Solar installation tips from utility-scale, C&I and residential contractors

While technology is making onsite tasks easier in many ways, solid planning and commitment to employee safety forms the backbone of many successful solar teams. Solar Power World talked to leaders in the residential, C&I and utility-scale solar space about how they make work on the jobsite as smooth as possible.

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What are the benefits of pre-assembly on large-scale projects?
We’ve learned that labor is the most unpredictable and critical part in your estimating. If you get bad weather on a site and you’ve scheduled two weeks to build it, your cost overruns are catastrophic. What we learned doing a lot of these “smaller,” repeatable projects is that we had to kit it — kitting and pre-building rows in our warehouse. We have a 200,000-ft² facility in Kansas where we pre-kit tracker rows. We know exactly every part that goes into a row, and we can put that row into a box so that when it comes off the truck, it gets deployed quickly out in the field. There aren’t any guys with hard hats sitting on buckets counting nuts and bolts and then bringing them out to the field. We’ve done that all within our control air-conditioned facility. We’ve done it with people who do it all day long, and their accuracy is very, very good.

Last year, we had over 5,000 truckloads of metal coming and going, so it’s a super busy time in our field, in our industry. We’re just trying to expand to keep up with it. We couldn’t expand by hiring more mechanical contract labor. We felt like we could make the biggest impact and get more projects done by kitting and helping other people build fast and efficient.
Jay Miles, VP of Customer Excellence, Ampacity

How does your company evaluate and adopt new installation technologies, like robotic aids?
When it comes to automation and technology, there’s always a spectrum. Our workforce is important to us. We’re never going to go fully automated. But there are a ton of innovations that can help us do the work better. For example, we’ve evaluated certain exoskeletons to help take the burden when lifting panels. We’re in the middle of the spectrum, trying to figure out what those tools are, whether they’re agnostic to certain technologies or designs, finding that happy medium of how we help our teams work better, faster, safer.

We pride ourselves on being innovative and being on the forefront of new technology, but that can be a huge burden to any company. McCarthy is super focused on an internal filtering process to ask where we really want to prioritize innovation. What is going to have the greatest ROI? There are so many things that we could spend a ton of time testing, and they’re all great in their own way, but what’s going to be best for us and have the largest impact? Over the last few years, instead of our focus being a mile wide and an inch deep, we’ve prioritized two or three things and deployed those on a single project here and there. Then, we can take a step back and see the results, how it worked, how it can be improved, if it can roll out on a large-scale. We don’t want to deploy something new on 500 MW. But we can map out a block here on this specific site and try it on 2 MW or a single tracker. We’ve explored a variety of things, and some haven’t worked out and that’s OK. We have to be willing to say the industry isn’t ready for it, or it needs a few more years.
Brett Foster, VP of Renewable Energy, McCarthy Building Companies

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What’s the best way you’ve found to track installation progress?
We use a printed site plan posted on the wall, where we highlight or circle completed tasks in different colors. This provides a clear visual representation of progress and allows us to easily calculate the percentage of completion.
Michael Methot, Outside Superintendent of Commercial Construction, ACE Solar

For us, it starts with the estimation work well before we mobilize. Installation progress is tracked against the estimates using phase codes for each activity, and over the course of the project, all labor, material and equipment expenses are tracked against the estimate for various phases of a solar installation. Our crew leads in the field have iPads that they use to track their crew’s time against the various phase codes, which is then reviewed and approved by the jobsite superintendent. Our software generates weekly reports about the various labor inputs and equipment used which helps us track the progress of a solar installation. These reports help us understand what we need to do to stay on time and on budget, as well as informing the estimating team for future projects.
Geoff Greenfield, Director of Solar Strategy, Kokosing Solar

Integrating Procore into our workflow has been invaluable for managing and tracking installation progress across multiple projects nationwide, providing real-time visibility and improved coordination.
Bryan Tornetta, Program Manager, DCE Services

What is your preferred method of wire management on C&I sites?
Ultimately, it comes down to the type of system and client preference. Generally, we’ve been using stainless steel panel clips to secure the module leads around the underside of the module frame to minimize slack/low hanging wires, especially on fields that involve some sort of a tracking system so we can avoid any pinch points once the tables are tracking. Sometimes, we’ll coil the leads instead of stretching them out and clipping them to the module frame but the home runs are generally managed with a similar method across the board depending on the type of system we’re installing.
Michael Methot

As a company with a dedicated O&M division, we see how important wire management is for troubleshooting and system safety, as well as what stands up over time (or not). Wire management is something we care a lot about — these details are not left to chance but rather are a focus of the design phase. Typically, most racking systems have an integrated wire management system that we use. On a ground-mount, the racking is robust, so we can put cable into the purlins that support the modules. On a roof-mount there may be rail, and in that case, we attach wire to the rail. We pay a lot of attention to possible friction points, and have details for transitions, walkways, entering cable trays etc.
Geoff Greenfield

For C&I rooftop installations, we prefer using conduit (EMT/IMC) for a cleaner, more organized setup. When securing PV wire to the racking system, Heyco SunBundlers have become our go-to standard.
Bryan Tornetta

How do you keep workers safe when handling increasingly heavy panels?
We prioritize safety by implementing a team lift or “buddy system,” ensuring that two crew members handle each panel during installation. Additionally, we utilize machinery to transport modules as close to the installation point as possible, minimizing the distance employees need to carry them.
Michael Methot

I remember carrying 75-W modules up the ladder back when I was in the field 20 years ago, and it was sketchy even with the smaller modules back then. Today, I am grateful that Kokosing Solar has a variety of equipment, so that is always the first choice — both for safety as well as productivity. Each project is unique, so we might use telescopic handlers, cranes, scissor lifts, skid steers with forks or a tractor and flat top wagon on a ground mount. Eventually, we need to set the modules by hand, and for this we use a team lift.
Geoff Greenfield

To enhance safety, we implemented a policy requiring two employees to handle and install heavier solar modules along with appropriate breaks. This approach reduces physical strain on individual workers and minimizes the risk of injuries, ensuring a safer work environment.
Bryan Tornetta

What recent technology has simplified installation for your company?
The development of manufacturer-provided apps for inverter programming and troubleshooting has significantly streamlined our installation process, improving efficiency and reducing downtime.
Michael Methot

Drone technology has significantly improved our surveying and layout accuracy, enhancing efficiency. Additionally, leveraging Procore for RFIs, submittals and scheduling has streamlined project management and installation processes.
Bryan Tornetta

How do you divide work among the team at installations?
We assign tasks based on skill levels, pairing crew members with complementary strengths. For example, if two team members excel in wire management, they are paired with someone less experienced to promote skill development. This approach ensures efficiency while fostering mentorship and growth within the team.
Michael Methot

Typically, jobs are sequenced from layout to material handling, then mechanical assembly and then electrical. It is critical that the teams are not slowing each other down, so understanding production factors of different crew sizes (and how weather conditions can impact them) is critical. This is another place where our installation progress tracking really helps, and experienced field supervision can make adjustments to avoid inefficiency. On any given project site, our superintendents work closely together, coordinating between the different trades to optimize efficiency. For example, if our electricians can’t get started onsite until a specific project phase, we prioritize having our carpenters get us to that phase first, before they move on to the next phase of their work. This helps us optimize the installation schedule, so everyone is working on the jobsite sooner.
Geoff Greenfield

We believe in putting the right people in the right roles. Identifying skill sets, providing training and fostering professional development are key. Typically, dedicated mechanics handle racking, foundations and module installation, while electricians focus on equipment, conduit and system wiring. Operators manage heavy equipment, ensuring seamless execution based on project scope and labor requirements.
Bryan Tornetta

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How long do you typically train new hires and what does that process entail?
New hire training is custom to each role, however, eEquals typically offers a robust 30-day training period which includes the introduction and use of different technology platforms, our company safety standards and our company protocols. During the first 30-days, new hires are introduced to a variety of online paid training programs and learning courses ranging from OSHA, battery, and fleet training. They also receive on the job training with a Field Manager and a full crew consisting of more than one role. At the end of their 30-day training, new hires are assessed through a quiz to celebrate their progress and identify any areas for improvement, which are addressed in the following 30-days if needed.
Tanya Hall, COO, eEquals

New hires in the field go through a week of shadowing to understand the ESP way of doing things. We generally hire techs with some level of experience, and pair off newcomers with a crew who scores high on quality assurance checks and safety so they learn the right way of doing things and lose any bad habits as quickly as possible.
Jordan Gietz, President of Energy Service Partners (ESP)

What do you tell a trainee before they go on a roof for the first time?
Safety is our top priority, so before we allow anyone on a roof, we make sure they fully understand our safety standards and ensure they have the correct equipment for the job. This includes how to use and check all of their PPE, how to order replacements in the future and how to provide regular checks to the field operations team. We’d also stress the importance of making sure their fall protection gear is properly secured. We’d remind them to use three points of contact when climbing, to keep their tools secure, and to communicate clearly with their team. Lastly, we’d remind them to stay aware of their surroundings and if they’re unsure about anything, ask for help.
Tanya Hall

Safety first, second, and third! Going home to your family at the end of every day is more valuable than rushing to get a job done. We have a saying — “Slow down to speed up.” If you’re going too fast, you’re more likely to make a mistake and have to do it all over again, which will take twice as long when you could have done it slow and steady and properly the first time through.
Jordan Gietz

How do you handle curious homeowners and their concerns about the array being installed on their roof?
eEquals employs a 5-Star Checklist to ensure our customers know and understand what is being installed on their home and share construction methods or equipment placement. We welcome any questions or comments and utilize this time with our customers to educate and excite them about their new investment.
Tanya Hall

Our field teams have QR codes on handouts and trucks for homeowners or neighbors to scan and learn more about the solar process. Also, our in-house customer concierge service calls every homeowner on the day of the install to check in and answer any questions on the spot, as well as a follow-up a day or so after to ensure everything met or exceeded their expectations once the dust has settled.
Jordan Gietz

What is the strangest project layout you’ve encountered, and how did you approach it?
The strangest eEquals project we’ve encountered was a 75-panel system, on a 10/12 pitch, that consisted of 15 arrays. We sent multiple teams to the site over the course of FOUR days to make sure we could meet the customer’s timeline, while still allowing our crews to work at a safe pace.
Tanya Hall

We’ve completed over 20,000 installations since 2015 so there have been plenty. Lots of high-end homes tend to have funky architectural embellishments and cut-up roof planes, which we’ve run into in San Diego and outside LA too many times to count. The right approach is always setting the proper expectation with the homeowner. That means working with them on potential design layouts and equipment locations, as well as coaching them on timelines and scope of work for what’s going to happen when we’re on-site and working with AHJ’s for approvals.
Jordan Gietz

What is the hardest thing about residential solar installation? What is the easiest?
Hardest: Often there are challenges that arise specific to any given home’s structure that we cannot capture in a site survey. This could be anything from bringing various elements of a home up to code or the complexities of the electrical system within the home that can give us unexpected challenges. Luckily, our experienced and well-versed employees are able to handle and mitigate these surprises to ensure our customers have a wonderful experience from beginning to end.

The easiest part about being in the residential solar industry is the demand. eEquals has found that many homeowners are increasing their interest in solar due to various motivators: rising energy costs, tax incentives or a growing awareness about sustainability. It makes our job that much easier when we have an eager and receptive customer base.
Tanya Hall

The hardest thing is that every single homeowner is different, every home is unique, and there’s no such thing as one-size-fits-all so we have to find the consistent, repeatable and sustainable practices and processes while still allowing for customization that works for the customer. The easiest thing is knowing we’re saving the planet with every panel we install, so it makes getting up in the morning exciting and easy, knowing we’re going to leave a bunch more people better off than we found them every day.
Jordan Gietz

How do you prepare to work in inclement weather conditions?
eEquals takes pride in outfitting our crews for any weather condition. In our market, we deal with both extremely cold and hot weather. In the winter, our cold weather kits include snow torches, de-icers, body warmers and company issued coats. In the summer months we provide water, hard hat visors, moisture-wicking shirts and cool wraps. Overall, we constantly monitor the weather conditions to ensure we are not putting our crews in unsafe environments.
Tanya Hall

Back to safety, we have a tight threshold for keeping our people out of harm’s way, if there’s going to be rain that leaks to slick surfaces or other weather that creates unsafe working conditions. We know it can lead to disappointed customers who have to wait for another day to get their job finished up, but more often than not people are very understanding and don’t want to put anyone at risk for the sake of speed.
Jordan Gietz