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How Belmont Solar Rebuilt a Storm-Damaged Solar System
Do you know how to choose a trusted solar contractor? Discover some principles today that you can apply in your search for a trusted solar installer.
Distressed by the many obstacles on the road to solar, Michael of Robesonia, PA, approached Belmont Solar in mid-2019 after experiencing serious problems with his installation. The building inspector did not approve the system or grant a Certificate of Completion (COC) due to numerous flaws in the setup, which had been installed by another local solar contractor. Both technically and administratively, there was significant work that needed to be completed or corrected. Addressing the installation issues would increase costs, and additional work was required to resolve permitting concerns and establish the Solar Renewable Energy Credits program.
At Belmont Solar, we hesitated to step into the project right away. We wanted to allow the original contractor to correct the issues and complete the installation properly. We also understood that bringing in a second contractor would increase Michael’s overall costs, potentially making it difficult for him to move forward with the project.
For a while, we heard nothing more and assumed a solution had been reached. Then, in early 2020, we received another call from Michael, this time with even more troubling news. Strong winds had severely damaged the solar system before it had ever delivered the reliable performance he had hoped for. After dealing with inspection failures, permitting challenges, and mounting frustrations, Michael found himself facing a damaged system as well.
Michael’s experience underscores the importance of working with an established solar contractor. Certifications such as NABCEP, customer reviews, and involvement in organizations like the Better Business Bureau or local Chamber of Commerce can often provide insight into a company’s experience and reputation. While every project is unique, these are the types of details many homeowners consider when choosing a contractor they can trust with a long-term investment like solar.
The Hidden Issues Behind Michael’s Solar System Failure
After the storm damaged Michael’s solar system, Belmont Solar conducted a thorough evaluation of the installation. The photos below reveal the extent of the damage. The panels had shifted out of place, and portions of the support structure were bent and leaning forward. What initially appeared to be storm damage soon revealed deeper issues with the way the system had been constructed.
As our team looked closer at the system, it became clear that the damage was not caused solely by the storm. Ground-mounted solar arrays are exposed to the elements every day and must be engineered to withstand typical weather conditions. In this case, the system had been in service for only a few months before being damaged by winds of approximately 32 mph, with gusts reaching 40 mph, conditions that are not uncommon in Pennsylvania.
Further investigation revealed several concerns with the original installation. The ground mount was constructed using thin-walled, 1.5-inch unthreaded pipes anchored only 1.5 feet into the ground, despite the local frost line extending to approximately 3 feet. Beyond the structural deficiencies, we also discovered electrical components that were not properly sized for the application. For example, a 60-amp breaker box contained a 100-amp fuse, creating a potential overload and fire hazard. Together, these issues highlighted the need for a more robust and properly engineered solution.
Rebuilding the Solar Install in Robesonia, PA
Once the issues with Michael’s original system had been identified, the next step was designing a solution that would provide the long-term reliability he expected from his solar investment. To rebuild the ground mount, Belmont Solar partnered with Josh Miller of GoliathTech Keystone, LLC, a trusted local contractor who has helped construct many ground-mounted solar systems throughout the Lancaster area.
Rather than relying on poured concrete foundations, Josh used specially designed Earth Augers to create a stronger foundation for the new array. This approach provided the stability needed for a properly engineered ground-mounted solar system and laid the groundwork for a complete rebuild designed to withstand Pennsylvania’s weather conditions for years to come.
Earth Augers, part of a helical (screw-type) pile system, are not affected by frost in the wintertime and have a much higher pull-out rating than poured concrete pillars. They are the ideal solution for the solar industry, as there is no need to wait for concrete to harden after the installation. The solar contractor can start working while other piles are being installed. Designed for the highest wind exposure (Factor C), and installed deep into the ground beneath the freezing level, they ensure that the system can withstand a constant wind speed of 100 mph and a snow load of 40 psi. The framework connected to the Earth Augers uses thick-walled, 2-inch threaded tubing. Michael’s new system already withstood a storm in May 2020 that produced gusts up to 80 mph.
Once the frame is up, we step in and build the solar array using our signature Tough Trac mounting rail. Tough Trac is a subsidiary of Belmont Solar and produces mounting rails with exceptional rail strength, the strongest in their class. They are rated for 120 mph winds for spans of up to 80 inches as well as 80-pound snow loads over 48-inch spans.
The result is a 25 KW system delivering ample power to Michael’s home, and a happy family with the promise of guaranteed power production for many years to come.
After facing permitting challenges, installation issues, and significant storm damage, Michael finally had a solar system he could rely on. What began as a frustrating experience ultimately resulted in a stronger, properly engineered 25 kW solar system designed to deliver dependable performance for years to come.
The Right Solar Contractor Matters
Michael’s story is a reminder that solar is more than just panels on a roof or in a field. The long-term success of a solar system depends on proper engineering, quality materials, and careful planning from the very beginning. Factors such as foundation depth, frost lines, wind exposure, electrical design, and system placement all play an important role in ensuring a solar installation can withstand the test of time.
While Michael’s original system failed after only a few months, the rebuilt system was designed with those long-term considerations in mind. The result was a stronger, safer installation that could deliver reliable performance for years to come.
At Belmont Solar, we believe in looking beyond the initial installation to help homeowners avoid costly problems down the road. When important details are overlooked, homeowners can end up playing what we call “Solar Whack-A-Mole,” fixing one issue after another as new problems continue to surface. That’s why we focus on identifying potential concerns before they become expensive repairs later on.
Watch this video to learn more about the factors that impact long-term solar performance and how proper planning can help protect your investment.
In summary, don’t make the same mistake. Doing your research prior to choosing a solar contractor will certainly help your solar installation process go much smoother. If you do have questions about the solar installation process or choosing a trusted solar contractor, contact our knowledgeable team at Belmont Solar. We have plenty of experience installing all types of solar systems, including Grid-Tie, Off-Grid, and Grid-Tie with Battery Backup. It’s our personal goal to help you experience the benefits of solar without the hassle!
Ben Zook
Articles: 34
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