Hot-Dip Galvanized Steel, ZAM, Aluminum, or Carbon Steel Which Solar Mounting Material Is Right for You? large ground-mounted systems

Choosing the right material for your solar mounting system is critical to the long-term durability, safety, and cost-effectiveness of your PV installation. With multiple options available—Hot-Dip Galvanized (HDG) steel, Zinc-Aluminum-Magnesium (ZAM) coated steel, aluminum alloy, and carbon steel—it's important to understand the strengths and trade-offs of each material.

In this blog, we’ll break down the key differences and help you decide which material best fits your solar project.

 

 

 

1. Hot-Dip Galvanized (HDG) Steel

Overview:
HDG steel is carbon steel coated with a thick layer of zinc through a hot-dip process, forming a durable, corrosion-resistant barrier.

Pros:

Strong mechanical load capacity—ideal for large ground-mounted systems

Proven corrosion protection in inland and industrial settings

Cost-effective for utility-scale projects

 

Cons:

Heavier than aluminum—may increase transportation and installation labor

Zinc coating may wear faster in highly corrosive environments (e.g., coastal areas)

Best For:
Ground-mount PV systems, utility-scale farms, mountain and rural installations

 

 

 

2. ZAM (Zinc-Aluminum-Magnesium Coated Steel)

Overview:
ZAM is a next-generation coated steel alloy that combines zinc, aluminum, and magnesium for superior corrosion resistance, even in aggressive environments.

Pros:

2–5x better corrosion resistance than HDG in salt spray tests

Excellent for coastal, humid, or desert conditions

Thinner coating provides same or better protection with less weight

Cons:

Slightly higher cost per unit than traditional HDG

Limited familiarity in some regions; may require technical validation

Best For:
Coastal solar farms, desert PV systems, high-humidity or typhoon-prone areas

 

 

 

3. Aluminum Alloy (Usually 6005-T5)

Overview:
Aluminum is lightweight, rust-proof, and commonly used in rooftop systems due to its high strength-to-weight ratio.

Pros:

Naturally corrosion-resistant—no coating required

Lightweight for easy handling and faster rooftop installation

Long lifespan and low maintenance

Cons:

Higher material cost than carbon or galvanized steel

Lower mechanical strength compared to steel—less suitable for high-wind or snow-load areas

Best For:
Residential and commercial rooftops, lightweight canopy or carport systems

 

 

 

4. Carbon Steel (Untreated or Painted)

Overview:
Carbon steel is strong and economical, but prone to rust if not properly treated.

Pros:

Very cost-effective

Strong structural properties

Cons:

Requires painting or coating to resist corrosion

Shorter lifespan and higher maintenance in outdoor environments

 

Best For:
Temporary installations, non-corrosive indoor solar frames, or low-budget rural projects with dry climates

 

Comparison Table

Material	Corrosion Resistance	Weight	Cost	Strength	Best Use Case
HDG Steel	★★★☆☆	High	Low	High	Utility-scale, ground mount
ZAM Steel	★★★★★	Medium	Medium	High	Coastal, humid, or desert climates
Aluminum	★★★★☆	Low	High	Medium	Rooftop, carport, C&I rooftops
Carbon Steel	★★☆☆☆	High	Very Low	High	Indoor or low-cost dry-zone installs

 

 

 

Conclusion

There’s no one-size-fits-all material for solar mounting systems. The optimal choice depends on your project’s location, scale, environment, and budget. For rugged durability and cost-efficiency, HDG steel is a trusted standard. For corrosive coastal or desert environments, ZAM-coated steel offers cutting-edge protection. Aluminum is perfect for lightweight, rooftop projects, while carbon steel remains a low-budget option for simple needs.

At Xiamen TopFence, we offer a full range of solar mounting solutions using HDG, ZAM, aluminum, and carbon steel—customized for your specific project requirements. Contact our business team to get expert advice on the right material for your solar system.