| Work Detail |
The US-based Clean Energy Associates (CEA) is receiving increasing calls from solar developers concerned about damage to stored panels. Claire Kearns-McCoy, CEAs engineering director, explains how improper handling, stacking, and storage conditions can lead to long-term problems. Solar developers typically acquire modules stored in warehouses in two ways: They either purchase them from warehouses or store the products themselves, perhaps after purchasing them in advance and experiencing project delays. Thorough inspections of warehouses during storage and before transfer to project sites are vital. Buyers must assess module quality, storage conditions, and inventory accuracy. Inspection steps Visual inspection identifies external damage, assesses the condition of the packaging, and ensures that the modules are stored according to the manufacturers guidelines. Improper handling can be detected, as indicated by broken pallets, crushed corners, or torn wrapping. Pallet and storage condition assessments involve checking climate control, humidity levels, stack arrangement, and other factors to verify that modules are stored in a safe and controlled environment. Electroluminescence (EL) testing can be performed on a sample of the modules for a more detailed evaluation. This testing method, combined with a detailed visual inspection of the modules, helps identify defects or damage to the panels that may not be immediately apparent. This is especially important for modules purchased from warehouses of unknown manufacturing quality, as this inspection provides an opportunity to identify manufacturing defects, as well as damage from shipping and handling. EL testing is also important for identifying microcracks, as these can negatively affect panel performance over time and ultimately compromise the integrity of the module. Inventory verification is another critical aspect of warehouse inspections, especially for shippers who use warehouse storage to comply with safe harbor tax requirements, which would protect them against tax penalties. Inventory verification confirms that all intended pallets are present and that serial numbers match supplier records. Verifying inventory accuracy helps shippers maintain proper documentation and ensures that no modules have been lost or swapped during storage. In-person verification Warehouse workers can provide developers with information on storage conditions, but it isnt always accurate. Some developers have been told their modules were stored in climate-controlled conditions, according to the manufacturers guidelines, but inspectors have found them in an unregulated space, exposed to high humidity or extreme temperatures, or improperly stacked. Regular in-person inspections ensure modules are stored as promised and allow developers to resolve issues before shipping the panels to the project site. Modules that have remained intact in a warehouse are generally less at risk than those that are frequently moved. In some cases, warehouse personnel may move modules to make room for new stock, exposing them to potential damage. If modules are repeatedly moved with forklifts or repositioned in a manner that doesnt follow stacking guidelines, their structural integrity may be compromised. Developers who store modules for extended periods should schedule periodic inspections—typically every six months or a year—to ensure their inventory remains in good condition, regardless of whether it has been disturbed in the meantime. Finally, monitoring the container loading process for shipping modules from a warehouse to the construction site can detect additional problems. On a recent project, the CEA observed the loading process at a warehouse and was surprised to see that a different loading procedure was used for each container; none of them matched the manufacturers guidelines. When modules are loaded incorrectly into a shipping container or onto a truck, they are damaged due to vibrations caused during the transport process and can even shift in a truck if not properly secured. Outdoor storage Some consider storing modules outdoors a cost-saving measure, but it is strongly discouraged. Although the panel packaging is designed to withstand short-term transit and handling, it is not intended for prolonged exposure to the elements. One of the biggest risks of outdoor storage is exposure to moisture. Moisture, rain, or condensation can seep into the packaging and cause corrosion and water damage. Uncapped photovoltaic connectors are especially vulnerable. Prolonged sun exposure can weaken packaging materials, making modules more vulnerable to contamination or breakage. In some cases, unprotected storage areas can attract rodents or insects that can nest in the packaging and cause further damage. Many manufacturers explicitly prohibit outdoor storage. Failure to follow these guidelines may void warranties. Contractual protections When purchasing panels stored in warehouses, developers should ensure that the contracts explicitly describe their rights to inspect and report defects. The contract should specify a clear timeframe within which buyers can conduct inspections and document any issues before taking possession of the modules. Liability during storage must also be clearly defined. Developers should confirm whether they or the warehouse operator are responsible for any damage that occurs while the modules are in storage. Ownership conditions should be carefully reviewed to avoid ambiguities. Contracts should also address proper loading and transportation procedures to minimize the risk of damage when modules are shipped from a warehouse to the project site. The agreement should require warehouse operators to follow the manufacturers guidelines for container loading, including stacking configurations, securing pallets with straps, and placing airbags or other protective materials in the correct positions. Ensuring contractual compliance with these standards can prevent unnecessary damage during transportation. Contracts should also specify who assumes financial responsibility in the event of unforeseen damage, such as a warehouse fire or structural failure. Forwarders should confirm that their supplier or warehouse provider has adequate insurance coverage to protect their inventory. Claire Kearns-McCoy is CEAs Engineering Director. She has extensive experience in module field inspections and EL imaging test analysis. |
