Origami Solar Unveils Findings from Third-Party Evaluation of Steel Solar Module Frames

Following extensive testing conducted at CFV Labs and the Renewable Energy Test Center (RETC), Origami Solar has announced that its modules featuring Origami’s steel module frames comply with the frame-related industry-standard tests necessary to obtain module maker certifications. These certifications include those stipulated by the International Electrotechnical Commission (IEC), particularly IEC 61215 static mechanical load testing, IEC 61701 salt-mist corrosion testing, and continuity testing of equipotential bonding.

This testing confirms that module manufacturers contemplating a transition from imported aluminum frames to domestic steel frames can proceed confidently.

CFV conducted both mandatory static load testing and optional test-to-failure evaluations. During the static mechanical load tests, Origami’s steel frames comfortably exceeded the standards required for IEC module certification. On a tracker equipped with 400mm bolts, the modules successfully underwent the IEC 61215-prescribed sequence of three cycles, each consisting of one hour of downward pressure and one hour of uplift pressure, at pressure levels of +/- 2400 Pa. Similarly, when utilizing quarter point clamps along the module’s long side, with racking beneath the module, the modules endured the same cycle durations but with downward pressure of 5400 Pa and uplift pressure of 3000 Pa. All static mechanical load tests were easily surpassed by the modules, satisfying the requirements of the IEC 61215 standard.

While modules employing Origami steel solar frames passed the requisite IEC 61215 tests, the test-to-failure experiments further demonstrated the frames’ ample safety margin, providing additional reassurance to module makers. Remarkably, even under maximum pressure as permitted by CFV, some trials did not result in module breakage, a significant finding given the solar industry’s mounting concern regarding diminished module strength.

RETC’s testing on modules utilizing Origami’s steel solar frames yielded similarly favorable outcomes, affirming impressive corrosion protection capabilities of zinc-aluminum-magnesium coatings (Z-A-M). Given the extensive laboratory and real-world trials undergone by Z-A-M-type coatings within the steel industry and their widespread utilization across various sectors, there was little doubt regarding the success of modules incorporating Origami steel solar frames in salt mist corrosion testing. Additionally, the testing regimen included assessments for continuity bonding both before and after the salt mist exposure, which the test module framed with Origami’s steel passed without any issues.

“Over the last five years, CFV Labs has identified a decrease in module strength, both in laboratory testing and in fielded module projects,” said Colin Sillerud, Vice President of Engineering at CFV Labs. “The steel-frame modules supplied by Origami to CFV for testing exhibited test-to-failure pressure values that were higher than similarly sized and constructed modules with aluminum frames. While CFV cannot say that laboratory tests translate directly to field performance, these results show a strong relative lab performance when compared to traditionally framed PV modules.”

“As our modeling predicted, Origami steel module frames demonstrated excellent performance across the full range of certification tests,” added Lauren Ahsler, Vice President of Engineering, P.E., S.E., at Origami Solar. “The tests prove to the industry that there is minimal risk to module makers’ ability to get modules certified when they switch to steel solar frames. These rigorous, third-party tests also show that switching to steel module frames has the potential to address the decrease in allowable loading specifications for large format modules and to improve overall PV plant reliability. The steel frames’ excellent performance in the salt-spray test sequence should resolve any concerns about corrosion protection. This independent testing demonstrates that Origami’s steel solar frames represent a big step forward for the solar industry.”