We speak with solar contractors every day, and one of the most frustrating things they experience are revisions or changes on install day.
In fact, over half of contractors report experiencing at least a 25% revision rate, which costs them hundreds or even thousands of dollars per project.
It goes without saying that staying ahead of these issues is crucial for an efficient and successful solar business. After all, who wants to have their margin eaten up by preventable change orders? That’s why we were so excited to team up with Scanifly to create more resources for installers who are trying to reduce their revisions and delays.
As a platform specifically built to help with PV design and field operations, Scanifly has identified the top 7 causes of revisions and change orders among solar installers. Lucky for us, they’ve also discovered how solar companies can avoid these costly delays — and they’ve shared all these tips and tricks below.
Cause 1: Inaccurate roof measurements
If you’ve been in solar long enough, you’ve experienced an install day that was completely derailed by inaccurate roof measurements. That’s because measurements that are off by even just a few inches can cause significant delays and result in costly change orders.
Despite this, many solar companies still rely on satellite imagery or hand measurements to guide their designs and install plans. We hate to say it, but therein lies the problem. Satellite measurements can be off by as much as a foot or more, and hand measurements take up a lot of time and are prone to human error.
But if remote imagery or getting on the roof to measure isn’t optimal, then what?
Using technology like drones and photogrammetry software provides the most accurate, real-time measurements available, eliminating any guesswork. With this precise on-site data, your designs will always fit perfectly on install day.
Cause 2: Inaccurate site context
Lacking accurate site context can lead to consequential fitment issues. Elements like trees, chimneys, and neighboring buildings must be precisely accounted for.
Many installers try to rely on remote imagery to accelerate project timelines. However, remote imagery is notorious for missing details, like small vent pipes, which can cause big problems, including:
- Re-permitting fees at roughly $1k a pop
- Installing fewer modules than purchased
- Stopping work while installers figure out the necessary revisions on the fly - costing potentially a few thousand dollars in labor
- Possibly the worst - negative customer reviews
As we get into below, this is why it’s worth the initial time investment to actually have your team go on-site and do a thorough inspection of the property — inside and outside. Quality-obsessed contractors know that by taking the time upfront, and coupling it with a strong training regimen and the right technology, you save yourself these costly setbacks later on.
Cause 3: Skimping (or skipping) on on-site structural analysis
Has your team had to deal with roof damage or potential system failures? If you want to make sure these issues don’t cause install delays, don’t skip (or skimp) on the on-site structural analysis.
Using drones to capture roof measurements and identify obstructions works great, but don’t forget to verify structural integrity from within the home whenever possible — and document your findings using a mobile solution and digital checklist to ensure no detail is missed.
To ensure sure you’re getting a comprehensive understanding of the structural and roof health, check:
- The attic
- Support beams
- Shingle layers
Now that you’re confident the roof can support a PV system, you’ll need to gather the home’s electrical anatomy. Which brings us to the fourth common cause of solar revisions and change orders….
Cause 4: Missing details on electrical analysis
It’s no surprise that a precise electrical analysis is vital to an accurate solar install. Missing details on existing electrical systems can lead to major design changes, re-permitting, and delays on install day. So how do you avoid these issues?
It starts at the top. Executives and ops leaders must establish a set of standards and training regimen to ensure that field teams are equipped to conduct thorough on-site surveys — gathering information on meters, main breakers, and wiring quality. Knowing these details upfront helps avoid surprises and costly change orders.
Then, the best practice is to digitize this data-collection process. Your team gets bonus points if you can centralize everything in one place so your design teams can easily access this critical field data when beginning the system design.
Believe us, not only will your design and engineering teams thank you, you’ll start seeing a difference in your bottom line as well. It’s cheaper to do it right the first time than to have to do it twice!
Cause 5: Remote shading analysis
Solar shading technology has evolved dramatically over the years. Yet, one thing remains certain: On-site data is always the most accurate option.
With the rise in sales-first and remote-first cultures, remote shading techniques have become commonplace. However, this data is often outdated and misses critical updates, like new trees or structures. While remote shading has benefits, its shortcomings can lead to inaccurate production estimates and high rejection rates from TPO financing partners.
We know that giving up remote shading can be a difficult operational switch. However, you do have options. We recommend using real-time on-site shade data and converting it into a 3D model ensures accurate shading analysis and vegetation modeling. This way, you can optimize panel placement and avoid overpromising on system production.
Cause 6: Changing local regulations
Solar installs require permits from local jurisdictions — and we’re going to teach you a foolproof way of dealing with these AHJs.
Often, each region has unique rules, which is why you should create new templates for each AHJ you work with. These templates should always include:
- A property overview
- Electrical information
- Array plan
- Stamps and placards
- Additional AHJ or Utility-specific needs
Ignoring or misunderstanding local AHJ and utility requirements when preparing and submitting your plan sets can lead to significant delays and re-permitting. It’s vital you stay updated on local regulations and ensure your designs comply from the start.
If using third-party design or engineering firms to outsource plan set creation, make sure they know each AHJ’s requirements, like fire setbacks and voltage drop calculations.
Cause 7: Doing it without any help
We spoke with an installer recently who told us proudly, “We don’t pay for any kind of software.” They went on to explain that between Google Sheets and their hardworking team, they were able to get everything done without the need for tech investment.
We know that adopting new technology can be intimidating. It takes time and money to vet vendors, find the right solution, and fully adopt it within your company. Many installers think this upfront investment just can’t be worth it. But if you stop to quantify the effect of doing things “the old fashioned way” you may find the cost to be higher than you would think. Especially since, as we go over in the rest of the blog post, taking this manual (disorganized) approach usually results in more change orders.
When it comes to revisions, the cost of doing nothing far outweighs the initial investment in new tech as a solution. Let’s break it down. If you decide not to help with tech to help you with the roof measurements or site analysis, you could:
- End up installing one less module — $1000
- Stop work for your 3 installers while this change is relayed to the customer to make sure they’re alright with the new production specs — at $10/ worker for 30 minutes, that’s another $30
- Resubmission of permits — $300
And that’s not even mentioning what happens if the customer ends up leaving a bad review about the last minute change. Their complaint about how your crew was “unprofessional” and how they “installed something different than what we agreed on in the proposal” can cost your solar company future business — resulting in thousands of dollars of loss.
Leveraging solutions like drones, photogrammetry software, and mobile field apps can significantly enhance data accuracy and project planning, reducing the likelihood of these other costs. This tech ensures you get it right from the start, eliminating the various pinch points in the survey, design, and engineering stages that can cause revisions.
Integrating these tools across your project workflow enables you to capture precise roof measurements, real-world site context, and comprehensive shading analysis. This approach leads to smoother installations and happier customers.
Finding the right partner to reduce revisions
If you’re interested in finding a partner who can reduce site survey time by 90% and eliminate revisions on install day, we recommend our friends at Scanifly. They help installers create preliminary estimates, gather on-site data, and generate photorealistic PV designs, shade analysis, plan sets, and maintenance reports — all on one platform.
And if you’re looking for a partner who can help your team automatically engage customers throughout the entire customer journey, from lead to install to repeat customers, then Bodhi can help. With Bodhi, operations teams can automate site survey scheduling, reminders, updates on the install, and more. To learn more, schedule a time with us or get started for free now.
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