Numerous engineering case studies have shown that the rapid rusting of scaffolding is by no means solely due to “harsh environmental conditions”; rather, the core issues lie in three major industry malpractices: cutting corners in construction, using substandard materials, and non-compliant construction practices.

1. Fake hot-dip galvanizing and severely substandard zinc coating thickness

This is the most common pitfall with low-cost brackets. To cut costs, many small manufacturers abandon standard hot-dip galvanizing processes in favor of simpler alternatives such as electrogalvanizing, spray painting, or applying zinc powder. These methods only coat the bracket surface with a thin layer of zinc or paint, resulting in extremely poor adhesion. After 1–2 years of exposure to the elements outdoors, the coating will peel and flake off, leaving the base material directly exposed to the air and causing rapid rust and corrosion.

Even when hot-dip galvanizing is used, non-standard brackets often have their zinc coating thickness deliberately reduced to levels far below industry standards. This fails to provide effective protection, and in humid or rainy environments, extensive rusting is inevitable within three years.

2. Poor-quality base material with excessive impurity content

High-quality photovoltaic mounting systems are made from premium steel that meets national standards. This steel is pure, structurally stable, and suitable for anti-corrosion treatments. In contrast, low-cost, substandard mounting systems use recycled scrap steel or non-standard steel. The base material itself contains high levels of impurities and has uneven density, making it highly susceptible to oxidation. Even after anti-corrosion treatment, defects in the base material can lead to localized blistering and rust, accelerating overall deterioration.

3. Inadequate Manufacturing Processes: No Acid Washing or Rust Removal; Inadequate Edge and Corner Treatment

Proper anti-corrosion production requires multiple stages of acid washing, rust removal, and impurity removal to ensure the substrate surface is clean, allowing the zinc coating and oxide layer to adhere tightly. Small workshops simplify the production process by applying the zinc coating directly onto surfaces containing rust and impurities, resulting in extremely poor adhesion between the protective layer and the base material. Additionally, the cut edges, corners, and drilled holes of the brackets are not treated with secondary corrosion protection. These areas become entry points for corrosion, which gradually spreads to the entire bracket.

4. Mixing Materials Leads to Electrochemical Corrosion

To reduce costs, many installation teams use products made of different materials and treated with different anti-corrosion processes for the main structure, clamps, bolts, and other components. In rainy or humid environments, contact between different metals can cause electrochemical corrosion, accelerating metal degradation. This leads to premature rusting of components and connection points, which in turn compromises the entire mounting system.

5. Inappropriate Bracket Selection for Harsh Environments

In coastal areas, chemical industrial parks, and regions with high rainfall and humidity, the requirements for bracket corrosion resistance are extremely high. Thickened hot-dip galvanized or custom-made brackets with high salt spray resistance must be used. If standard corrosion-resistant brackets are used without proper consideration, they will be unable to withstand salt spray and acid-alkali corrosion, leading to rust and deterioration within a short period of time.

Our company, POWERACK, manufactures photovoltaic mounting systems using premium materials and is dedicated to producing high-quality products. Our entire product line undergoes standardized anti-corrosion treatment to ensure the long-term, stable operation of photovoltaic power plants.