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Ensuring Safe Solar Maintenance

Ensuring Safe Solar Maintenance

The world is rapidly moving towards increasing the use of sustainable, green power sources and, as a result, the solar panel industry has boomed over the past decade.

According to the Economic Times, India is one of the leading generators of solar energy in the world due to its location, receiving tropical sunlight and clear blue skies 300 days a year. Because of this, rooftop solar panels, or solar photovoltaic (PV) systems, have become popular both domestically and commercially.

However, installing and maintaining these units is not a danger-free task. Injuries resulting from poor handling of the panels, burns, falls, or electrocution are all real hazards that engineers face without proper prevention measures and training.

As leading safety experts, we emphasise planning and prevention when it comes to tackling any project, and solar safety is no different.


What are the main hazards associated with solar panel installation and maintenance?

Safety issues are common for solar installations and maintenance. Three of the most common hazards that you can encounter when installing or maintenining PV panels:

  1. Electrocution or other electric hazards. Just as with other electric power generation, PV systems present the risk of shock and electrocution when current takes an unintended path through a human body.
  2. Fire and burns. When performing solar plumbing jobs, burns are one of the largest risks.
  3. Falls from high rooftops. As with any job performed at heights, solar panel installation carries the risk of dangerous slips, trips and falls.
  4. Ladders. Solar installations often involve working on roofs from ladders. Having the right type of ladder and using it correctly is essential to worker safety.




Solar panels can generate up to 600 volts when exposed to sunlight, which makes them extremely hazardous to work around. There is a risk of electrocution if corroded cables are present, wiring is loose, or grounding has not been done properly.

Those most at risk are inexperienced technicians who are not aware of the intricacies of working with these systems.

Prevention tips:

Always thoroughly check the PV system and all its components before starting work; check the combiner box, PV source and output circuit conductors, as well as the equipment grounding conductor.

Always use the DC disconnect switch when working on a string of solar panels, as the panels will keep producing power even when the main breaker for the building is off. The modules should be packed in a box until the last minute before installation, with the face covered with opaque material to stop electrical production. Never touch the modules that are exposed to light.

Use a meter or circuit test device to ensure circuits are de-energized before working on them, and only use insulated tools. Avoid contact with nearby high-voltage power lines during installation.


Fire and burns

Fires and explosions usually happen as a result of faulty wiring and careless installation near flammable gases or vapours. Installers can also get burns if they apply fluids to a hot solar panel, as the liquid will rapidly turn into steam.

Prevention tips:

Use the correct wire size and earth all electrical systems and tools properly. Carry out a site survey first to ensure that you check for hazardous gases or vapours in the area before beginning the installation process.

Handle the panels with gloves, and always allow enough cooling time before performing maintenance.


Falls from height

Without suitable fall protection systems such as guardrails, skylights and lifelines, technicians are all at risk of falls when installing PV panels. It only takes a moment of inattention for a slip, trip, or fall to occur, all of which can be lethal on rooftops.

There is a range of systems and solutions to help prevent falls from height, and key duty holders such as employers and building owners should always invest in these systems where possible.


Roof guardrails

Where the layout of the roof permits, guardrails are some of the most efficient systems you can put in place to keep workers safe. They require no user training and are extremely resistant to both weather and time when installed properly.

What’s more, a roof edge barrier can protect multiple users at the same time, as well as prevent materials and tools from falling off the roof and endangering the public. Most modern roof guardrails are quick to install, reliable, and can save on costs - and trouble - in the long run.


Skylight fall protection

A large number of commercial buildings feature skylights; these panels are never safe to step on and should be protected by either a roof guardrail or fragile roof light covers.

These prevention measures will help technicians navigate the roof safely and avoid falls through the roof.


Roof walkways

Depending on the angle and shape of the roof, guardrails may not always be suitable.

Alternatively, you can protect solar panel technicians performing work at height with a roof walkway system. Rooftop walkways enable workers to safely navigate the roof, allowing safe access to panels and preventing them from having to walk across the roof surface or get close to the roof edge.

Together with suitable PPE such as harnesses, roof walkways are a fantastic way to minimise the risk of falls from height.



Choosing the correct ladder for accessing roofs is also important. Fixed ladders made of solid, resistant materials such as titanium and steel are ideal.

Extra protection in the form of cages, lanyards or roof access gates is recommended on a case-by-case basis. Never carry solar panels or any bulky or large equipment up a ladder; instead, try moving materials to rooftops using mobile elevated work platforms or cranes.


Planning is Critical

As with any type of work, the installation and maintenance of solar panels should be thoroughly planned beforehand. Here are a few aspects to take into consideration before starting any project that requires access to roofs:


1. Do your risk assessment beforehand

A risk assessment is a document that will help you build a complete picture of the project, and identify and prevent potential hazards before workers are exposed. A few questions you should ask are:

  • What is the roof layout?
  • What is the roof surface like?
  • Are there any obstacles, unprotected skylights, cracks or other faulty machinery?
  • Are all areas safe to access and work on? If not, what safety measures can you put in place to ensure that engineers do not get hurt?
  • What equipment is needed to safely complete the work?
  • Are there other hazards present around such as cables, power lines, AC units, etc.?
  • What is the work environment like? Take into consideration weather conditions, space available, etc.


2. Assess the competency and physical capabilities of roof workers

All technicians installing or maintaining solar panels should be specifically trained to do so. They should also be aware of all the details of the project, including roof layout, the equipment or safety system they are using, and emergency procedures.

Key duty holders should ensure that only those who are trained and permitted to access the roof do so.


3. Have a contingency plan

Sometimes, things can go wrong, and accidents can happen even with the best intentions.

When that happens, you need a rescue plan in place to mitigate the consequences. Always ensure that there is an emergency contact list and a rescue procedure in the unfortunate event that someone does get hurt.

Planning and prevention are key aspects when it comes to solar panel installation and maintenance. As fall protection experts, we can help you choose the best safety system for your solar panel project.


If you need any help or want to find out more about safety systems that help prevent falls from height, get in touch.

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