steel is the preferred choice for large-scale solar installations, particularly those located in areas with challenging environmental conditions.

One of the key advantages of steel is its ability to withstand heavy loads and extreme weather. Solar farms in regions prone to high winds, heavy snowfall, or intense heat often rely on steel mounting systems to ensure structural integrity. Advanced treatments such as galvanisation or the use of materials like Galvalume have further enhanced steel’s resistance to corrosion, making it a reliable choice even in humid or coastal areas.

Steel is also a sustainable material. As the global push toward renewable energy continues, the recyclability of steel aligns well with the industry’s focus on reducing environmental impact. Additionally, its cost-effectiveness makes it a practical option for utility-scale projects where long-term reliability and durability are non-negotiable.

The Lightweight and Flexible Nature of Aluminium
Aluminium, on the other hand, offers a distinct set of advantages, particularly for rooftop and smaller-scale installations. Its lightweight nature makes it easier to transport, handle, and install, reducing both labor costs and installation time.

Aluminium’s natural corrosion resistance is another significant benefit. Unlike steel, which often requires additional coatings to protect against rust, aluminium’s protective oxide layer ensures long-term performance in most environments. This makes aluminium particularly suitable for regions with high humidity or saline conditions, such as coastal areas.

From an aesthetic perspective, aluminium has a sleek, modern finish that appeals to clients looking for a polished appearance for their installations. This is especially relevant in residential and commercial rooftop projects where visual appeal can be as important as functionality.

However, aluminium’s advantages aren’t just limited to its weight and aesthetics. It also offers excellent adaptability, which is critical for custom designs and innovative solar mounting solutions. While aluminium may have a higher initial cost compared to steel, the savings in transportation, labor, and maintenance often balance out the expense over the lifecycle of the project.

Choosing the Right Material
The choice between steel and aluminium ultimately depends on the specific requirements of the project. Factors such as location, environmental conditions, load-bearing needs, and budget all play a role in determining the most suitable material.

For large-scale ground-mounted solar farms, steel remains the go-to material due to its strength and cost efficiency. Its ability to endure harsh weather conditions and maintain structural stability over time makes it indispensable for projects requiring a robust foundation.

Conversely, aluminium is often the material of choice for rooftop installations and smaller projects where weight and ease of installation are critical. Its corrosion resistance and modern appearance add to its appeal for residential and commercial applications.

In some cases, a hybrid approach that combines the strengths of both materials can offer the best solution. For example, using steel for the base structure and aluminium for the above-ground components can provide a balance of strength, weight reduction, and cost efficiency.

The Role of Precision Engineering
While selecting the right material is vital, the engineering and design of the mounting system are equally important. High-quality manufacturing and precision engineering ensure that the materials—whether steel or aluminium—perform to their full potential.

Attention to detail in areas such as wind resistance, load distribution, and corrosion protection can make a significant difference in the longevity and reliability of the system. Companies that prioritise these aspects in their design and manufacturing processes are better equipped to meet the diverse needs of solar energy projects.

Sustainability in Focus
As the world moves toward renewable energy, the sustainability of every component in a solar installation is under scrutiny. Both steel and aluminium are recyclable materials, which aligns with the industry’s commitment to reducing environmental impact. Choosing the right material not only ensures the efficiency of the system but also contributes to the broader goal of sustainable development.

The manufacturing processes for solar mounting systems are also evolving to minimise waste and energy consumption. By incorporating sustainable practices, the solar industry can deliver solutions that are not only economically viable but also environmentally responsible.

The Future of Solar Mounting Systems
The rapid growth of the solar energy sector demands innovative solutions that can adapt to diverse requirements. As projects become more complex and the need for customisation increases, the choice of materials will continue to play a central role in the design and implementation of mounting systems.

Steel and aluminium will remain the primary contenders, with advancements in material science likely to enhance their properties further. By focusing on precision engineering, sustainability, and client-centric solutions, manufacturers can ensure that their systems meet the evolving demands of the renewable energy market.

In conclusion, the choice between steel and aluminium is not a one-size-fits-all decision. It requires a careful evaluation of the project’s needs and a commitment to delivering reliable, efficient, and sustainable solutions. Whether it’s the strength of steel or the versatility of aluminium, the right material can make all the difference in the success of a solar energy project.

- Tejas Patel, Director, MTE Structures Limited