2MW Solar Racking System Solution Using Scaffolding (HDG Pipe) for DIY Installation

In the world of solar energy, flexibility and customization are key. One standout project in Japan demonstrated how a 2MW solar racking system can be successfully installed using scaffolding (HDG pipe) as the racking structure, with the added benefit of DIY cutting and fixing at the installation site.

Scaffolding, typically used as a temporary construction tool for buildings under construction or large mobile items such as ships, was repurposed here for a solar racking system. Made of metal conduit, scaffolding is often modular, making it highly versatile for various construction projects. For this solar project, scaffolding pipes, couplers, solar ground screws, and module clamps were used to create the racking structure.

The customer’s primary requirement was the ability to cut and adjust the pipes themselves at the installation site, allowing them to customize the racking structure based on their specific needs. Interestingly, this approach did not require any advanced structural design, making it a flexible, cost-effective solution for large-scale solar power installations.

Key Advantages of Scaffolding for Solar Racking Systems:

1. Large Bearing Capacity:

Scaffolding columns have an impressive load-bearing capacity, with a single tube column capable of supporting between 15kN to 35kN. This ensures that the racking system is strong enough to support large solar modules, even in challenging environments.

2. Ease of Installation and Dismantling:

Scaffolding is well-known for its ease of installation and dismantling. The adjustability of steel pipes allows for quick and efficient assembly, reducing installation time and labor costs. This feature is especially useful for large-scale solar projects, where swift construction is key.

3. Cost-Effective:

Scaffolding systems are highly economical, especially when compared to more traditional materials like aluminum. With simple processing and lower material costs, scaffolding offers a cost-efficient solution for customers looking for quality solar racking without exceeding their budget.

Steel Pipe vs. Aluminum Alloy for Solar Mounting

While scaffolding made of HDG pipes (steel pipes) is the primary choice in this project, it is important to consider the differences between steel pipe racking and aluminum alloy solar mounting systems, especially since aluminum is often a popular choice in the Japanese solar market.

Advantages of Aluminum Alloy Solar Brackets:

Light Weight:

Aluminum is lighter than steel, making aluminum alloy solar brackets easier to handle and install.

Corrosion Resistance:

Aluminum naturally reacts with oxygen to form an oxide layer, which enhances its corrosion resistance. This is especially beneficial for installations in areas with high humidity or coastal environments.

Better Conductivity:

Aluminum alloy is a better conductor of electricity compared to steel, which allows for better voltage balancing and a reduced risk of electrical incidents.

Ease of Manufacturing:

Aluminum is softer than steel, which makes it easier to process and manufacture into various required shapes, including sawing, drilling, punching, and folding. This makes aluminum a more versatile material for custom racking solutions.

Low-Temperature Resistance:

Aluminum alloy has excellent low-temperature resistance, ensuring that the material remains durable even in freezing climates.

Recyclability:

Aluminum is fully recyclable, making it an eco-friendly choice for solar racking systems. The recycling process requires much less energy than creating new aluminum, contributing to a more sustainable approach.

Benefits of Steel Pipe Solar Racking:

While aluminum has its advantages, steel pipe solar racking also offers significant benefits, particularly in terms of strength and cost. Steel is inherently stronger than aluminum and may be a better option for installations in areas prone to extreme weather conditions. Additionally, steel is often more affordable, which can be crucial for projects with tighter budgets.

Conclusion: Choosing the Right Solar Racking Material

The decision between steel scaffolding pipes and aluminum alloy solar mounting systems ultimately depends on the customer’s specific needs and preferences.

• Steel scaffolding systems offer excellent cost-efficiency, strength, and ease of installation, making them an ideal choice for DIY installations or large-scale solar projects.

• Aluminum alloy systems provide lightweight, corrosion-resistant, and better conductivity benefits, though they are generally more expensive than steel options.

At Xiamen TopFence Co.,Ltd, we are committed to offering the best solar mounting solutions tailored to each customer's requirements, ensuring high-quality, affordable, and efficient solar power installations. Whether you choose steel pipe racking or aluminum brackets, we provide the support and materials necessary to meet your unique installation needs.