How common zip ties can drive significant cost over the life of a solar installation
Solar farm projects can be large and complex and involve a myriad of systems and thousands of parts. The conditions found on solar sites are unique and using inferior products, not designed for solar applications, can result in hundreds of thousands of dollars in added costs as a result of reduced efficiency, system damage and operations and maintenance over the life of a project.
A recent study by HelioVolta illustrates a common pitfall to avoid. Overlooking a seemingly simple component of the installation – cable zip-ties – can lead to significant O&M costs. According to HelioVolta’s 2024 SolarGrade PV Health Report, 80% of solar projects have issues relating to wiring with more than a quarter of issues being directly related to poor cable management. Clearly, it is imperative that installers have the right solutions on hand to suitably manage and protect wires.
Utility-scale solar farms use vast amounts of zip ties, often in the hundreds of thousands if not the millions. Their simplicity and price make them convenient and versatile, but any benefits can quickly vanish due to poor performance and a lack of longevity. Exposure to high levels of heat, UV light, and chemical reactivity, mean low-cost nylon zip ties are prone to failure, at best needing replacement every seven years and at worse, every six months.
Given the significant material and labor costs of replacement – often required multiple times across the lifespan of the project – coupled with the costs associated with site downtime, the need for a more permanent solution is paramount. Perhaps the simplest, most effective direct-fix solution may be Power-Tie.
Gripple Power-Tie
Combining the convenience of zip ties with the strength and durability of steel banding, Power-Tie has been specially designed for utility-scale solar farms. Like zip ties, Power-Tie can be installed by hand with no tools and no training, making it very accessible and versatile to installers on-site. Engineered for lasting performance, Power-Tie is made from high-strength corrosion-resistant materials including 316 stainless steel wire, ceramic gripping rollers, hard-wearing zinc housing and a UV-stabilized HDPE strap. This ensures Power-Tie will only need replacing once over a 40-year project, compared to the tens of times required with standard zip ties. Providing complete peace of mind to EPCs and contractors, Power-Tie comes with an unrivalled 20-year warranty, meaning drastically fewer replacements and significant cost savings.
This is particularly important in areas more exposed to extreme weather conditions, where high winds and below-zero temperatures can exacerbate the limitations of some other methods. Steel banding, crimp wire ties or p-clamps may be more robust and durable, but their sharp edges, if installed incorrectly, can lead to excessive damage to the cable’s protective insulation. The need for hand tools to install these products also slows down installation and can even lead to repetitive strain injuries due to the volume of installations required. With Power-Tie, Gripple engineers have combined all the advantages of zip ties, with the long-lasting durability of more mechanical solutions. The result is a permanent zip tie you can rely on.
Dependable supply
Choosing the right solution is also about reliability. With hundreds of thousands of units required across a utility-scale solar farm, one of the biggest challenges is securing a dependable supply. Consistency of performance, reliability of lead time and control of supply are all crucial factors for EPCs.
Made in the USA and UK at vertically integrated manufacturing sites, Gripple maintains complete control over its supply chain, ensuring every Power-Tie is the same quality, even in large quantities. Gripple maintains control over its supply chain also means complete transparency in product traceability, giving installers complete faith in the longevity of the product.
With Power-Tie you are getting a game-changing solution – a secure, durable and simple way to manage string cables on utility-scale solar farms.
Learn more about Gripple Power-Tie here: https://www.gripple.com/en-us/products/solarsolutions/power-tie.
Discover how else Gripple could support your next solar project, visit: https://www.gripple.com/en-us/products/solar-solutions
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