Solar Industry Faces Quality Crisis: 70% of EPCs Report Major Issues
A recent report by HelioVolta has revealed alarming quality issues within the solar industry, with 70% of surveyed EPCs facing significant problems. The PV Health Report found that 85% of projects contained major issues, and 7% had critical issues needing immediate remediation. U.S. developers rushing to meet accelerated deadlines for tax incentives are exacerbating the situation.
The report evaluated 70 EPCs with over 1,000 projects representing 5 GW of solar assets between May 2021 and May 2025. VDE America's Brian Grenko expressed concerns about clients rushing to construction to beat deadlines, potentially compromising quality. HelioVolta's findings indicate that improper wiring, grounding, or connections are the majority of quality issues, leading to overheating and hotspots. These issues result in revenue loss and higher incidents of unscheduled maintenance calls. Quality issues were found to be endemic across EPCs of all sizes, from those with over 10,000 employees to those with less than 50.
The implementation of independent oversight was found to improve construction quality. However, the rush to meet accelerated deadlines for tax incentives may increase the frequency of quality issues. Developers must balance the need for speed with the importance of quality to ensure the longevity and efficiency of solar projects.
The solar industry is facing a significant quality crisis, with 70% of EPCs surveyed reporting major or critical issues. Improper wiring, grounding, or connections are the primary culprits, leading to overheating, hotspots, revenue loss, and increased maintenance calls. While independent oversight can improve construction quality, the rush to meet tax incentive deadlines may exacerbate the problem. Developers must prioritize quality and implement robust quality control measures to ensure the long-term success of solar projects.
