Solar panels break more now? Here's what's going on

American solar experts report an increase in damage to solar panels and the manufacturers are to blame. What is going on? Why do solar panels break in the first place and how to prevent it? Let’s cover it in this article.

Why has solar panel breakage increased?

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Renewable Energy Test Center (RETC) reports an increase in solar panel glass breaking in the field, sometimes even before the PV modules are commissioned. Manufacturers try to make the glass on panels thinner to improve production but this makes it more fragile, according to the National Renewable Energy Laboratory (NREL). Solar panels used to pass the IEC 61215 static load with a big safety margin but new models just barely qualify.

The situation may lead to the appearance of climate-specific solar panels, NREL reports. We use the same models in coastal areas, hot states, and northern areas. In the future, we may see sturdier panels for states where hurricanes are common.

How do solar panels break?

What causes solar panel glass to break in the first place? There are three main reasons: 

• Careless delivery. The risk of damage grows with distance and the size of the panels ordered. Small orders tend to break more often than large ones.

• Wrong or DIY installation. Not only can an installer accidentally drop a panel and break it, but he also might, for example, pick the wrong mounting for a panel. 

• Extreme weather. Strong winds can tear off the panels from your roof if they’re installed incorrectly. About half of solar panel losses are caused by hail. 

A panel with broken glass is not good for anything. It is not safe to try to use it, its performance drops heavily and the cells inside quickly deteriorate because they become exposed to oxygen and moisture. 

How to avoid damage to solar panels?

A few precautions will minimize your risks and render your solar system safe. Here are four tips to avoid damage to solar panels from our engineer Vic. 

1. Pick sturdy panels

If you live in an area where hail, hurricanes and tornadoes are common, you need strong panels. We recommend brands like Panasonic, REC, Mission Solar — their panels are generally sturdier than Chinese PV modules.

Check the maximum front load in the datasheet of a panel. For example, a 2400 Pa rating shows that the panel is tough enough to withstand a 140 mph wind. If the panel is rated for 5600 Pa maximum front load, it should be able to withstand 200 mph winds. Some manufacturers mention what kind of testing the panel underwent.

Vasilii Smirnov

Solar Installation Expert

The more powerful a solar panel is, the larger and the floppier it is. The windage of solar panels over 500 watts gets high and if there is a strong wind, it may very well get under your panel and tear it off from your roof. If you live in a Tornado Valley or Florida, I wouldn’t recommend large panels.

2. Avoid ordering delivery from far away

Orders that have to travel long distances break more often. If a carrier has to cover over 2,000 miles to get to you, there is a high chance some panels won’t make it.

The smaller your order is, the higher the risk of damage. When a customer wants less than 10 panels, we recommend they pick up the order from one of our fulfillment centers or get extra panels. Large PV modules of 500 watts and above are more fragile than standard 400-watt solar panels for home.

3. Find a good installer

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5 tips on choosing a solar installer from A1 SolarStore engineer

When it comes to installation, you have to find a good installer. You want a professional with at least 3 years of experience. It’s a good sign when a contractor has an industry-standard certificate — for the US, it’s NABCEP. Make sure it’s clear, what kind of warranties the installer offers and what kind of post-installation maintenance you can expect from him.

Vasilii Smirnov

Solar Installation Expert

There are situations where it may tempting to just lay solar panels flat — for example, if you have a flat roof. Don’t. First of all, they won’t work as well unless you live on the equator. Second, the first hail will decimate them because the ice balls will not bounce off the panels. It’s like the windshield of a car: the reason why it is angled is because it resists damage better.

4. Prepare for hurricanes ahead

If a hurricane is coming, you can call your installer and ask them to take the panels off the roof. After the storm passes, they will put them back on. Sometimes these expenses are covered by the insurance company of the installer, but it’s one of the things you should ask about beforehand. 

Hail is harder to predict but the panels can be insured against hail damage. To lower the risks, you can use protective covers or hail nets for solar panels.

How do we deal with broken solar panels at A1 SolarStore? Read our article on what to do in case of a damaged order.

Find your best solar panels!

Take a look at the brands we have in stock and get a quote for a system from our engineer.

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Andrey Gorichenski

Senior Editor

Andrey had been a news editor and freelance writer for a number of medias before joining A1SolarStore team. Climate change and its impact on people's lives has always been among his interests and it partially explains his degree in Philosophy and Ethics.

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