Heatwaves are becoming more common in Europe. This is especially true for Southern countries like Spain, Italy, and Greece. Solar installers now face a new challenge. They need to make sure that solar mounting structures and fasteners can handle extreme heat.
High rooftop temperatures can exceed 75°C in summer, causing metal expansion, material fatigue, and even fastener failure. Without the right precautions, solar arrays may shift, loosen, or degrade prematurely.
This checklist helps installers and EPCs get ready for extreme heat. It covers everything from choosing materials to installation methods. This ensures the system is safe and performs well over time.
1. Choose Heat-Resistant Materials
In high-temperature zones, not all materials perform equally. Focus on structural components that resist both heat and UV degradation.
| Component | Recommended Material | Why It Matters |
|---|---|---|
| Rails / Frames | 6063-T5 Aluminum | Excellent thermal stability, lightweight |
| Clamps | Anodized Aluminum | UV-resistant, corrosion-proof |
| Fasteners | SUS304 / SUS316 Stainless Steel | High tensile strength, rust-proof |
| Screws | SUS410 + Dacromet Coating | Heat-resistant + anti-corrosion |
| Anchors / Brackets | Hot-Dip Galvanized Steel | Durable for ground or rooftop structures |
Tip: Avoid untreated carbon steel in high-humidity or high-heat environments—it corrodes faster and expands more under heat.
2. Use Proper Surface Treatments
Surface finish is key to protecting metal from both heat and moisture stress.
| Treatment | Where to Use | Benefits |
|---|---|---|
| Anodizing (≥12μm) | Aluminum parts | Improves UV and corrosion resistance |
| Dacromet Coating | Screws, bolts | Withstands 1000+ hours of salt spray |
| Hot-Dip Galvanizing (HDG) | Steel components | Long-term protection in outdoor use |
| Passivation | Stainless steel | Enhances anti-rust properties |
Reminder: Always verify surface treatment thickness and quality from your supplier.
3. Account for Thermal Expansion in Design
High temperatures cause all materials to expand. If this isn’t addressed in the design:
- Rails may bend or warp
- Clamps can loosen
- Modules may shift under pressure
Checklist for Expansion Management:
- Leave thermal expansion gaps between rails
- Use slotted holes in connection points
- Install EPDM rubber pads with clamps to absorb movement
- Avoid rigid connections that restrict natural expansion
4. Choose the Right Fasteners (It’s Critical)
Fasteners are often overlooked—but they are the first point of failure in extreme climates.
What to Look For:
| Parameter | Recommendation |
|---|---|
| Grade | SUS304 or higher |
| Head Type | Flange head or anti-slip design |
| Locking Feature | Nylon insert nuts / spring washers |
| Coating | Dacromet or HDG for harsh conditions |
Installers’ Tip: For metal roofs, self-tapping screws with rubber washers help seal the penetration point and prevent heat-related leaks.
5. Use Verified, Certified Components
Don’t risk your project on cheap, uncertified parts.
Check for:
- ISO 9001 / CE certifications
- Salt spray test reports (min. 720–1000h for Dacromet)
- Pull-out and torque strength test results
- Material certificates (SS grade, anodizing thickness, etc.)
Suppliers like Suzhou Bilateral provide full documentation + testing support for each shipment.
6. Optimize Installation Technique for Heat Zones
Installation practices matter just as much as product quality.
Best Practices:
- Use torque wrenches to apply correct tightening force
- Check fasteners after 48–72 hours of sun exposure (post-expansion check)
- Avoid installing during peak mid-day heat; early morning or evening is best
- Inspect all connection points for alignment and spacing tolerances
- Ground every rail with certified grounding clips or wires
7. Plan for Long-Term Maintenance
Even well-installed systems need periodic checks, especially in harsh climates.
Schedule Maintenance Every 6–12 Months:
- Inspect for corrosion, loosening, or deformation
- Recheck torque levels of major fasteners
- Clean surface rust or replace affected parts
- Check grounding continuity
Use maintenance-friendly components, like easy-release clamps and standardized bolts, to simplify future repairs.
Conclusion: Build Resilient solar Structures for a Hotter Future
Heatwaves are not going away. As rooftop and utility solar projects become more common in heat-prone zones, structural resilience is essential.
Using this checklist helps solar installers. They can avoid costly mistakes. It also keeps clients safe. Plus, it protects the value of PV investments.
Need Certified Mounting Parts for Hot Climates?
Suzhou Bilateral offers:
- High-performance aluminum rails with anodizing ≥12μm
- Stainless steel fasteners (SUS304/316/410) with Dacromet coating
- Custom clamps, bolts, hooks, and structural kits
- ISO, CE, RoHS, and material traceability certifications
Contact us for samples, catalogs, or technical drawings:
