In this blog, aimed at the project manager, site supervisor or solar installer, we look at commercial solar panel installation on a high roof (13-14 metres).

Safety is paramount, and each approach has unique advantages, disadvantages, and cost considerations.

The Contenders:

•    Elevated Work Platform (EWP): A mobile platform for workers and materials.

•    Crane (Intact Pallets): Lifting large quantities of palletized panels.

•    Crane (Glaziers Cage): Lifting a cage containing multiple panels.

•    Panel Lifter: A smaller, mechanized device for lifting individual panels.

Method Comparison: Pros, Cons, and Safety

EWP

Pros:

•    Easy and safe access to the roof.

•    Versatile for various heights and locations.

Cons:

•    Expensive to rent or purchase.

•    Requires trained operators.

•    Limited reach and mobility on large roofs.

Safety:

•    An EWP Operation SWMS is required, outlining potential hazards like falls from height, equipment failure, and dropped objects.

•    Control measures include proper training, regular maintenance, secure setup, and use of PPE.

Crane (Intact Pallets)

Pros:

•    Lifts large quantities quickly, reducing overall lifting time.

•    Minimizes manual handling on the roof.

Cons:

•    Requires space for setup and operation.

•    Very expensive due to crane rental, operator, and setup costs.

•    Risk of damage if panels not properly secured.

Safety:

•    A Crane Lifting SWMS is required, addressing hazards like crane tipping, load drops, and equipment failure.

•    Control measures include certified operators, secure setup, exclusion zones, and regular inspections.

Crane (Glaziers Cage)

Pros:

•    Safer for panels, reducing damage during lifting.

•    Allows for controlled placement of panels.

Cons:

•    Requires space for setup and operation (multiple lifts needed).

•    High cost due to crane rental and operator.

•    May require additional handling on the roof.

Safety:

•    Similar safety considerations and SWMS as Crane (Intact Pallets).

Panel Lifter

Pros:

•    Cost-effective for smaller projects.

•    Easy to use and set up.

•    Ideal for tight spaces with limited access.

Cons:

•    Limited lifting capacity (multiple trips required).

•    Slower compared to crane methods.

•    Requires more manual handling on the roof.

•    Not suitable for very high or large-scale installations.

Safety:

•    A Manual Handling SWMS is required, addressing hazards like equipment tipping and manual handling injuries.

•    Control measures include proper setup, secure footing, and use of PPE.

Choosing the Right Method

The ideal method hinges on several factors, including:

•    Roof size and complexity

•    Budget

•    Site access

•    Number of panels

For large, open roofs with a significant budget, a crane (either intact pallets or glaziers cage) might be the most efficient option. For smaller projects or those with limited space, an EWP or panel lifter could be suitable.

Cost Considerations

While cost shouldn't be the sole factor, it's undeniably important.

Here's a breakdown of estimated costs to give you a better idea:

•    EWP: Renting an EWP for a day can range from $1,000 to $2,500 depending on size and reach. Purchasing an EWP is a significant investment, typically exceeding $50,000.

•    Crane: Crane rentals are priced based on size, capacity, and rental duration. For a high roof installation, expect costs between $2,000 and $5,000 per day, with additional fees for the operator and setup.

•    Glaziers Cage: This option generally adds $500 to $1,000 to standard crane rental costs due to the specialized cage.

•    Panel Lifter: Panel lifters are a more affordable option, ranging from $1,000 to $3,000 to purchase.

Remember, these are just estimates.

The actual cost will vary depending on your location, the specific equipment used, and the duration of the project. It's crucial to get quotes from various suppliers of this kind of machinery.

Here are some additional factors to consider when comparing costs:

•    Labor Costs: The number of workers required can vary depending on the chosen method. Cranes typically require a smaller crew compared to EWP or panel lifter installations due to their lifting capacity. This can impact labor costs.

•    Permitting Fees: Some localities may have specific permitting requirements for using cranes or EWPs on high roofs. Factor in any potential permitting fees when comparing quotes.

•    Project Complexity: Complex roof features or tight spaces might necessitate additional equipment or labor, impacting the overall cost.

Getting the Best Value

Don't solely focus on the initial equipment rental or purchase cost. Consider the total project cost, including labor, permits, and potential damage risks associated with each method.

Detailed SWMS Breakdown by Task

Here's a breakdown of the relevant SWMS (Safety Work Method Statement) for each task involved in high roof solar panel installation:

EWP Operation SWMS

Task Name: Setting Up EWP

•    Description: Positioning and stabilizing the EWP for use.

•    Potential Hazards: Tipping, falls from height, equipment failure.

•    Risk Ranking: High

•    Control and Safety Measures: Proper training, regular maintenance, secure setup, use of PPE.

Task Name: Operating EWP

•    Description: Using EWP to transport workers and equipment to roof.

•    Potential Hazards: Fall from platform, collision with obstacles.

•    Risk Ranking: High

•    Control and Safety Measures: Operator certification, adherence to safety protocols, spotters

Task Name: Panel Installation

•    Description: Installing panels from EWP.

•    Potential Hazards: Panel dropping, overexertion, electrical hazards.

•    Risk Ranking: Medium

•    Control and Safety Measures: Secure footing, proper lifting techniques, use of insulated tools.

Crane Lifting SWMS (for both Intact Pallets and Glaziers Cage)

Task Name: Crane Setup

•    Description: Setting up crane and securing area.

•    Potential Hazards: Crane tipping, load drop, equipment failure.

•    Risk Ranking: High

•    Control and Safety Measures: Certified operators, secure setup, exclusion zones, regular inspections.

Task Name: Lifting Panels (Intact Pallets or Glaziers Cage)

•    Description: Lifting pallets of panels or the glaziers cage to the roof.

•    Potential Hazards: Load swing, falling objects, crane overload.

•    Risk Ranking: High

•    Control and Safety Measures: Load securing, use of taglines, proper load calculations.

Task Name: Unloading Panels (for Glaziers Cage method only)

•    Description: Unloading and positioning panels on the roof from the glaziers cage.

•    Potential Hazards: Manual handling injuries, panel damage.

•    Risk Ranking: Medium

•    Control and Safety Measures: Team lifting techniques, careful handling, clear communication.

Manual Handling SWMS (for Panel Lifter method)

Task Name: Setting Up Panel Lifter

•    Description: Setting up and positioning the panel lifter.

•    Potential Hazards: Equipment tipping, manual handling injuries.

•    Risk Ranking: Medium

•    Control and Safety Measures: Proper setup, secure footing, use of PPE.

Task Name: Lifting Panels

•    Description: Lifting panels to the roof using panel lifter.

•    Potential Hazards: Falling panels, overexertion, equipment failure.

•    Risk Ranking: Medium

•    Control and Safety Measures: Secure load, proper lifting techniques, regular equipment checks.

Task Name: Unloading Panels

•    Description: Unloading and positioning panels on the roof.

•    Potential Hazards: Manual handling injuries, panel damage.

•    Risk Ranking: Medium

•    Control and Safety Measures: Team lifting techniques, careful handling, clear communication.

Conclusion

A commercial solar system is a wise investment for your customer and careful planning regarding installation on a high roof is crucial to the success of the whole project.

By understanding the pros, cons, safety considerations, cost comparisons, and SWMS requirements of different methods, you can make an informed decision. Remember, safety is paramount!

Stay tuned for some specialised on line training in this area soon!