Hailstorms Now Top Threat to Large-Scale Solar Farm Profits
Hail has become the leading cause of financial losses in large-scale solar projects. The issue first gained attention over a decade ago when a severe storm cut one system’s output by 70%. Now, insurers, developers, and operators are facing growing challenges from hail-related damage.
The problem began when early utility-scale solar farms were built in California and Arizona. These regions had low hail risk, so thinner glass modules were favoured for their cost and efficiency. But as projects expanded east of the Rockies, hailstorms caused widespread damage.
Electroluminescence scans later revealed hidden cracks in solar cells after hail impacts. These cracks reduced energy production and increased long-term costs. Tracker systems, designed to stow panels during high winds, sometimes made matters worse by positioning modules directly in the path of falling hail. Heliene Inc., a solar manufacturer, now uses 3.2mm front glass on all its modules. This thickness balances weight, clarity, and durability. The company also relies on aluminium frames for added strength without extra cost. CEO Martin Pochtaruk first recognised the threat over ten years ago when a customer’s system lost most of its output after a storm. Insurance requirements for solar projects have since tightened. Stricter standards now reflect the rising financial risks from hail damage, energy shortfalls, and liability claims.
The solar industry is adapting to hail as a major operational risk. Thicker glass, stronger frames, and revised stow strategies are now common solutions. With insurers demanding better protection, manufacturers and developers must prioritise resilience in future projects.
