Carbon Steel vs. Aluminum Alloy: How to Choose Solar Mounting Systems? A Professional Breakdown!

Faced with various solar bracket systems on the market, many customers are hesitant between carbon steel and aluminum alloy.This is not only a common question we installers hear, but also one of the most critical technical decisions in the early stages of project planning.

Today, we will delve deeply into the characteristics of these two common materials to help you make a suitable choice based on the actual project conditions.

Carbon steel

1.Bending strength is the most notable advantage of carbon steel. This makes it particularly suitable for regions with heavy snow accumulation, such as Northern Europe, Canada and Russia, as well as places with frequent strong winds like Saudi Arabia and the United Arab Emirates. Under extreme natural conditions, the rigidity of carbon steel provides additional safety guarantees.

2. Cost-effectiveness is another key consideration. Carbon steel is usually 30% to 40% cheaper than aluminum alloy. For large-scale projects or budget-sensitive application scenarios, this difference may directly affect the feasibility of the project.

However, carbon steel systems also have their limitations.

3. The installation process is relatively complex and often requires the use of hexagon socket bolts, which demands a high level of professionalism from the installation team. Therefore, it is more suitable for regions with lower labor costs and experienced photovoltaic installers    

(solar ground mounting system)

Aluminum

Aluminum alloy brackets, with their unique advantages, meet market demands in another dimension.
1.The material is relatively soft and may bend under extreme conditions. However, by increasing the structural load calculation of the guide rails, bases or crossbeams, the usage requirements in windy areas can be fully met.

3.In terms of corrosion resistance, aluminum alloy can usually be used for 8 to 12 years under normal conditions. However, it is worth noting that any material will corrode over time. Aluminum alloys can oxidize and turn black or white. If a supplier claims that aluminum alloys never rust, this could be false advertising (except for aerospace or military-grade aluminum materials).
4. Ease of installation is the core competitiveness of the aluminum alloy system. The prefabricated and telescopic design makes the installation process fast and simple, making it particularly suitable for areas with high labor costs or novice installation teams.

(w type solar aluminum ground mounting bracket)

5. Price is the main consideration for the aluminum alloy system. As of December 2025, the price of aluminium alloy has risen by nearly 10% compared to April of the same year. This increase has further widened the cost gap with carbon steel systems, making budget considerations even more important.

Summary: How to choose the most suitable plan

The core principle is that "there is no best option, only the most suitable solution."
Structural strength should be given priority in areas with heavy snow or strong winds. Under these extreme climatic conditions, the natural advantages of carbon steel become even more prominent. However, if aluminium alloy is chosen, it is essential to conduct a detailed structural load calculation and ensure system safety by adding support elements.
The balance between budget and timeline is equally crucial. Carbon steel systems can significantly reduce initial investment and are suitable for budget-sensitive projects. The rapid installation feature of aluminium alloy can shorten the construction period and may be more economically efficient overall for projects under time pressure.
The experience level of the installation team should also be taken into consideration. For novice or time-limited installation teams, the prefabricated design of aluminum alloy can significantly reduce installation difficulty and error rates, and minimize potential on-site issues.