| Work Detail |
With increasing module sizes, worsening labor shortages, and rising workplace safety risks, automation is a necessity. By Frank Oudheusden and Chris Needham . The future of solar module design will be heavier, not lighter. With the increase in hail and extreme weather events, module manufacturers are expected to shift toward thicker glass to improve impact resistance and long-term durability. This will significantly improve their ability to withstand high-energy hail impacts and wind-borne debris. While this design change improves system survivability, it also poses a critical challenge: heavier modules require a new approach to installation. Todays large-format modules already weigh about 40 pounds, pushing the limits of what installers can safely handle. OSHA (Occupational Safety and Health Administration, a U.S. federal agency within the Department of Labor) guidelines and NIOSH (National Institute for Occupational Safety and Health) lifting models highlight the risks: Lifting heavy objects multiple times a day, above knuckle height, away from the body (especially overhead), dramatically increases the likelihood of musculoskeletal injuries. Imagine a team of workers lifting modules weighing more than 100 pounds from crates, navigating rows of solar panels, and mounting them on fixed-tilt or tracking systems hundreds of times a day (especially in moderate winds)—its not just an efficiency challenge, its a workplace safety crisis. Arguments in favor of robotics in the installation of solar modules Reducing module size is also not a viable solution to the weight problem. Large-formats promise of fewer modules per megawatt has reduced racking and structural costs and improved installation efficiency. These savings, coupled with the advent of 210 mm wafers, have driven module design and volumes to the current scale. If the trend were reversed and module size were reduced, the number of units per project would increase, requiring more electrical and mechanical connections, with a resulting increase in installation labor, material costs, and long-term reliability risks. Large-format modules will continue to exist because their cost advantages outweigh the difficulties of handling them. The only logical path is to eliminate human labor from the lifting equation. This need for automation is amplified by the severe labor shortage in major solar markets, where labor availability already limits deployment timelines. Solar installers are in high demand but in short supply, and as the industry grows relentlessly, the gap between labor availability and project needs will only widen. Rather than forcing workers to perform repetitive, injury-prone tasks, robotics can allow skilled labor to transition into higher-value roles such as project management, system commissioning, and electrical installation. This shift not only protects workers but also creates opportunities for career growth in an industry poised for long-term expansion. The hidden costs of manual labor: Workers compensation and budget offsets Solar plant construction budgets not only consider salaries, but also workers compensation insurance, liability for injuries, and lost time due to work-related injuries. As the weight of the modules increases, the frequency of overload injuries, back problems, and repetitive strain disorders will inevitably increase, increasing workers compensation and insurance costs. For developers and EPCs, these are costs that will be absorbed by everyone and will put downward pressure on the viability of the projects. If left unaddressed, this increased risk is not only a safety issue, but also a financial one. Over time, the added insurance burdens from increased injuries will offset or even exceed the initial costs of adopting robotics for module installation. By proactively integrating automation, companies can reduce long-term liability and redirect those budget offsets toward investments in higher-value projects rather than avoidable injury costs. Robotics not only offsets the financial headwinds associated with these risks, but also reduces module breakage rates, lowers quality control and O&M inspection costs (on-site technologies), and minimizes downtime due to wind. At the same time, they significantly improve worker safety. Robotics: The next evolution in module installation Companies such as Luminous Robotics, AES Corporation, Sarcos Technology, ULC Technologies, and Vispect are addressing this challenge by automating the handling and installation of individual modules. These robotic solutions eliminate human lifting limitations, enable the use of thicker glass and stronger frames, accelerate deployment, and improve accuracy, ensuring modules are mounted correctly and reducing the risk of misalignment. As robotic module handling becomes more widespread, the industry no longer needs to design modules to meet the limits of human lifting. Instead, we can prioritize durability and reliability, optimizing panels for automation rather than manual labor. Total system pre-assembly: The next frontier Beyond module handling, Terabase Energy, 5B, Planted Solar, and Charge Robotics are revolutionizing solar deployment through factory pre-assembly and on-site robotic construction. Charge Robotics is automating module assembly and streamlining row-by-row installation. Terabase Energy is developing robotic on-site solar deployment solutions to eliminate manual labor in large-scale installations. 5Bs prefabricated solar panels arrive on-site virtually assembled, reducing labor by up to 80%. Planted Solar is integrating automation throughout the entire solar plant construction process. By pre-assembling large sections of solar panels in controlled environments or leveraging field robotics for installation, these companies are changing the way solar farms are built. Why the solar industry needs to embrace robotics now With increasing module sizes, worsening labor shortages, and rising workplace safety risks, automation is no longer a luxury, but a necessity. As robotics becomes more integrated into solar module installation and system deployment, were likely to see a fork in module design: One path will optimize modules for automated installation, enabling larger, heavier, and more durable designs that robots can effectively handle. The other will focus on modules for human installation, which will remain smaller and lighter for residential, commercial, and carport projects. By accelerating the deployment of robotics today, the industry will be able to overcome its dependence on human labor, improve module durability, and reduce costs through automation, paving the way for the next evolution of solar energy. |
