Solar panels are designed to last 25 – 30 years, yet some systems fail earlier. When this happens, it’s often a result of preventable issues like poor installation practices, environmental factors, or improper maintenance.
At PSC Energy, we understand the most common causes of solar panel failure and will help homeowners identify problems early and take steps to avoid them. After all, installing solar is what we do.
In this article, you’ll learn about the following:
- Microcracks: The Silent Killer of Solar Panels
- Solar Panel Installation Errors and Their Impact
- Environmental Factors That Cause Solar Panel Failure
- Solar Panel Maintenance Mistakes to Avoid
By the end of this article, you’ll know the ins and outs of what might cause your panels to fail and how you can avoid it.
Microcracks: The Silent Killer of Solar Panels
One of the most common and damaging issues affecting solar panels is the development of microcracks. Microcracks are tiny fractures in the silicon cells of a solar panel. These cracks may not be visible to the naked eye, but they can severely impact a panel’s performance over time.
What Causes Microcracks?
Microcracks often form during the installation process. Improper handling can lead to tiny fractures in the cells. For example:
- Transportation Damage: Panels that are dropped, banged, or dinged during transit may develop cracks before they’re even installed.
- Installer Mistakes: Some untrained or careless installers lean or walk on the panels during installation. Solar panels are not designed to bear such weight. Walking on panels can crush the silicon cells, even if the damage isn’t immediately apparent.
How Do Microcracks Affect Performance?
Initially, microcracks may not cause noticeable problems. The panels will continue to function normally for the first few years. However, by year three or four, the damage begins to affect performance.
- Snail Trails: Microcracks lead to visual defects called snail trails: greyish streaks that appear on the panel’s surface. These streaks indicate where the cracks have disrupted the silicon cells.
- Decreased Efficiency: Cracks reduce the panel’s ability to generate electricity. Over time, this can lead to significant performance drops, making it harder for the system to meet your energy needs.
How to Avoid Microcracks
- Work with reputable solar installers who follow proper handling and installation protocols.
- Avoid walking on or applying pressure to solar panels.
- Use trusted brands known for durable panel designs.
If you’re interested in learning a bit more about solar panel efficiencies, you might want to check out the following article titled, How Efficient Are Solar Panels? Shade, Heat, and Seasonal Considerations in NSW, Australia.
Solar Panel Installation Errors and Their Impact
The quality of the installation is critical to the long-term success of a solar system. Poor installation practices can lead to a range of issues, including structural problems and early panel failure.
Importance of Proper Rail and Clamping Placement
Solar panels are mounted on mounting systems, which are attached to your roof. Each panel must be clamped within specific zones, called clamping zones, to distribute weight and stress evenly along the mounting system.
Imagine a diving board with most of its length hanging off the edge of the pool. If you jump on the end, the board will bend and flex. Solar panels behave similarly.
If clamping zones are ignored, the unsupported parts of the panel can bend under pressure, leading to microcracks. No one wants this.
Wind Damage from Poor Installation
Loose or poorly mounted solar panels can move in the wind. That movement leads to damage and safety risks.
What happens when panels are loose
- Panels flap or vibrate in the wind instead of sitting firm on the mounts.
- Constant movement puts extra stress on the panel frame.
- Vibrations create microcracks in the solar cells and reduce efficiency.
- Frames can weaken or warp and struggle to hold position.
- In severe weather, a panel can detach from its mounting.
Why this matters
- Microcracks lower power output and waste energy.
- A loose or dislodged panel can damage your roof or a neighbour’s property.
- Detached panels are a serious safety hazard during storms.
How to avoid it
A well-mounted array stays secure and handles high winds.
Make sure the system is installed correctly from the start.
How to Ensure Proper Installation
Getting your solar panels installed correctly is one of the most important steps in ensuring their long-term performance and durability. Follow these steps to make sure your system is set up for success:
Verify Installer Experience: Always hire a professional installer with a proven track record. Ask about their experience. A knowledgeable installer will make sure each panel is properly secured and positioned for the best energy production.
Inspect the System Post-Installation: Once your system is installed, take a moment to inspect the work. Check to see that all panels are evenly supported by the mounting system and properly aligned. Look for any obvious issues, like gaps between the panels and the mounting system or loose connections, which could lead to problems down the line.
Invest in Quality Mounting Systems: Don’t cut corners on the mounting system. Choose a high-quality mounting system that has been tested for durability and rated for the wind region in your area. This ensures that your panels stay secure, even in high winds or extreme weather conditions. A solid mounting system reduces the risk of movement or stress that could lead to microcracks or other damage.
Taking these steps gives you peace of mind that your solar panels are installed properly and built to last, helping you make the most of your investment.
If you’re interested in learning a bit more about the importance of a good installer for your solar (the most important component of any system, seriously), you might want to check out the following article titled, In-house Installers vs. Subcontractors: Which is Better?
Ready to go solar? Click here.
Environmental Factors That Cause Solar Panel Failure
Solar panels are built to take on sun, wind, rain, and snow, but sometimes Mother Nature throws a little extra at them. Extreme weather conditions like hailstorms, heavy winds, or impacts from flying objects can still cause damage. Here’s what to watch out for and how you can keep your panels safe.
Hailstorms
Solar panels are tested to resist hailstones up to 25mm in diameter. That’s roughly the size of a golf ball. If hailstones get much larger or if there’s a prolonged hailstorm, those tough glass surfaces could crack, or the internal silicon cells might suffer damage.
- What to do if you live in a hail-prone area: If hailstorms are a regular event where you live, it’s worth considering panels with thicker glass or ones that have hail-resistant certifications. These panels are designed to handle a bit more punishment and give you some extra peace of mind during a storm.
Wind
Wind alone doesn’t usually damage your panels directly. However, (as we mentioned earlier) if the racking system (the frame that holds your panels in place) isn’t installed correctly, high winds can make panels wobble or flex. Over time, this stress causes microcracks or even loosens the panels from their mounts.
- Pro tip: Always make sure your racking system is solid. A professional installer who follows proper guidelines, like adhering to clamping zones, will keep your panels in place on the windiest of days.
Impact from Objects
Whether it’s a wayward basketball, a tree branch during a storm, or some debris blowing around, heavy impacts can do real damage to your solar panels. A single hit might not look too bad at first, but cracks can spread over time, reducing the panel’s efficiency and lifespan.
Simple ways to protect your panels:
- Trim nearby trees regularly to keep branches from falling onto your panels during storms.
- Keep basketballs, soccer balls, and other projectiles away from your panels.
- In areas prone to severe storms, consider hail guards or protective coverings for extra reinforcement.
Your solar panels are built to be resilient, but a little preparation goes a long way. A good installation will help your solar setup stay strong and efficient—no matter what the weather throws at it.
If you’re interested in learning a bit more about how weather affects your solar panels, you might want to check out the following article titled, How Does The Weather Affect Your Solar Panels?
Get Your Sunny’s Worth and Take Care of Your Solar Panels
Solar panels are a reliable source of energy, but they require proper care to perform at their best. Common causes of failure include microcracks, installation errors, environmental damage, and improper maintenance.
By working with a reputable installer like PSC Energy and choosing quality components that are installed properly, you can maximise the lifespan of your solar system and avoid costly repairs.
If you’re interested in learning a bit more about solar panels and energy systems, you might want to check out the following article titled, Are Solar Panels Worth It in NSW, Australia? A Price Breakdown for 2025.
FAQ: Solar Panel Failure
What are the most common causes of solar panel failure?
The most common causes are microcracks in the silicon cells, poor installation practices, environmental damage from hail or wind-induced movement, and basic maintenance mistakes like allowing debris to build up.
What are microcracks in solar panels?
Microcracks are tiny fractures in the silicon cells inside a panel. You usually cannot see them at first. Over time they interrupt the flow of electricity and reduce output.
How do microcracks form?
They form from mishandling during transport and installation. Dropping panels, knocking corners, leaning panels against hard edges, or walking on panels can all create microcracks.
What are the signs of microcracks on my solar panels?
A common visual sign is “snail trails.” These are grey streaks that appear on the glass over time along the lines of the cracks. You may also notice a steady drop in energy production after a few years.
How do microcracks affect solar panel performance over time?
Performance can look normal at first. By year three or four, output can decline as cracked cell areas stop producing power. The loss compounds as cracks spread.
Can I prevent microcracks?
Yes. Choose a reputable installer that follows proper handling rules. Never walk on panels. Use proven brands with robust cell and frame designs.
How do installation errors lead to early solar panel failure?
Incorrect clamping, poor rail placement, loose fixings, and uneven support can make panels flex. Flexing stresses the cells and frame and leads to microcracks and water ingress over time.
What are clamping zones and why do they matter?
Clamping zones are specific areas on the panel frame where clamps must go. Proper clamp placement spreads weight and wind load evenly. Wrong placement leaves parts of the panel unsupported and prone to bending and cracking.
How does wind damage solar panels?
Wind itself usually does not break panels. But poor mounting can let panels wobble or flap. That constant movement stresses frames and cells, creating microcracks and loose connections. In extreme cases panels can detach.
Do hailstorms break solar panels?
Panels are tested to handle hail up to about 25 mm. Very large hail or long storms can still crack the glass or damage cells. Regions with frequent hail should use panels with thicker glass or hail-resistant certification.
What else can hit and damage solar panels?
Falling branches, roof debris in storms, or sports balls can crack glass and cells. Even small impacts can spread into bigger problems over time.
What maintenance mistakes shorten solar panel life?
Letting dirt, leaves, or droppings sit on panels, ignoring warning signs in your monitoring app, and skipping periodic visual checks can all mask problems until they are costly.
How often should I inspect my solar panels?
Do a quick visual check from the ground every few months and after major storms. Look for broken glass, loose rails, gaps, or debris. Use your monitoring app to watch for unexplained drops in output.
Can poor solar panel installation void warranties?
It can. Many product warranties require correct mounting and handling. Keep your installation documents and photos, and use an experienced, accredited installer.
Is it better to repair or replace a cracked solar panel?
If glass is cracked or output has dropped a lot, replacement is usually the safest option. Minor issues with fixings or clamps can be repaired if caught early.
How can I choose a reliable solar panel installer to avoid failures?
Ask about experience, training, and accreditation. Request details on clamping zones, wind ratings, and the mounting brand. Check past projects and make sure they offer post-install support.
What role does the mounting system brand play?
Quality rails, clamps, and fasteners keep panels stable under wind and heat. A well-rated mounting system matched to your roof and wind region reduces flex and movement that lead to failure.
What is the single best way to extend panel life?
Pair quality components with careful installation and basic upkeep. Proper handling on day one and steady monitoring across the years prevent most failures.
