As solar systems proliferate on India’s rooftops, a silent crisis is unfolding. The promise of clean energy and cost savings is being increasingly undercut by poor engineering practices and subpar installations, many of which cannot withstand the monsoon winds and cyclonic conditions common in several parts of the country.

Recent weather incidents in cities like Bhilwara, Gwalior, Indore, Mira Road, Kanpur, and Lucknow have highlighted this issue. These were not extreme weather events but typical pre-monsoon storms. Yet, many rooftop solar systems could not survive even 120 kmph winds. Experts warn that if systems fail under such common wind conditions, they will be destroyed in stronger cyclonic winds that often reach up to 200 kmph.

Weak mounting structures, inferior materials, and rushed installations are creating a trail of damaged rooftops, uprooted systems, and broken modules.

The failures are not just technical. They are systemic, stemming from a lack of regulation, cost-cutting tendencies, and insufficient awareness about the structural demands of rooftop solar. This is even more pressing as most people are opting for rooftop solar due to the incentives announced by the government through programs like the PM Surya Ghar: Muft Bijli Yojana.

India added 1.2 GW of rooftop solar capacity in the first quarter (Q1) of 2025, up 232% year-over-year from 366.5 MW, according to Mercom India Research’s newly released Q1 2025 India Rooftop Solar Market Report. The quarter’s installations were driven by the residential segment under the PM Surya Ghar program, which made up nearly 77% of the capacity additions.

Pre-installation study

Wind resilience starts long before systems are placed on a roof. According to Nikhil Nahar, Founder of SolarSquare, site evaluations encompass everything from building height to terrain and local wind speeds. “We follow IS 875 and ASCE 7 standards,” said Nahar, noting that SolarSquare’s engineering process includes simulation tools like STAAD.Pro and CFD to model wind forces.

Nahar said that SolarSquare’s Intelligent WindPro Mount, developed in collaboration with IIT Bombay, is designed to withstand wind speeds of up to 170 kmph.

Terence Alex, Founder and CEO of Wattsun Energy, has witnessed the consequences of poor engineering firsthand. He points out that though guidelines exist, especially from bodies like the National Institute of Solar Energy, they are often ignored on the ground. “Some installers are not adhering to wind speed guidelines. Modules are just being placed without proper footing.”

The results are predictable. Even systems of four, six, or ten feet are placed on flimsy mounts that cannot resist 90 kmph winds, let alone the recommended 160 kmph threshold. These installations are happening despite IS 875 Part III clearly outlining the required wind-load standards.

The lack of strong foundations is a recurring issue. On concrete or sheet rooftops, installers frequently skip structural feasibility checks. “There’s a proper way to anchor systems —chemical bolting into reinforced cement concrete (RCC), proper vacuuming, and using threaded rods and base plates. But most do not do this,” Alex notes.

System standards

Solar systems in cyclone-prone coastal zones demand more than a one-size-fits-all approach. Installers adapt their component choices depending on geography. In coastal areas, thicker steel sections, rust-resistant SS-304 fasteners, and high-performance coatings are used to resist corrosion from saline air. Inland installations, while slightly more forgiving, are still subject to rigorous structural considerations.

Every installation is standardized down to the torque settings of bolts. “We conduct pre-monsoon torque checks and mark each joint,” said Nahar.

Much of a rooftop solar system’s resilience is rooted in the physical design of its mounts. Nahar said his company’s mounting structures use tapered C-channels. The structures also use virgin 550 MPa steel, which the company claims is stronger than the common 250 MPa steel found in budget systems.

SolarSquare said its installation follows a Japanese poka-yoke approach, minimizing human error by using pre-manufactured components that fit only in the correct configuration. This ensures both consistency and performance. The system is also leak-proof, thanks to airtight German-engineered seals that anchor it to RCC slabs without compromising the roof’s integrity.

The contrast between engineered and non-engineered systems becomes glaring during extreme weather events. Traditional low-cost setups often crumble under cyclonic pressure. Common issues include uprooted mounts, torn modules, and water-damaged roofs.

Installers note that failures typically result from loose fasteners or poor-quality frames. Even minor issues, such as occasional frame deformation, have led to design tweaks to eliminate stress points, particularly in fastener placements.

Developers also noted that many systems are installed on pre-existing truss works without an assessment of their load capacity. In some cases, elevated legs are added to increase module exposure, inadvertently creating wind traps that rip systems off roofs during storms.

Post-storm inspections are a vital part of ensuring long-term safety. The process involves checking displaced components, verifying torque integrity, and inspecting water ingress in electrical parts. Advanced diagnostics, such as thermography and electroluminescence imaging, are used to detect deeper issues that are invisible to the naked eye.

Taking these precautions obviously has a cost. Wind-resilient systems can cost 10% to 15% more than low-cost alternatives. However, Nahar argues that the returns are both financial and emotional in nature. “The cost difference is marginal compared to the reliability and peace of mind it offers.”

As climate-related events become more frequent and destructive, customers are beginning to understand the value of this approach. Cyclone news and visible rooftop failures are shifting public opinion in favor of stronger, safer systems.

While installers are leading with best practices, they believe lasting change must come from policy. Mandatory compliance with IS 875 and structural approvals from certified engineers are necessary to create a level playing field.

Insurance gap

Adding to the complexity is the insurance loophole. Even when systems are insured, many policies exclude natural calamities from their coverage. “Insurance companies deny compensation, citing the ‘Act of God’ clause. So, customers pay premiums, but when systems fail, they’re left on their own,” said Alex.

Most installers strive to be transparent about this, clearly stating that storm damage falls outside their contractual responsibility. But in some cases, customers are unaware until it is too late.

Unfortunately, when such damage occurs, homeowners often have little to no support. For example, in 2023, a legal case in Gujarat involved a homeowner whose solar modules were torn off during a 2020 cyclone. The Bhavnagar District Consumer Dispute Redressal Commission granted compensation. Still, the state commission dismissed it, stating that warranties only cover manufacturing faults and cannot guarantee protection from natural forces.

Installation inspections

Distribution company (DISCOM) inspections also lack the technical depth needed to ensure structural integrity. “Many officials who come for inspection aren’t trained to evaluate solar installations,” said another installer. “They are often junior staff following instructions from sub-engineers. If the sub-engineer doesn’t know the standards, the whole system is compromised.”

This lack of expertise at the inspection level undermines the safety of rooftop systems. These systems are approved despite poor workmanship, missing fasteners, and unstable mounts, all of which are invisible to the average homeowner but catastrophic during storms.

If India is serious about scaling solar safely, it must invest in training DISCOM personnel, mandate structural checks by certified engineers, and enforce compliance with IS 875 Part III, the wind load standard for solar installations.

Installers also call for a nationwide awareness campaign led by the Ministry of New and Renewable Energy, as well as more rigorous training to ensure that installers accurately interpret and adhere to safety standards. “People must realize that rooftop solar is a structural addition to their home,” Nahar says. “Safety must never be optional.”