5 advantages of galvanised steel support posts in solar projects

Solar structures are designed to position solar panels at optimal angles and orientations to maximise sunlight exposure throughout the day. This ensures that solar panels can generate the maximum amount of electricity possible, increasing energy production and efficiency. Galvanised steel is highly sought after due to its exceptional durability in solar projects, combining steel's robustness and malleability with the zinc-iron coating's protective properties. For optimal protection, it's recommended to have a zinc coating of at least 10 micrometres on the surface and a total galvanised layer of about 80 to 85 micrometres when embedding steel in concrete.

Zinc is usually inactive or doesn't react much when embedded in concrete because the concrete's pH is relatively high (13.5). When the pH of the concrete is a bit lower (but still within a safe range), around 13.3, a protective layer forms on the zinc; this layer prevents further corrosion. During this process, a thin layer of zinc (about 10 micrometres thick) gets used up uniformly. A pure zinc coating provides better protection compared to a zinc-iron alloy coating.

This versatility makes galvanised steel suitable for various agriculture, solar energy, automotive, and construction applications. Below, we'd like to offer an in-depth overview of the galvanisation process, its diverse methods, benefits, and use in various sectors.

The galvanisation process unfolds in the following steps:

• Degreasing: the steel undergoes cleaning in a degreasing solution.

• Pickling: the steel is immersed in diluted hot sulfuric acid to remove impurities.

• Fluxing: the steel is treated in an aqueous solution, typically zinc-ammonium chloride, to prepare its surface for galvanisation.

• Galvanisation: the steel is then immersed in a vat of molten zinc to apply the protective coating.

• Inspection: finally, the coated steel undergoes thorough examination to ensure uniformity and complete coverage.

Using galvanised steel support posts in solar projects offers several advantages:

1. Corrosion resistance: Galvanised steel's sacrificial anode mechanism protects exposed or damaged areas. Regardless of how much of the steel is uncovered, the zinc coating will corrode before the steel does. This sacrificial corrosion acts as a shield, safeguarding vulnerable sections of the steel support posts.

2. Strength and durability: galvanised steel support posts have high tensile strength and can withstand heavy loads, such as solar panels and mounting structures. This strength and durability make them reliable for supporting the weight of the solar array over its operational lifespan.

3. Cost-effectiveness: while initial costs may be slightly higher compared to other materials, galvanised steel support posts offer significant cost savings over the long term due to their durability and low maintenance requirements. Their corrosion resistance reduces the need for frequent inspections and replacements, resulting in lower overall project expenses.

4. Tolerates higher chloride migration: Galvanised steel demonstrates a superior capacity to withstand elevated levels of chloride migration compared to its uncoated counterpart. Chloride migration refers to the movement of chloride ions through a material, which can accelerate corrosion. Zinc has a higher standard electrode potential than steel, which is more likely to corrode sacrificially in corrosive elements like chloride ions.

5. Environmental sustainability: galvanised steel is a highly recyclable material, making it an environmentally sustainable choice for solar projects. The steel can be recycled and repurposed at the end of its lifespan, reducing the project's environmental impact and contributing to circular economy practices. This aligns with the sustainability goals of many solar energy initiatives.

Galvanised steel components are typically lightweight and easy to handle, facilitating the installation process of solar structures. Their standardised sizes and shapes also simplify construction, saving time and labour costs during installation.