Why Some Rooftop Solar Systems Are Blowing Away

In a recent viral video, a rooftop solar panel was seen blowing away and crashing onto a public road in a residential colony in India — posing a serious risk to both people and animals. The incident comes at a time when the country is witnessing rapid growth in residential rooftop solar installations under the PM Surya Ghar scheme, which has increased consumer subsidies and set ambitious new targets.

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However, this and similar incidents reported from Rajasthan and Madhya Pradesh raise red flags about the quality of rooftop solar installations in the country. Many such failures go undocumented, unnoticed by the media, or remain confined to local reports.

The influx of inexperienced vendors trying to make quick profits, the tendency of consumers to opt for the cheapest bids, the lack of mandatory technical standards for certain rooftop solar components, and the apathy of discoms in conducting safety checks have together made these systems increasingly vulnerable. This risk multiplies in cyclone-prone coastal states like Andhra Pradesh, Odisha, and Tamil Nadu.

[caption id="attachment_73428" align="alignleft" width="70"] Shreya Mishra[/caption]

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A look at the PM Surya Ghar portal reveals hundreds of solar vendors — from companies with thousands of installations to new entrants with little to no track record.

"There are a lot of amateur installers in the market, and that’s a serious safety risk. There’s an urgent need for standardized norms to ensure quality installations," says Shreya Mishra, Co-founder of SolarSquare, a leading rooftop solar firm.

Gaps That Lead to Disaster

Maitreyi Karthik, a clean energy researcher based in New Delhi, highlights exactly where things go wrong.

“Many rooftop solar failures can be traced to poor installation practices and non-site-specific design. When structures are under-designed or fasteners aren’t secured properly, it’s just a matter of time before they give way — especially under high wind loads,” she explains.

Karthik adds that awarding projects based on L1 bids — or the lowest quoted price — often leads to compromises in structural quality and engineering oversight.

Lack of Standards for Mounting Structures

[caption id="attachment_73456" align="alignleft" width="70"] Maitreyi Karthik[/caption]

While solar modules and inverters are subject to mandatory BIS certification, mounting structures still fall outside any enforced national quality framework. This regulatory gap is proving hazardous, Karthik warns.

“Unlike panels and batteries, there are no mandatory BIS certifications yet for rooftop mounting structures. Until these are made compulsory, substandard work will continue to threaten both assets and human safety,” she adds.

Designing for a Changing Climate

At SolarSquare, Mishra says their mounting structures are cyclone-proof, prefabricated, and made with galvanized, recycled steel — designed to eliminate on-site welding, which reduces human error and enhances safety.

She also stresses the importance of location-specific design.

“We cannot apply the same design principles for a rooftop solar system in New Delhi and one in a cyclone-prone coastal city. Their design and structures must be different. Scientifically, we need to analyze the region’s maximum historical wind speeds and align the system design accordingly. In some regions, this may add to the installation cost, but it's necessary to prevent destruction,” Mishra explains.

“Our design process uses civil codes and wind speed data for any location in India — something we believe should become the industry norm.”

Mishra further emphasizes that the civil engineering codes themselves need updating:

“Climate change is intensifying, and the civil codes need to evolve accordingly. Existing standards don’t fully account for today’s extreme weather conditions.”

Consumers Must Demand Structural Audits

[caption id="attachment_78533" align="alignleft" width="70"] Radhika Choudary[/caption]

Radhika Choudary, Co-founder of Freyr Energy, calls for greater consumer awareness. She warns that most homeowners focus on panel efficiency and brands — while ignoring the mounting structure, which is just as critical.

“Even the best solar panel is worthless if the structure fails in a storm. Before each monsoon season, your solar system needs a health check. Loose bolts, poor waterproofing, or blocked drainage can cause serious damage — or even injury,” she says.

Choudhary adds that for Commercial & Industrial (C&I) rooftop installations, corrosion is a frequent concern if left unaddressed.

“We test all mounting rails for structural integrity and require full engineering certificates, wind-speed calculations, and warranties of 25+ years,” she adds.

The Path Forward

With BIS standards for modules, inverters, and batteries becoming mandatory soon, there is growing demand for similar mandates for mounting structures — a long-overdue measure to improve overall system safety.

“Safety should be the core value for solar vendors. Even though it’s not always top of mind for consumers, we don’t compromise on it,” says Mishra.

Until robust post-installation audits and mandatory structural codes become a reality, both consumers and developers must prioritize structural design as the first line of defense — especially in an era of increasingly volatile weather.