This guide covers how a solar EPC team should receive, store and handle modules on site.
Receiving deliveries
Each delivery should be checked against the packing list before the driver leaves: pallet count, serial number lists, the condition of packaging and any tilt or shock indicators. Damaged pallets should be photographed, noted on the delivery documents and set aside unopened for inspection. The flash test data supplied by the manufacturer for each module should be filed with the serial numbers.
Storage on site
Store pallets on firm, level, well-drained ground, in the orientation the manufacturer specifies, and never stack pallets higher than the manufacturer allows. Keep modules in their packaging until installation. In windy areas, secure pallets so opened packaging cannot become a sail, and keep storage away from traffic routes and dust from earthworks. Plan the laydown area as part of the site layout, close to the installation front to reduce double handling.
Unpacking
Follow the manufacturer’s unpacking instructions, which usually describe cutting straps in a set order and removing modules one at a time while the rest are supported. Unpack only what can be installed the same day, so modules are not left loose on the ground overnight or in high wind.
Handling during installation
Two people should carry each large module by the frame, not by the junction box or cables. Do not place modules face down on rough ground, stack loose modules on top of each other, or stand, kneel or lean on them. Keep cable connectors off the ground and capped until connection, to keep dust and water out. These rules sound basic, but they are where most site damage happens.
Quality checks for microcracks
| Check | When | Purpose |
|---|---|---|
| Visual inspection | Receiving and installation | Broken glass, frame damage, backsheet damage |
| Electroluminescence imaging on samples | After delivery and after installation | Finds microcracks invisible to the eye |
| String tests | Commissioning | Open-circuit voltage, current and insulation |
| Thermal imaging | Commissioning and later | Hot spots from damaged cells |
Sample electroluminescence testing at delivery separates factory and transport damage from site damage, which matters for warranty and insurance claims. Our page on PV commissioning tests covers the electrical tests.
Records and warranty
Keep delivery records, photographs, serial lists, flash test data and test results together. If a warranty claim is needed later, the manufacturer will ask how the modules were handled and stored. Good records are the difference between a claim accepted and a claim refused.
Planning deliveries to match installation
Large solar plants receive modules over many weeks. Matching delivery rates to installation rates keeps storage time short and laydown areas small, which reduces handling and the risk of damage. Agree a delivery schedule with the supplier that follows the installation sequence block by block, and keep a running count of modules received, stored, installed and rejected. A weekly reconciliation against the serial number list catches losses and mix-ups early, before they become a problem at commissioning or in the warranty file.
Where modules from more than one production batch or bin are delivered, keep them separate so each string uses modules of the same electrical class.
Mistakes we see
Common mistakes include stacking pallets too high, storing modules on soft ground that settles, leaving opened pallets in the wind, carrying modules by their cables, and crews walking on installed rows to reach the next. A short toolbox talk at the start of module installation, and a supervisor who enforces it, prevents most of them. On dusty sites, see also dust storm planning.
Solar EPC with quality on site
USP&E builds solar and hybrid power plants for mines, industry and utilities under EPC and O&M contracts, with ISO certified quality processes. We have 150+ power projects in 45+ countries and 25,000 MW contracted since 2002. See our hybrid solar power systems.
Offices: Colorado Springs (1755 Telstar Dr, Suite 300), Knoxville (800 S Gay St, Suite 700), London (162-168 Regent Street), Johannesburg (22 Kildoon Rd, Bryanston), Cape Town (31 Brickfield Road, Woodstock) and China (No. 1 Ningzhou Road, Wuxi). Regions: USA | AFRICA | UK | UAE | CHINA. ISO 9001 and ISO 45001 certified.
Module handling FAQ
How should solar panels be stored on a construction site?
On firm, level, drained ground, in their packaging, in the orientation and stacking height the manufacturer allows, secured against wind.
Can you walk on solar panels during installation?
No. Standing, kneeling or leaning on modules can cause microcracks that reduce output and may void the warranty.
How are microcracks in solar modules detected?
Electroluminescence imaging finds microcracks invisible to the eye; thermal imaging later shows hot spots from damaged cells.
Why keep handling records for solar modules?
Because manufacturers ask how modules were handled and stored when assessing warranty claims.
Planning a solar build?
We can deliver solar and hybrid EPC projects with site quality control from delivery to commissioning.
An engineer will reply if you email info@uspeglobal.com, call +27 10 822 2324 or fill in the solar EPC team. Firming generators for solar hybrids are in the USP&E inventory.