Australians are increasingly installing solar panels and there’s a huge push to get more installers on roofs. K2’s Ian Ross looks at everything needed to safety install PV panels.

When it comes to solar energy, rooftop photovoltaic (PV) systems are as natural a fit as rum and coke.

I’ve always believed that solar belongs on every rooftop with no need for extra land or additional grid expansions. The energy gets generated and used right where it’s needed and it goes from my rooftop, straight into my washing machine.

We’ve come a long way in renewable energy, and it’s clear to see: one in three Aussie homes – about three million – now have solar installations. Rooftop solar has climbed up the ranks to become the second-largest source of renewable electricity generation in Australia, just behind wind energy. In 2023, rooftop solar made a huge impact by providing over 10% of the nation’s total electricity, marking a significant milestone with more than 20GW of installed capacity across the country.

What’s driven this growth? Well, with falling equipment prices, rising energy costs and overall energy consumption the average system size has increased, making rooftop solar an even more crucial part of our energy landscape.

Rooftop solar isn’t just the second-largest source of renewable energy, it’s also the fourth-largest source of overall electricity generation in Australia, contributing around 11.2% of the country’s power supply according to the Clean Energy Council’s latest Rooftop solar and storage report.

Australia is known around the world as a leader in solar energy, mainly thanks to household rooftop installations. But there’s still massive untapped potential across the commercial and residential rooftops in this country. It’s estimated that Australia’s total potential for rooftop solar is about 179GW, with an annual energy output of 245TWh – more than enough to cover the current electricity consumption on our main grids. Roughly half of this untapped potential still is in residential areas, accounting for 96GW. Commercial and industrial zones together have the potential for another 28GW of rooftop solar.

It’s time to unlock this vast potential and move towards a cleaner, more sustainable energy future.

Installing PV systems on rooftops is no walk in the park. It’s a job that demands precision, careful planning, and strict adherence to safety protocols. In this guide, I’ll walk you through the essential training, safety precautions and best practices needed to ensure a successful and safe PV installation on various types of rooftops.

Training and Safety Requirements

Before you even think about getting up on a roof, you need to make sure everyone on the team has the right training. It’s not just about ticking boxes; proper training ensures that the installation is carried out safely and efficiently, protecting both your crew and the equipment.

Here are some of the key areas of training:

• Workplace safety and working at height: Understanding safe practices when working at height is critical. This includes the correct use of PPE: helmets, safety boots, harnesses, ropes and other fall protection gear.
• Structural knowledge: Knowing the ins and outs of different roof types and materials is essential. You need to be able to spot potential hazards that could compromise safety or the system’s integrity. This means understanding the roof’s load-bearing capacity and how to work with materials like tiles or metal sheets.
• First aid procedures: Even with the best precautions, accidents can happen. All team members should be trained in basic first aid so they can handle emergencies effectively until professional help arrives.
• Standards and regulations: You’ve got to be across local and national safety standards and regulations. Compliance not only keeps everyone safe but also keeps you out of hot water legally.

Roof access precautions

Before starting work, give the roof a good once-over to assess its structural integrity. Look for any signs of wear and tear, damage or anything else that might pose a risk during installation. Pay close attention to the condition of the roofing material and check for any loose or dodgy sections.

Weather is a big factor in whether it’s safe to work on a roof. You don’t want to be up there in the rain, strong winds, or extreme temperatures. Adverse conditions like these can make the job more dangerous and increase the risk of accidents.

Wearing the right PPE isn’t just a recommendation, it’s a must. Make sure everyone on the team has helmets, gloves, safety glasses, harnesses and anchor ropes, and that their gear is in top condition. Regularly check that the PPE fits properly and is still effective throughout the installation.

Getting onto the roof safely is crucial. Only use stable, appropriate ladders or other access equipment, and make sure they’re well-positioned, anchored and secure. The type of ladder or scaffolding you use should be suitable for the height and roof type you’re working on.

When you’re handling PV system components like solar panels, mounting structures and cables, follow the manufacturers’ recommendations to the letter. Proper handling not only prevents damage to the equipment but also keeps your team safe. Be mindful of the weight and size of the panels, and make sure cables are secured properly to avoid tripping hazards.

Installation procedures

Proper planning is the foundation of a successful PV installation. Before anyone sets foot on the roof, make sure the system layout is thoroughly planned.

This means determining the best placement for equipment, calculating the necessary materials and ensuring all tools are on-site. Good planning minimises unnecessary movements on the roof, which can reduce the risk of accidents.

Clear communication is essential on the job. Coordination is especially important when you’re dealing with large or heavy components that need more than one person to handle.

Documenting the installation process is crucial. Keep detailed records of each step, including written reports and photographs. This documentation is invaluable for future maintenance and ensures that nothing gets overlooked during the installation.

Choosing the right mounting system

The mounting system is the backbone of any PV installation. It’s what keeps the panels securely positioned to capture the maximum amount of sunlight and ensures the stability of the entire system.

The quality and design of the mounting system have a direct impact on the safety, efficiency and lifespan of the PV installation.

Choosing the right mounting system starts with understanding the specific needs of your project. Here’s what to consider:

• Type of installation: The roof type plays a big role in determining the mounting system. Sloped roofs typically use railed systems, while flat roofs might require ballasted systems. Ground-mounted systems need sturdy foundations and floating solar farms require specialised systems that can handle water currents.
• Weather conditions: The mounting system needs to be able to withstand the local weather, whether that’s high winds, heavy snowfall or extreme heat. Make sure you choose a system that’s been tested and rated for these conditions to avoid panel displacement or damage.

Safety and compliance are non-negotiable. Your chosen mounting system must meet all relevant standards, and your supplier should provide detailed resistance data.

Tools like calculation software from the supplier can also help in the design process and ensure everything is up to scratch.

Different roof types need different mounting solutions:

• Sloped roofs: Railed systems are adaptable and can fit various roof pitches, making them ideal for sloped roofs. On metal roofs, rail-less systems offer a streamlined installation with added resistance.
• Tile roofs: For tile roofs, you’ll need specialised tile hook systems to avoid damaging the tiles. These involve lifting the tiles, securing hooks to the roof structure and then replacing the tiles.
• Flat roofs: Ballasted systems are often the go-to for flat roofs since they don’t require penetration, which helps maintain the roof’s integrity. However, in areas with high wind or snow loads, a penetrating system may be necessary to keep everything stable.
• Standing seam roofs: Standing seam metal roofs benefit from specialised clamps that grip the seams without needing to penetrate the roof surface, preserving its integrity while ensuring a secure installation.

How easy and fast a system is to install can make a big difference. Systems designed for quick installations, especially those with pre-assembled components or snap-together designs, can save on labour costs and shorten project timelines. Lightweight yet durable materials are particularly beneficial for rooftop installations where the structural load is a concern.

A PV mounting system is a long-term investment, so durability is key. In areas exposed to harsh environments, like coastal or industrial zones, choose corrosion-resistant materials such as anodised aluminium or stainless steel and opt for systems that require minimal maintenance and feature self-cleaning surfaces or designs that reduce debris accumulation.

It’s always a good idea to go with a supplier that has a solid track record in the solar industry. Reputable brands offer reliable products and robust customer support, which can be crucial if problems arise. Look for suppliers that offer additional features like design software, structural calculation tools or extended warranties to add value to your installation.

While sticking to a budget is important, balancing cost with quality is essential. High-quality mounting systems may cost more upfront but they usually offer better durability, require less maintenance and improve energy production efficiency over the long haul. Consider the total cost of ownership over the lifespan of the system when making your decision.

Compliance and permitting

Every PV installation needs to comply with local building codes, electrical codes and zoning regulations. Make sure you have all the necessary permits and that the installation meets all legal requirements to avoid fines and other legal issues down the road.

Working with the local utility company for grid interconnection is a critical step. Make sure all the paperwork is submitted and approvals are obtained before starting the installation to prevent delays and ensure a smooth process.

Post-installation procedures

Once the installation is complete, a thorough inspection of the entire system is necessary to make sure everything is functioning as it should. This inspection should include checking the mounting hardware, electrical connections and panel alignment for any potential issues like loose connections or improperly sealed penetrations.

Testing the system is vital to ensure it’s generating power as expected. Take voltage and current readings at various points in the system to confirm that everything is working properly.

Finally, provide the homeowner with detailed documentation of the installation. This should include system specifications, warranties, maintenance recommendations and emergency shutdown procedures. Proper documentation not only helps the homeowner but also serves as a reference for any future maintenance.

Conclusions

In conclusion, the installation of rooftop PV systems is more than just a technical task, it’s a critical step towards a sustainable energy future in Australia. As solar continues to become a dominant force in our energy landscape, the importance of proper training, safety and meticulous planning cannot be overstated.

By following the best practices outlined in this guide, electricians and solar installers can ensure that each installation not only meets safety standards but also delivers long-term efficiency and durability.

In today’s digital age, leveraging technology can significantly ease the complexities of rooftop solar installations. Digital services like specialised software and mobile apps are transforming the way we approach the design, planning and execution of these projects. Whether it’s using software for precise structural calculations, apps that streamline site assessments or digital tools that facilitate communication and project management, these innovations are making it easier than ever to ensure that every installation is as smooth and successful as possible.

As we continue to advance in the solar industry, embracing these digital solutions will be key to staying ahead. By integrating these tools into your daily routine, not only can you enhance the efficiency of your installations, but you can also provide a better service to your clients, ensuring they receive the most reliable and effective solar solutions available.

The future of rooftop solar in Australia is bright and with the right approach and tools, we can all contribute to a cleaner, more sustainable energy landscape for generations to come.