Recent extreme weather events in Rajasthan and other parts of the country have raised concerns about the structural durability of rooftop solar installations, with industry experts citing aluminum frames used in solar modules as a key vulnerability.

During high winds and storms, several solar modules have reportedly been bent, torn, or detached.

Experts say the failures are often linked to inadequate reinforcement at the module edges, where the frames cannot withstand high wind loads. These issues are not limited to Rajasthan; they have been observed in other states as well.

Quality Crisis at the Core of the Problem, Manufacturers Differ

Kamal Subhash Jolly, Managing Director at Anatoly Energy, said, “It’s not just limited to Rajasthan. It’s happening everywhere. The thickness of aluminum frames is reduced to ensure greater profits. There’s no framework to monitor quality.”

“The frames cannot withstand high winds and extreme weather conditions, and this leads to wear and tear of frames in a short span of time. This places an additional burden on us. As there is no warranty for frames, we must replace them, and it’s not the obligation of the panel manufacturer,” he said.

Jolly noted that these frames are often the point of failure, with modules experiencing bending, tearing, or even detachment during high winds and storms. The key issue is inadequate reinforcement at the module edges, which cannot withstand severe-weather forces.

Further concerns include the lack of comprehensive wind-pressure-strengthening reports, as structural engineers are not typically involved in assessing the wind resistance of solar modules.

The issue has highlighted the need for module manufacturers to focus not just on the size of module frames, but also on frame thickness, material quality, and overall structural strength. Installers believe that manufacturers are primarily pursuing cost-cutting, which has led to a gradual decline in the quality of module frames.

Uttam Patel, Director at H&H Aluminium, said, “One of the primary reasons behind the rising failure rates of solar modules is the cost-cutting undertaken by some panel manufacturers. Over the years, frame thickness has been reduced significantly, from around 1.6 mm earlier to nearly 1.2 mm in some cases. At the same time, module sizes have increased substantially, resulting in larger panels being supported by lighter frames. This combination can adversely affect the module’s structural integrity, particularly during transportation and under wind, mechanical, and thermal stresses, potentially leading to long-term reliability issues such as microcracks and reduced performance.”

“Also, it’s the responsibility of the manufacturers to provide a warranty and take care of the frames, which they are not doing. There are also cases where frame manufacturers use scrap, which reduces quality and creates trouble in the long run,” he said.

Another area of concern is the use of low-quality aluminum scrap by some frame manufacturers as a cost-reduction measure.

“If the scrap is not properly processed, it can affect alloy composition, mechanical strength, corrosion resistance, and overall frame reliability, potentially creating performance and durability issues over the long term,” Patel said.

Ajay Yadav, President of Renewable Energy Association of Rajasthan (REAR), said that there are critical issues with the durability and quality of rooftop solar modules, particularly their wind-load resistance. “In my view, the recent thunderstorm in Rajasthan exposed serious concerns regarding rooftop solar module quality and wind-load durability. At several sites, mounting structures remained intact, but module frames were damaged or cracked, or panels were displaced due to high wind pressure,” he added.

Another concern is the lack of comprehensive wind pressure-strengthening reports for rooftop solar systems. Structural engineers are often not involved in evaluating the wind resistance of solar modules, leading to designs that may prioritize cost efficiency over long-term safety and performance.

Module manufacturers beg to differ from frame suppliers and some installers, who argue that rooftop solar installations face an inherent problem due to module-frame design.

According to Ashok Kumar Singh, President of Solar Business at Novasys Greenergy, the issue is not with aluminum frames as a category, but with whether the module, as a complete system, has been designed, assembled, and tested in accordance with recognized standards.

“If they define and follow IEC or equivalent standards, it should withstand 160 kmph,” he said, adding that the module includes not just the frame but also the glass, bonding material, assembly process, and overall mechanical strength.

Manufacturing efficiency depends on various other factors, but aluminum alloy composition, frame strength and thickness, glass retention capability, silicone bonding quality, and the module’s ability to withstand long-term mechanical loads and environmental stresses are equally important.

Ashok observed that failures should therefore be examined in terms of material quality, certification, installation design, and extraordinary weather conditions rather than being blamed solely on manufacturers.

As module sizes and power ratings increase, the weight of the aluminum frames supporting them is, in some cases, decreasing due to cost pressures. Ultimately, frame design and material usage are at the discretion of manufacturers, who must balance cost competitiveness with structural durability. Industry experts note that some manufacturers have reduced aluminum usage by around 10%. For example, while a 330 W module typically uses about 3 kg of aluminum, some 590 W modules today are being covered with less than 2.5 kg of aluminum, despite their larger size and weight.

Need for Strict Guidelines

Yadav said that to address these challenges, the Ministry of New and Renewable Energy should strengthen guidelines focused on module durability, wind resistance, and product accountability to enhance resilience in extreme weather conditions.

“Another solution put forward by the stakeholders is steel frames, which are expected to offer greater rigidity and durability in regions prone to harsh weather conditions,” Jolly added.

Singh rejected the need to shift to steel frames, noting that aluminum-framed solar modules have been used globally for decades and that even steel-framed modules can fail during extreme, sudden wind events, such as localized tornadoes or wind speeds beyond design specifications.

Yadav observed that proper warranty support and grievance mechanisms must be established to safeguard consumer interests and maintain trust in the rooftop solar market.

Patel added that MNRE should develop a new framework for module frames that defines all parameters, which will help consumers and all stakeholders in the long run.

The industry now needs to focus on long-term quality and reliability, alongside rapid installation growth, to foster sustained consumer trust and sector growth.

Experts say manufacturers and installers must prioritize structural integrity in module and system design. Strengthening rooftop solar installations against extreme weather is considered essential to improving the safety, reliability, and long-term performance of solar projects in Rajasthan and other regions prone to such events.