From steel to power plant: what's behind the durability of photovoltaic structures

With the rapid expansion of solar energy in Brazil, attention is also growing regarding the durability and safety of the metal structures used in photovoltaic plants. Problems related to corrosion, mechanical failures, and short service life have become increasingly frequent, generating losses and requiring interventions in recently completed projects. 

In this scenario, the debate over the choice of materials, manufacturing processes, and applied engineering has gained momentum among manufacturers, integrators, and investors. To better understand the industry's challenges and the path to more efficient solutions, Canal Solar spoke with Ricardo Dias, CEO of the Metal Light Group. 

In the interview, he explains why hot-dip galvanizing has become a strategic differentiator, discusses the need for precise structural calculations, and comments on the trend toward "premiumization" of products – a natural movement in a market that is beginning to value not only lower costs, but also the performance and longevity of installations.

Check out the full interview below:

What are the main differences between Metal Light's metal structures in terms of durability, resistance and ease of installation?  

The company is 34 years old, and we entered the sector in 2019. It was clear to us that there was room for a premium product, as it was well known that solar farms would be recalled due to poor quality. structures in general. 

You don't build a house on shaky foundations; the logic of the structure is the same. That's why we manufacture with structural steel, the same steel used in dump trucks, bridges, and other basic industries. This guarantees adequate mechanical strength, combined with cutting-edge engineering and precise machinery to ensure ease of installation and alignment in the plant.

The solar industry requires highly weather-resistant materials. How does the company ensure the longevity and safety of its structures, especially in regions with adverse weather conditions? 

We are a player in the structural engineering sector that firmly believes in hot-dip galvanizing. Unlike much of the market, we invested in building a plant dedicated exclusively to this process, understanding that it is the only truly effective solution for ensuring long-term durability.

It's no coincidence that you don't see guardrails, traffic lights, or streetlights made with galvanized steel in factories. The reason is simple: cutting, stamping, welding, transporting, and stacking damage specific points of the material, removing the zinc layer and leaving the steel vulnerable to corrosion.

In the industry, it's common to hear that the world's largest steel consumer isn't China or India—it's rust. And it's precisely against rust that we direct our technical and structural efforts.

Metal Light is recognized for its personalized service and customized projects. How does this process work, and what are the main challenges when working with custom solutions? 

We're highly sought after for our development and prototyping skills. When you work with innovation and focus on specific solutions, you gain more market share. Of course, it's not easy to customize, but our modern manufacturing facilities are a big help. We have a very strong engineering team, and we've always invested heavily in that.

What does the company see as a trend for the future of solar energy structures in Brazil and how does it intend to position itself in this scenario? 

We see the "premiumization" of products linked to technological structures and components. Natural selection is at work, and the strongest and most competent will have greater market share. We will always position ourselves as a company that thinks about people, products, and customers. In any sector we operate, this is our focus.

In an increasingly competitive market, what are Metal Light's strategies to continue growing and standing out in the photovoltaic sector?  

Our challenge is to educate the consumer market by explaining the advantages of having structures with good structural design and hot-dip galvanizing. Every day, we see customers regretting having invested a lot of money in factory-galvanized steel and experiencing headaches. 

We strive every day to be competitive in pricing and provide outstanding service. Today, we have fans, not customers. Our team works hard every day to achieve this, but it's rewarding. 

However, seeing customers who have purchased from us return to do business with us is inspiring. Our team is increasingly prepared for greater production scale, which is our goal. We are in one of the best moments of our lives. companhia.

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