How to Prevent Solar Corrosion and Optimise Solar Efficiency

Installing solar panels is a great way to manage your energy usage and contribute to a more sustainable future. However, like any long-term asset, your solar system requires maintenance to keep it functioning efficiently. One often overlooked issue is solar corrosion—a natural process that can affect key components when exposed to environmental factors over time. 

If left unchecked, corrosion may impact system performance and lead to expensive repairs. The good news? There are practical steps you can take to help protect your system and maintain its efficiency. Below, we’ll cover what solar corrosion is, why it occurs, and how to minimise its risks. 

What is Solar Corrosion?

Corrosion is the gradual deterioration of metal and other materials due to exposure to moisture, salt, and environmental contaminants. For solar power systems, corrosion can affect critical components such as panels, mounting structures, electrical connections, and enclosures. 

While coastal areas with salty air are more prone to corrosion, inland regions are not immune. Humidity, rain, and dirt accumulation can also contribute to material degradation. Fortunately, proper maintenance and preventative measures can help reduce the likelihood of corrosion-related issues. 

Why Preventing Solar Corrosion Matters 

• Support System Longevity: Corrosion can weaken components, potentially affecting the lifespan of your solar setup. 
• Maintain Energy Efficiency: Well-maintained components can contribute to optimal energy generation. 
• Reduce Maintenance Costs: Addressing corrosion early may help avoid costly repairs or replacements. 
• Protect Roof Integrity: Corrosion on mounting systems or fasteners can lead to rust formation, which may affect your roof over time. 
• By following best practices, you can take steps to help protect your system and support its long-term performance. 

7 Proactive Steps to Prevent Solar Corrosion  

1. Choose Reputable Installers 

The first and most important step in reducing the risk of corrosion is selecting a professional, experienced solar installer. A quality installer ensures proper system design and installation practices that help minimise exposure to corrosive elements. 

Key considerations include: 

• Careful Handling: Panels should arrive at your home without scratches or micro-cracks, which could lead to water seepage. 
• Galvanic Corrosion Prevention: Mixing metals in mounting equipment can accelerate corrosion. Reputable installers use protective coatings, anti-seize compounds, and insulating washers to mitigate this. 
• Roof Protection: Installers should remove any drilling residue (such as metal shavings) and ensure penetrations are watertight to help reduce the risk of roof damage. 

When selecting an installer, consider companies with verified customer reviews, relevant certifications, and a strong track record. 

2. Use Components Rated for Your Environment 

Not all solar components offer the same level of durability. To help prevent corrosion, ensure your system’s parts meet appropriate environmental standards. 

Standards to look for: 

• IEC 61701 Certification for Salt Mist Corrosion Resistance: Essential for homes in coastal or humid climates. 
• AS 4312 Atmospheric Corrosivity Zones in Australia: Determines the corrosivity level of your area (zones C1 to C5) and ensures your system’s mounting hardware is suitable. 
• IP Ratings for Electrical Enclosures (e.g., IP67): Indicates how well electrical enclosures are sealed against solids and liquids. 
• When choosing an installer, ensure they are Clean Energy Council (CEC) accredited and use CEC-approved products that meet Australian safety and durability standards. 

Ask your installer for documentation or written assurances that all components comply with these standards. 

3. Place Components in Protected Areas 

Where possible, position sensitive components away from direct exposure to weather elements. 

Best practices: 

• Install inverters, wiring, and battery systems inside garages or shaded areas. 
• Use weather-resistant enclosures for outdoor components that are rated for local environmental conditions. 
• Ensure junction boxes and other electrical equipment are properly sealed and shielded from excess moisture or pooling water. 

Positioning sensitive equipment in more protected locations may help extend its operational life. 

4. Conduct Regular Maintenance and Cleaning 

Routine maintenance is essential to minimise build-up that could contribute to corrosion. 

Maintenance tips: 

• Clean Solar Panels: Remove dust, leaves, bird droppings, and grime as per the manufacturer’s recommendations. For hard-to-reach panels, consider professional cleaning services. 
• Inspect Hardware & Enclosures: Remove any dirt, spider webs, or debris that could retain moisture around inverters or mounting hardware. 
• Look for Early Signs of Damage: Regularly check for rust, cracks, or loose fittings and address them promptly. 

5. Schedule a Professional System Check Every Five Years 

While regular cleaning and inspections help, periodic professional assessments can help detect early corrosion issues. Some Australian states require inspections every five years, but even where not mandatory, they are highly recommended. 

During an inspection, an accredited professional will assess: 

• Solar panels and mounting hardware for early signs of corrosion or wear. 
• The integrity of wiring and electrical connections. 
• Weather seals to ensure no water ingress into sensitive areas. 

Regular inspections can help identify potential problems before they become costly. 

6. Use Corrosion-Resistant Materials 

Investing in high-quality materials may help support your solar system’s long-term durability. Many modern solar components are designed to withstand harsh conditions. 

Key materials to consider: 

• Aluminium Framing: Naturally resistant to rust and commonly used in solar panel frames and mounts. 
• Stainless Steel Fasteners: Durable and less prone to corrosion, ensuring secure connections over time. 
• Protective Coatings: Some systems include factory-applied coatings to add an extra layer of environmental protection. 

Ensure all materials are compatible with your system to prevent galvanic corrosion, which can occur when different metals interact. 

7. Keep the Surrounding Area Clear 

Overhanging trees and shrubs can introduce moisture and organic debris that contribute to corrosion. Regularly trimming vegetation around your solar panels may help reduce these risks. 

Additional benefits of keeping the area clear: 

• Improves airflow around your panels. 
• Reduces shade-related efficiency losses. 
• Helps prevent roof debris build-up that may cause drainage issues. 

These measures can help reduce the likelihood of corrosion-related damage and support the longevity of your solar system 

Supporting the Long-Term Performance of Your Solar System 

Switching to solar power is a positive step toward sustainable energy usage, but proper maintenance is key to getting the most from your system. By choosing quality installers, using certified components, protecting your hardware, and scheduling regular inspections, you can take proactive steps to help mitigate the effects of corrosion and support the efficiency of your solar setup over time. 

For those looking to compare solar providers and access competitive quotes, Econnex provides a transparent platform to help you make informed choices about your solar options.