2025 Solar Mounting Brackets Guide: Al vs Galvanized Steel

I. Why Choosing the Wrong Solar Mounting Brackets Can Ruin Your PV Project?

PV projects have a lifespan of 25-30 years, and solar mounting brackets, as the core structure supporting PV modules, directly determine the project’s safety, stability, and cost return rate. Many owners and contractors easily fall into misunderstandings such as “only focusing on price” or “blindly choosing materials” when selecting brackets: some choose corrosion-prone brackets that rust and deform in 3-5 years; others ignore local wind speed and snow load, leading to bracket collapse; some even select the wrong materials, doubling installation time and increasing long-term maintenance costs.

As a factory with over 10 years of experience in solar mounting bracket manufacturing (direct supply from a 28,000㎡ production base), TopBestSolar has served thousands of PV projects. We’ve found that choosing the right brackets can reduce project costs by more than 18% while minimizing 90% of long-term maintenance issues. This solar mounting brackets selection guide will help you avoid common pitfalls and select cost-effective solar mounting brackets from three core dimensions: material comparison, scenario adaptation, and key parameters.

II. Core Selection Dimension: Aluminum vs Galvanized Steel Solar Mounts – How to Choose?

If you want to first understand the basic differences between aluminum and steel solar mounts (e.g., strength, cost, corrosion resistance), check our basic comparison guide: Aluminum vs Steel Solar Mounting

The core materials of solar mounting brackets are mainly aluminum and galvanized steel. Neither is absolutely superior— the key lies in your project requirements. The following detailed comparison table helps you make quick decisions:

Comparison Dimension	Aluminum Solar Mounting Brackets	Galvanized Steel Solar Mounting Brackets
Material Properties	Lightweight (density 2.7g/cm³), corrosion-resistant, easy to process	High strength (tensile strength ≥355MPa), strong load-bearing capacity, cost-effective
Service Life	25-30 years (no additional anti-rust treatment required)	20-25 years (galvanized layer thickness ≥85μm, rust-proof and durable)
Installation Difficulty	Lightweight and easy to transport, high installation efficiency (operable by a single person)	Slightly heavier, requires auxiliary tools, suitable for professional teams
Cost Advantage	Higher material cost, ideal for weight-sensitive scenarios	15-20% lower material cost; inventory design enables further cost reduction
Core Advantages	Corrosion resistance, aesthetic appearance, low maintenance cost	Strong load-bearing capacity, wind and snow resistance, high cost-performance
TopBestSolar Recommendation	Residential rooftops, small distributed power plants, BIPV carports	Large ground-mounted power plants, commercial flat-roof power plants, areas with high wind speed/snow load

III. Scenario-Based Selection: Different Project Types, Corresponding Bracket Choices

1. Residential Rooftop PV Projects (Distributed Small-Scale Power Plants)

Core Requirements: Lightweight, no roof damage, easy installation, corrosion resistance
Recommended Selection: Aluminum solar rooftop brackets + leak-proof installation kits
Why Choose This? Most residential rooftops are concrete or color steel tile structures. Aluminum brackets are only 1/3 the weight of steel brackets, reducing roof load pressure. Combined with TopBestSolar’s leak-proof solar structure, it avoids roof water leakage caused by drilling during installation. Meanwhile, installation efficiency is increased by 50%, suitable for rapid construction.

2. Large Ground-Mounted PV Power Plants (Centralized/Commercial Power Plants)

Core Requirements: Strong load-bearing capacity, wind and snow resistance, cost control, bulk supply
Recommended Selection: Galvanized steel ground-mounted brackets + customized design
Why Choose This? Large ground-mounted power plants need to support a large number of PV modules. Galvanized steel brackets have 30% higher load-bearing capacity than aluminum ones, capable of withstanding level 12 typhoons and 50cm snow load. Through standardized inventory design, TopBestSolar can reduce project costs by 18%. Additionally, our 28,000㎡ factory ensures bulk supply without delaying construction schedules.

3. BIPV Solar Carport/Pergola Projects

Core Requirements: Aesthetic appearance, multi-functionality, leak-proof, compatible with architectural styles
Recommended Selection: Aluminum BIPV carport brackets + leak-proof solar structure
Why Choose This? BIPV carports integrate power generation, sunshade, and rain protection. Aluminum brackets can be customized in different colors and shapes to match architectural styles. Combined with TopBestSolar’s leak-proof solar structure, it completely solves the water leakage problem of carports. Meanwhile, aluminum’s corrosion resistance makes it suitable for long-term outdoor use.

4. Areas with High Wind Speed/Snow Load (e.g., Coastal Regions, Snowy Northern Areas)

Core Requirements: Wind and snow resistance, structural stability, high safety factor
Recommended Selection: Galvanized steel brackets + reinforced fixtures (grounding clips, end clamps)
Why Choose This? TopBestSolar’s galvanized steel brackets have passed wind tunnel tests, capable of withstanding wind speeds ≥25m/s (level 10 typhoons) and snow loads ≥1.0kN/㎡ (about 50cm snow). Equipped with dedicated grounding clips and end clamps, they not only ensure firm fixation but also guarantee the electrical safety of the PV system, reducing lightning strike risks.

IV. Selection Pitfall Avoidance: 4 Key Parameters Determining Bracket Quality

Material Compliance: Aluminum brackets should use 6063-T5 aluminum alloy (strength ≥240MPa), and galvanized steel brackets should have a galvanized layer thickness ≥85μm (complying with GB/T 13912-2022 standard). Avoid non-standard materials that cause safety hazards.
Wind and Snow Load Parameters: Confirm the wind speed and snow load of the project location before selection. TopBestSolar provides free wind load/snow load calculation services to customize suitable bracket structures.
Installation Details: Rooftop brackets should be equipped with leak-proof gaskets and anti-slip parts; ground-mounted brackets require solid foundation fixation (concrete embedding or spiral piles) to avoid loosening later.
After-Sales Guarantee: Choose manufacturers with over 10 years of industry experience. TopBestSolar offers a 10-year bracket warranty and lifelong technical support. One-stop procurement of replacement parts is available for old power plant renovations.

V. TopBestSolar: 10-Year Factory Direct Supply, Making Solar Mounting Brackets Selection Easier

As a professional manufacturer focusing on R&D and production of solar mounting brackets, TopBestSolar not only provides two major series of aluminum and galvanized steel bracket products but also offers:

Customized Design: Free exclusive bracket design based on project scenarios, climate conditions, and module specifications;
Cost Optimization: Reduce project costs by 18% through standardized inventory and modular production;
Quick Response: Provide quotes and technical solutions within 24 hours; delivery cycle for bulk orders ≤15 days;
Full-Cycle Service: Professional team follows up from selection consultation, installation guidance to post-maintenance.

Whether you are a residential PV installation owner, commercial power plant contractor, or have old power plant renovation needs, you can find suitable bracket solutions at TopBestSolar.

VI. Consult Now: Get Exclusive Selection Solutions

If you are struggling with solar mounting brackets selection for your PV project, or want to learn more about detailed parameters and quotes of aluminum/galvanized steel brackets, welcome to contact TopBestSolar:

Email: Info@TopBestSolar.com
Phone: +86-183-592-60008
Official Website: TopBestSolar.com

We will provide you with free selection evaluation and customized solutions, making your PV project safer, more efficient, and more cost-effective!

2025 Global Solar Mounting Brackets Selection Guide: Aluminum vs Galvanized Steel – TopBestSolar