Alarming Solar Quality Issues: 85% of U.S. Projects Flawed
A new report has revealed alarming quality issues across the U.S. solar energy sector. The study, covering 70 Engineering, Procurement, and Construction (EPC) companies between 2021 and 2025, found that 85% of projects contained major issues, with 7% requiring immediate shutdown. This has serious implications for project performance and costs.
The report, conducted by HelioVolta, analysed over 1,000 projects representing 5 GW of solar assets. It found that the majority of quality issues involved wiring, grounding, or improper connections, leading to overheating and hotspots. Connector failure alone resulted in a 58% loss of revenue from commercial solar portfolios.
Experts warn that rushed construction to meet accelerated deadlines for tax incentives is exacerbating the problem. Brian Grenko of VDE America expressed concerns about the impact of hurried construction on project quality. U.S. developers are under pressure to complete projects before the 'One Big Beautiful Bill Act' eliminates tax credits, which could impact companies like Baywa r.e. and SMA Solar, both facing challenges in the U.S. market.
The report highlights the urgent need for improved quality control in the U.S. solar industry. Independent oversight has been shown to improve construction quality measurably. With 70% of EPCs surveyed admitting to significant quality issues, the industry must address these challenges promptly to ensure the longevity and profitability of solar projects.
