Solar Storage Wars

A Comprehensive Guide to Solar Panel Removal, Storage, and Reinstallation for Roofing Projects

Author: Charles Sinclair Date: October 7, 2025

Introduction

The increasing adoption of solar energy for residential properties presents a unique challenge when homeowners need to undertake roofing projects, such as repairs or full replacements. The presence of a solar panel system requires a specialized approach to ensure the safety of the workers, the integrity of the solar equipment, and the preservation of both the roof and solar system warranties. This guide provides a comprehensive overview of the best practices, manufacturer recommendations, and safety standards for the removal, storage, and reinstallation of solar panels during a roofing installation. All information is supported by citations from authoritative sources to ensure accuracy and reliability.

The Importance of Professional Expertise

While it may be tempting to consider a do-it-yourself (DIY) approach or to allow a roofing contractor to handle the solar panel removal and reinstallation, industry experts and safety organizations strongly advise against it. A solar panel system is a complex electrical power plant, and improper handling can lead to significant risks, including:

•         Safety Hazards: Working with electrical systems on a roof presents a high risk of electrical shock, falls, and other serious injuries. According to the National Institute for Occupational Safety and Health (NIOSH), thousands of workers are injured each year in roofing and electrical installations [1].

•         Equipment Damage: Solar panels are fragile and can be easily damaged if not handled correctly. Improper removal, storage, or reinstallation can lead to microcracks, scratches, or other issues that can degrade the performance and lifespan of the panels.

•         Voided Warranties: Many solar panel manufacturers and installers have specific clauses in their warranties that require professional handling for removal and reinstallation. A DIY approach or the use of an unqualified contractor can void these warranties, leaving the homeowner responsible for any future repairs or replacements [2, 3].

Therefore, it is crucial to engage a qualified and certified solar installer for any work involving the removal and reinstallation of solar panels. These professionals have the necessary training, experience, and specialized equipment to perform the job safely and effectively, ensuring the long-term performance of the solar system and the validity of all associated warranties.

Manufacturer Guidelines and Best Practices for Storage

The process of removing, storing, and reinstalling solar panels for a roofing project can be broken down into several key phases. The following table outlines the typical steps involved, based on industry best practices [4, 5, 6].

Proper Storage Example

• Solar panels removed for reroofing are typically set on padded pallets or leaned safely against a wall inside a shed or garage, with each panel wrapped or separated by foam or cardboard for protection.

• Avoid direct outdoor storage; exposure can damage surfaces, electrical connections, or seals.

• Ensure panels are not exposed to weather or falling debris.

Professional Advice Summary

• Solar panel removal teams use labeled packaging to keep components organized for easy reinstallation.

• Standing panels upright (like windows) is safest, as stacking can risk pressure damage to glass layers.

• The storage spot must be secure from accidents, falling debris, temperature extremes, and moisture, as improper conditions may void warranties or cause panel failure.

Safety Standards and Regulations (OSHA)

The Occupational Safety and Health Administration (OSHA) has established specific safety standards to protect workers involved in the installation and maintenance of solar panels. These standards address the significant fall and electrical hazards associated with this type of work.

Fall Protection

OSHA has different fall protection requirements for construction (installation) and general industry (maintenance) activities [9]:

• Construction (Installation): Workers exposed to fall distances of 6 feet or more must be protected by guardrail systems, safety net systems, or personal fall arrest systems.

• General Industry (Maintenance): Workers exposed to fall hazards of 4 feet or more must be protected by a standard railing or, if that is not feasible, a personal fall arrest system or safety net.

Crucially, OSHA explicitly states that workers should never be allowed to climb ladders while carrying solar panels [9]. Safe lifting equipment, such as ladder hoists or cranes, should be used to transport panels to the rooftop.

Electrical Safety

Solar panels generate electricity, creating a risk of electrocution and arc flash hazards. OSHA requires that workers stay at least 10 feet away from overhead power lines and follow specific safety protocols for handling electrical components [10]. Depending on the system's connection to the grid, employers may be required to comply with OSHA's Electric Power Generation, Transmission, and Distribution standard (29 CFR 1910.269) or the electrical standards in Subpart S of the general industry regulations (29 CFR 1910) [10].

Warranty Considerations

Both roofing and solar panel warranties can be affected by the removal and reinstallation process. It is essential to understand the terms of these warranties and take the necessary steps to preserve them.

Roofing Warranties

Generally, the installation of solar panels will not void a roof warranty, provided that the installation is performed correctly and the roof is in good condition. However, any solar components installed on a roof that is deemed unfit to handle the extra weight will likely void the warranty [3]. It is standard practice for a qualified solar installer to obtain a warranty continuance letter from the roofing manufacturer or licensed contractor, which typically involves pre- and post-solar inspections [3].

Solar Panel Warranties

As previously mentioned, attempting a DIY removal or hiring an unqualified contractor can void the solar panel warranty [2, 3]. It is imperative to use a qualified solar service company to ensure that the removal and reinstallation are performed according to the manufacturer's specifications and industry standards.

Conclusion

Removing and reinstalling solar panels for a roofing project is a complex process that requires specialized knowledge and expertise. By hiring a qualified and certified solar installer, homeowners can ensure the safety of the workers, protect their investment in their solar energy system, and maintain the validity of their roof and solar panel warranties. Adhering to the manufacturer's guidelines for storage and the safety standards set by OSHA is crucial for a successful and risk-free project.

References

[1] SolarMedix. (2025, February 21). A Step-by-Step Guide to Solar Panel Removal and Reinstallation. Retrieved from https://solarmedix.com/a-guide-to-solar-panel-removal-and-reinstallation/

[2] GreenLancer. (2025, September 22). Solar Panel Removal and Reinstallation for Roof Work. Retrieved from https://www.greenlancer.com/post/solar-panel-removal-and-reinstallation

[3] Sunnova. (2024, August 16). Solar Panel Removal & Reinstallation: What You Need to Know. Retrieved from https://www.sunnova.com/watts-up/solar-panel-removal-and-reinstallation

[4] GreenLancer. (2025, September 22). Solar Panel Removal and Reinstallation for Roof Work. Retrieved from https://www.greenlancer.com/post/solar-panel-removal-and-reinstallation

[5] Palmetto. (2025, July 11). Removing and Reinstalling Solar Panels: Process and Cost. Retrieved from https://palmetto.com/solar/how-to-remove-and-reinstall-solar-panels

[6] SolarMedix. (2025, February 21). A Step-by-Step Guide to Solar Panel Removal and Reinstallation. Retrieved from https://solarmedix.com/a-guide-to-solar-panel-removal-and-reinstallation/

[7] JA Solar. (2024, May 29). JA Solar Panel Storage and Transportation Recommendations. Retrieved from https://www.janewenergy.com/JA-solar-panel-storage-and-transportation-recommendations.html

[8] PITT OHIO Logistics. (n.d.). Safe and Efficient Warehouse Storage for Solar Products. Retrieved from https://www.pittohiologistics.com/safe-and-efficient-warehouse-storage-for-solar-products/

[9] Occupational Safety and Health Administration. (n.d.). Green Job Hazards - Solar Energy: Falls. Retrieved from https://www.osha.gov/green-jobs/solar/falls

[10] Occupational Safety and Health Administration. (n.d.). Green Job Hazards - Solar Energy: Electrical. Retrieved from https://www.osha.gov/green-jobs/solar/electrical