Frames: A Critical Component of Solar Modules
* Frames account for approximately 15% of solar module costs. * Aluminum frames are being replaced by steel frames due to their superior strength and durability. * Steel frames can reduce module breakage rates by up to 50% compared to aluminum frames.
The Breakage Problem
* Thin glass modules are more prone to breakage due to their weaker materials. * The International Energy Agency’s Photovoltaic Power Systems program (IEA PVPS) report highlights the need for standardized tests for compressive stress and glass durability tailored to thin-glass PV modules. * Current testing and quality assurance programs fall short of addressing the specific vulnerabilities of thin glass in PV applications.
| Issue | Solution |
|---|---|
| Breakage of thin glass modules | Steel frames can reduce breakage rates by up to 50% |
| Lack of standardized tests for compressive stress and glass durability | Develop new testing methodologies and quality control standards specific to thin-glass PV modules |
| Higher failure rates due to extreme weather conditions | Steel frames can boost wind ratings and save money on tracker mount costs |
Superior Frame Strength Enables Better PV Plant Design
* Steel frames perform significantly better than aluminum frames, leading to improved module performance specifications and safety margins. * Steel frames can save money on tracker mount costs and provide a more resilient design.
Steel Frames in Action
The graphic below illustrates the evolution of solar modules over the past decade:
At the same time, industry testing standards have not kept pace with the growth in module sizes, leading to a higher failure rate in the field.
The Benefits of Steel Frames
* Steel is stronger than aluminum, reducing the risk of module breakage. * Steel is cheaper than aluminum, reducing costs and increasing profitability. * Steel is more abundant, reducing supply chain risks and increasing domestic value. * Steel is made in the U.S., eliminating tariffs and reducing delivery times.
Tackling Tariffs
* Tariffs on aluminum imports are impacting the solar industry, increasing costs and reducing competitiveness. * Steel frames made in the U.S. carry zero tariffs and can reduce inventory and delivery times.
A Future-Proof Solar Supply Chain
* U.S.-based steel frame manufacturing is a strategic reconfiguration of the solar industry’s foundation. * Steel frames are drop-in compatible with existing modules and installations. * Steel frames are stronger, greener, and more resilient to physical and geopolitical shocks.
The Transition to Steel Frames
The transition to steel frames is already underway, with local steel manufacturers and fabricators producing frames. Domestic steel manufacturers are also supplying tracker and racking components for the U.S. solar industry.
A Better Business Decision
* Steel is a smarter material that provides the strength, reliability, and domestic value needed to build a solar future that’s resilient by design. * Steel frames are a better business decision, reducing costs, increasing profitability, and enhancing the security of the solar supply chain.
The Future of Solar Energy
* Steel frames will play a critical role in building a solar future that’s resilient by design. * Steel frames will enable the solar industry to meet emissions reduction targets, enhance the security of the solar supply chain, and deliver a better-quality product.
“The transition to steel frames is a game-changer for the solar industry. It’s not just about replacing aluminum with steel, it’s about creating a more resilient, sustainable, and cost-effective solar supply chain.” – John Doerr, Partner at Kleiner Perkins
Steel frames are the future of solar energy.
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