Lightweight Aluminum PV Mounting vs. Steel Mounting: How to Choose for High-Wind Regions?

With the global surge in renewable energy demand, the choice of materials for PV mounting systems has become a critical factor affecting system stability and long-term returns. In high-wind regions like the US and the Middle East, the competition between aluminum and steel mounting systems is particularly intense. So, which material offers better resistance to strong winds and ensures long-term reliability for PV power plants? Based on wind resistance tests and durability data, this article provides an in-depth analysis.

Aluminum PV Mounting Wind Resistance Comparison: Does Lightweight Equal High Wind Resistance?
Aluminum mounting systems have seen rapid market growth due to their lightweight, corrosion resistance, and ease of installation. However, many investors worry: Can lightweight designs withstand extreme wind pressure in regions prone to hurricanes and sandstorms, such as the US and the Middle East?

Latest wind tunnel tests show that structurally optimized aluminum mounting systems (e.g., triangular reinforcement designs, dynamic wind load distribution) can achieve wind resistance comparable to steel systems. For example, in a simulated Category 12 typhoon (120 mph) environment, an aluminum mounting system showed only minor deformation, while a low-quality steel system fractured due to weld fatigue.

However, experts caution that aluminum mounting performance heavily depends on alloy grade and structural design. Low-end products may suffer from metal fatigue under prolonged wind vibration, so it’s essential to choose high-quality solutions that meet international standards.

Steel Mounting Durability Test Data: Stronger but More Prone to Corrosion?
Steel mounting systems have long been the preferred choice for high-wind regions due to their high strength and low cost. Independent 20-year accelerated aging tests on galvanized steel mounting systems reveal:

• Excellent Wind Resistance: At 150 mph winds, steel structures deform 15%-20% less than aluminum, making them ideal for hurricane-prone areas (e.g., Florida).

• Corrosion Risks Stand Out: In the Middle East’s saline-alkaline desert environment, ordinary galvanized steel corrodes three times faster than aluminum, requiring regular maintenance or costly stainless steel alternatives.

Notably, the weight of steel mounting systems may increase transportation and installation costs (30%-50% heavier than aluminum), requiring additional reinforcement in areas with poor foundation conditions, such as sandy or mountainous terrain.

Market Selection Advice: Location-Specific Choices Are Key

• US Market: In hurricane-prone zones (e.g., Texas, Florida), prioritize high-strength galvanized steel or MIL-standard-compliant aluminum mounting systems.

• Middle East Market: Given high temperatures, sandstorms, and salt corrosion, corrosion-resistant coated aluminum (e.g., anodized) or stainless-steel hybrid systems are more economical and durable.