Clean Energy Associates (CEA) receives more calls from solar developers who are concerned about damage to warehouse panel. CEA Senior Engineering Manager Claire Kearns-McCoy explains how incorrect handling, stacking and storage conditions can lead to long-term problems.
From PV Magazine 03/25
Solar developers usually experience warehouse-gathered modules in one of the two ways: they either buy them from warehouse storage or store products themselves, perhaps after buying in advance and experiencing project delays.
Thorough warehouse inspections during storage and before transfer to project locations are of vital importance. Buyers must evaluate the quality of modules, storage conditions and stock accuracy.
Inspection steps
Visual inspection can identify external damage, assess packaging conditions and ensure that modules are stored according to the manufacturer’s guidelines. Abuse indicated by broken pallets, ground corners or torn packages can be seen.
Evaluations of pallet and storage condition include checking climate control, humidity levels, stacking setups and other factors to check whether modules are stored in a safe, controlled environment.
Electroluminescence (EL) tests can be performed on a sample of the modules for a more detailed assessment. This test method is linked to a detailed visual inspection of the modules and helps to identify defects or damage in the panels that may not be clear immediately.
This is especially important for modules that have been purchased at warehouse storage that have an unknown production quality, because this inspection offers the possibility to identify production defects, in addition to shipping and handling damage. EL tests are also important to identify microcracts, because they can negatively influence the performance of panel over time and ultimately endanger a compromacy of module integrity.
Inventory verification is another crucial aspect of warehouse inspections, in particular for developers who use warehouse storage to meet the tax requirements for “safe haven”, which would protect them against tax sentences. Inventory verification confirms that all expected pallets are present and serial numbers match supplier records. Verifying the accuracy of the stock helps developers to maintain the correct documentation and ensures that no modules are out of place or changed during storage.
Personal verification
Warehouse operators can provide developers information about storage conditions, but it is not always accurate. Some developers have told that their modules were stored in climate-controlled conditions, according to the guidelines of the manufacturer, only for inspectors to find them in a non-regulated space exposed to high humidity or extreme temperatures, or incorrectly stacked.
Regular personal inspections ensure that modules are stored as promised and developers enable developers to tackle problems before they send panels to a project site. Modules that have remained untouched in a warehouse generally run a lower risk than they are often moved. In some cases, warehouse staff can move modules to make room for new inventory and to expose them to possible damage.
If modules are repeatedly moved with the help of forklift trucks, or repositioned in ways that do not follow stacking guidelines, their structural integrity can be affected. Developers who store modules for longer periods must plan periodic inspections – usually every six months to a year – to ensure that their inventory remains in good condition, regardless of whether it has been disturbed in the meantime.
Finally, the supervision of the loading process of the container to send modules from a warehouse to the work location can cause additional problems. In one recent project, CEA observed the charging process in a warehouse and was surprised to see another charging procedure used for each container – none of them corresponded to the manufacturer’s guidelines.
When modules are incorrectly loaded in a shipping container or truck, they are subject to damage caused by the vibrations caused in the transport process and can even move in a truck, if not correctly protected.
Outdoor storage
Some regard the storage of modules outdoors as a cost -saving measure, but this is very discouraged. Although panel packaging is designed to withstand passage and handling in the short term, it is not intended for long -term exposure to the elements.
One of the greatest risks of outdoor storage is exposure to moisture. Humidity, rain or condensation can seep in packaging, which leads to corrosion and water damage. Not -ing -fitted PV connectors are particularly vulnerable. Long -term sun exposure can weaken packaging materials, making modules more vulnerable to contamination or break.
In some cases, unprotected storage areas can attract rodents or insects that can nest in packaging and cause additional damage. Many manufacturers explicitly prohibit outside storage. Failure to follow such guidelines can make guarantees invalid.
Contractual protection
When buying warehouse-gathered panels, developers must ensure that agreements to inspect and report their rights to explicitly sketch. The contract must specify a clear time frame when buyers can carry out inspections and be able to document problems before the modules owns.
Liability during storage must also be clearly defined. Developers must confirm whether they or the warehouse operator are responsible for damage that occurs while the modules are in storage. Property conditions must be carefully revised to prevent ambiguity.
Contracts must also tackle the correct loading and transport procedures to minimize the risk of damage when modules from a warehouse are sent to a project site. The agreement must require that warehouse operators follow the manufacturer’s guidelines for loading containers, including stacking configurations, securing pallets with belts and placing airbags or other protective materials in the correct positions.
Ensuring that these standards are contractually maintained can prevent unnecessary damage during transport. Contracts must also specify who bears financial responsibility for unforeseen damage, such as a warehouse fire or structural failure. Developers must confirm that their supplier or warehouse provider has an appropriate insurance cover to protect the inventory.
Author: Claire Kearns-Mcoy
Claire Kearns-McCoy is a senior engineering manager at CEA. She has extensive experience with Moduleveld inspections and analysis of EL image formation tests.
This content is protected by copyright and may not be reused. If you want to work with us and reuse part of our content, please contact: editors@pv-magazine.com.
Popular content
