Why Fasteners Are the Backbone of Scalable Solar Installations
Flashy solar panels may get all the attention in a solar setup, but if the fasteners fail, so does every structural and electrical load. Also known as a solar array, solar power system, or a photovoltaic (PV) system, these terms include all the associated components, including the inverters, wiring and mounting structures used to generate electricity from sunlight.
The True Scale-Enabler
Consider this: Every structural and electrical force in a PV system ends at a bolt, clamp, or screw. If those points fail the entire solar array collapses, along with your entire investment. Since fasteners are usually the first components to degrade in a PV system, upgrading to high-grade aluminum at the start reduces the chance of pricey service visits halfway through the system's life. It also keeps operations and maintenance costs under control. Let’s dig into some of the reasons why.
First, fasteners are the first to show wear in a PV array. So upgrading to higher-grade aluminum or stainless can extend the life of the setup. For reference, panels last approximately 30 years, inverters for 12 to 15 years, and wiring and connectors are likely to need replacing between 5 and 10 years. Because fasteners wear out first, use them to set your earliest maintenance date.
Twice Annual Inspection Basics
As a rule of thumb, twice a year maintenance of your solar array should include:
Clean panels and check wiring
Re-torque or replace any loose or damaged fasteners
Look for rust, galling (threads sticking), or failed seals. Failure to do so can threaten the grounding system.
In addition, the following issues should be addressed and eliminated before they become major problems:
-Embedment: When a bolt head, washer or nut sinks into the softer material it’s clamping (e.g. aluminum rail or wood), it reduces clamping force over time. This may result in panels shifting or loosening.
-Galling: This term refers to a form of cold welding that happens when two stainless-steel threads slide under pressure, seize and tear each other apart. It shows up as scored, stuck or sheared fasteners that won’t tighten or loosen.
-Damaged threads: Threads that are nicked, flattened, or cross-threaded during installation cut the fastener’s load capacity and make accurate torque impossible. They’re a common precursor to early loosening or outright breakage.
-Loosened joints from heat cycles: Daily swings from cool nights to hot afternoons cause metals to expand and contract. The repetitive movement can slowly ease a bolt or screw out of its nut, eroding clamp load.
UV Resistant Fasteners: Designing for Real-World Extremes
Plan for the worst weather, not the average. High winds, UV exposure, salt spray, and sudden temperature swings are now everyday conditions for many. Choose fasteners proven to handle them.
Ask vendors for proof. Request test reports on corrosion, vibration, and chemical resistance so engineering doesn’t hit a roadblock during purchasing.
Quick Procurement Checklist
✔ ️ Check for the UL mark: Your whole assembly should be UL-listed, the safety certification that shows it’s been tested and approved.
✔️ Match the metal to the environment: Pick a fastener alloy that can stand up to corrosion risks like salt air, constant moisture, etc.
✔️ Get torque and anti-seize details: Ask the supplier for the exact tightening specs and whether you should use an anti-seize compound.
✔️ Use time-saving hardware: Choose pre-assembled clips or serrated flange nuts when you can.
✔️ Confirm fire and wind rating locally: Before you place an order, run the system’s fire-rating and wind-uplift numbers past your local building department to ensure the setup will pass inspection.
Every new megawatt adds thousands of attachment points. Invest in quality fasteners up front to reduce repairs and free your budget for expansion.
Melfast supports OEMs and contractors during peak installation periods, so be sure to reach out to us at [email protected] or at (973) 227-0045.
Photo by Bill Mead on Unsplash
