Dec. 11, 2023
By CJ Fu
Head of Product and Solutions
The typical solar module travels hundreds or even thousands of miles from the factory to the project site, and during this long journey they are packaged, palleted, and loaded and unloaded repeatedly before reaching their final destination. The vast majority of the millions of modules shipped every year arrive safely, but improper handling can result in damaged or broken modules – and potentially significant unexpected costs and delays for solar projects.
Between accelerating solar industry growth, the increasing adoption of large format modules, and the gradual easing of pandemic-era supply chain disruptions, proper module handling has become a more urgent priority than ever. As a Tier 1 solar company, LONGi prides itself on working closely with freight carriers, EPC site teams, logistics providers, and customers to help ensure awareness of best handling practices every step along the way.
To this end, we’ve refreshed our PV module unpacking, handling and storing guide to reflect updated guidance for shipments of LONGi’s full range of products, including our 54, 60, 66, and 72-cell solar modules. We’ll cover some key highlights below, but if you are a solar supply chain professional we highly recommend downloading and reading the entire guide.
Packaging inspection upon arrival
When your shipment arrives, first verify that the delivered modules match your order by checking their serial numbers and model labels against the shipping label. Then, carefully inspect the packaging for signs of any visible damage, which can be a telltale indication of damage to modules themselves. Common issues may include:
If you discover your modules are damaged, let the driver know immediately and notify the carrier and LONGi staff within 24 hours of delivery. Then, within 48 hours of delivery, record and share key information with carrier dispatch and LONGi staff, including truck container ID, arrival and unload time and date, pallet ID, and photos and descriptions of damaged pallets and modules as applicable.
Maneuvering pallets with a forklift
Improper use of forklifts while moving pallets is a frequent cause of module damage, and several pages of the handling guide are dedicated to depicting various “dos and don’ts” in this area. With experienced operators and adherence to these best practices, the risk of forklift accidents causing damage to pallets and modules can be minimized.
For example, backrest impacts are the most common cause of forklift module damage, but these can typically be avoided by measures including the insertion of the fork from the short side of the pallet, the use of a backrest greater than 48 inches, and taking care not to press the fork into the packaging cardboard. Another important “do” is to always use the right sized forklift forks based on the pallet size, and never use oversized forks. That means using a 72-inch fork for 72-cell modules and forks between 60 and 70 inches for 54, 60, and 66-cell modules.
Several other guidelines for safe forklift maneuvering are included in the handling guide, including specifications for loading from both the short side or long side when necessary, tips for positioning the pallets in transit as well as before loading and unloading, and more.
Storing, staging, and unpacking
The proper storing, staging, and unpacking of pallets are also critical for minimizing module damage. Store pallets in a covered, dry, and ventilated area, and keep them inside their cardboard packaging until ready for installation. Then, pallets should be staged in a flat, open, and dry location, and positioned next to a solid, self-standing support structure such as a tracker post or wall. Modules can then be removed from their packaging one at a time and leaned up against this support structure.
Once they are unpacked, avoid placing sharp or heavy objects on modules, which can cause glass damage. Similarly, the maximum stacking limit indicated on the pallet should never be exceeded. And, perhaps needless to say, one should never stand or walk on PV modules.
Moving and preparing modules for installation
When it’s time to start moving the modules to be installed, always have two people lift and carry each module. This is becoming an especially important safety requirement with the advent of heavier, larger-format modules for utility-scale solar projects.
Even with two people, a module should never be carried above the head, nor carried by its cables, connectors, or junction box. Connectors require special attention while moving, as they must be prevented from resting on the ground, and more generally kept dry and free of dust, dirt, or other foreign debris.
A handy reference for safe module handling
As noted above, this blog is only a quick summary of some of the key ways to avoid module damage risks during unpacking, handling, and storage. For a more complete reference, download a copy of LONGi’s field guide for unpacking, handling and storing solar modules.
