Photovoltaic system maintenance: how to improve safety at height during the installation and maintenance of solar panels

The installation and maintenance of solar panels on industrial and residential roofs involve specific elements which, in terms of safety, require equally specific solutions.

Surprisingly, despite the increasingly widespread use of solar panels – taking Italy as an example – around 80% of these structures are not equipped with permanent fall protection systems for access at height, exposing those involved in photovoltaic maintenance and new installations to significant risk.

Working without adequate safety measures means operating in dangerous conditions, with falls from height representing one of the main causes of serious or fatal accidents.

According to statistics from Italy’s national workplace safety authority (INAIL), falls from height account for over 30% of fatal accidents in the construction sector. Many such incidents occur on roofs lacking appropriate fall protection systems, either during their construction or while performing maintenance and installing electrical, plumbing or photovoltaic systems.

To ensure safe access to roofs and full compliance with regulations, specific technical solutions must be implemented not only on-site but also with a view to future solar panel maintenance.

Standard EN 795 sets out the criteria for anchor and fall protection systems: numerous tools are available to ensure the safety of photovoltaic installation sites, from collective protective equipment to individual gear, including safety helmets or harnesses designed for work at height.

1. Access at height: ladders for safe roof access and secure routes.

One of the most overlooked issues is the lack of properly equipped access routes to the roof.
Many residential buildings are not equipped with ladders for safe roof access, and in industrial settings, proper planning for roof access is often overlooked. This forces roofers and technicians involved in photovoltaic maintenance to resort to makeshift solutions, significantly increasing the risk of slips and falls.

A properly designed ladder is crucial for safe roof access, allowing quick and secure ascent and descent at every step.
For installers and maintenance technicians, LADSTEP – the caged ladder by Rothoblaas – represents the ideal solution thanks to its aluminium alloy structure, which offers mechanical strength, corrosion resistance and durability against weathering. Furthermore, its modular system makes LADSTEP adaptable to every design requirement.

Safe access is the first step towards reducing risks and enabling faster, more efficient operations during solar panel maintenance.

2.Fall protection: Which lifeline is best for photovoltaic systems?

Operators working with photovoltaic systems must be able to move freely to position modules, make electrical connections and perform maintenance on solar panels.
However, many roofs with photovoltaic panels do not allow for the installation of traditional lifelines, as anchor systems may interfere with the layout of the modules and consequently affect their performance.

The ideal lifeline in these cases is one that can be quickly installed, has low-profile supports that sit close to the roof surface, and offers operators maximum freedom of movement once connected.
These fall protection systems must necessarily comply with regulations and be fully certified: Standard UNI EN 795 sets out the requirements, test methods, instructions for use and marking of anchor systems, classifying lifeline or anchor points into five main categories.

On industrial rooftops, particularly where photovoltaic systems are installed, the choice of lifeline supports becomes even more critical. These roofs often cover large areas and are typically made of sheet metal, meaning that incorrectly placed anchor points can not only compromise the efficiency of the modules, but also affect the waterproofing of the roof.

It is therefore essential to choose certified supports that do not cast shadows on the panels, thus preserving the system’s performance, that can withstand high stress, thus ensuring maximum safety, and that are designed for quick installation, also helping to protect the roof’s waterproofing.

SHIELD is an adaptable support suitable for all trapezoidal metal roofs with an inter-fret spacing of up to 420 mm. It is the ideal system for creating straight or angular anchor points and lifelines on both flat and pitched roofs, and comes with mounting rivets and cellular rubber gaskets to ensure full waterproofing after installation. Its design prevents shadows being cast on the panels.

3.Risk of breakthrough: protection for PVC skylights and fragile areas

As previously mentioned, the majority of workplace accidents are caused by falls from height in industrial settings or construction sites.
However, when we talk about "falls from height", most people tend to think of accidents involving scaffolding or roof edges. In reality, a common cause of fall-related injuries is the failure of fragile roof areas that give way underfoot.

Industrial roofs, and all flat roofs in general where photovoltaic panels are normally installed, often include skylights in PVC.
Although these elements are not load-bearing, it is not uncommon for maintenance technicians working on photovoltaic panels to walk on them, taking advantage of the space not occupied by the system. A typical scenario occurs during panel replacement, when the additional weight on the PVC skylight while lifting the module causes it to give way, resulting in a fall.

A misstep on a PVC skylight during the installation or maintenance of photovoltaic systems can have fatal consequences.

Installing safety nets is the most effective solution to safeguard these areas. OVERNET is ideal – it prevents accidental falls through PVC skylights or fragile areas, while still allowing natural light into the interior spaces.

It should be remembered that, under current regulations, skylights are considered non-load-bearing surfaces unless otherwise certified.

4.Essential Personal Protective Equipment (PPE).

Anyone working at height must always wear personal protective equipment (PPE) to reduce risks.
For those who install or perform maintenance on solar panels, the most common PPE include:

• Safety helmet: protects against accidental impact and falling materials.

• Safety harness: allows secure anchoring to certified points.

• Lanyards and energy absorbers: reduce impact in the event of a fall.

All of these devices must comply with EN 361 (harnesses) and EN 397 (safety helmets).
Having the right equipment is key to minimising operational risks and working in safe conditions: the full range of Rothoblaas products dedicated to PPE can be found here.

5.Folding railings: shadow-free fall protection systems.

One of the main challenges in ensuring safety on photovoltaic systems is that collective protective equipment, such as traditional railings, can cast shadows on the panels, reducing the system’s output.
In the photovoltaic sector, the need to protect workers without compromising energy production poses a constant challenge.

Folding railings offer a practical solution, ensuring safety during the installation and maintenance of photovoltaic systems without affecting performance, whenever collective equipment is not required, that is, when no workers are on the roof.

These railings offer reliable protection and can be folded down when no longer needed, thus avoiding permanent shading on the panels.

The integration of railings with uprights into fall protection systems for photovoltaic installations helps maximise both safety and efficiency. More broadly, railings are an excellent solution for industrial settings with photovoltaic roofs: they are installed at the roof edge without interfering with the panels, protect multiple operators at once, are weather-resistant and can be adapted to various types of substrates.

In general, a key principle to keep in mind when working with renewables is that no photovoltaic system should be designed without integrated fall protection solutions for ongoing maintenance. If your installation lacks a complete or partial fall protection system, contact us using the dedicated form. Together, we’ll develop a solution tailored to your needs. https://www.safety-rothoblaas.com/energie-rinnovabili