Solar panels cracked by hail

This page is about visibly broken or cracked glass. For hidden micro-cracks, snail trails and hot spots on panels that look whole, read our guide to solar panel hot spots and cracks.

Safety first. A broken panel still produces DC voltage in daylight, and the rest of the string adds to it. Broken glass can expose live cell connections, and rain on a broken panel can make the frame and structure unsafe to touch. Do not walk on the array, touch broken panels or hose them down. If the inverter shows an isolation or earth fault alarm, keep people off the roof until an engineer has isolated the string.

Solar panel broken glass: what it means

Most solar panels use toughened (tempered) front glass, a few millimetres thick. When toughened glass breaks, it usually shatters into a web of small pieces that stay in the frame, held by the encapsulant behind them. That is why a broken solar plate often looks "crazed" rather than missing glass.

Once the glass breaks:

• Water gets in through the cracks and reaches the cells, solder ribbons and encapsulant.
• Insulation drops, so the inverter may raise an isolation or earth fault alarm, especially on damp mornings. See inverter isolation fault.
• Cells crack under the broken glass, creating hot spots that can scorch the back sheet.
• Output falls, sometimes slowly, sometimes suddenly as damage spreads.

Quick-check table: broken solar plate

Safe owner checks

1. Look from a safe place, such as the ground, a staircase landing or the roof edge, without stepping onto the array.
2. Photograph everything: each damaged panel, its label if visible without touching, the clamps and structure around it, and the whole array. Note the date and weather.
3. Check the app. Look for alarms and compare string data. A damaged panel usually pulls down its whole string; see one string low output.
4. Do not cover or tape the panel. Tape and sheets trap water and heat, and you would need to touch the array to fit them.
5. Keep people off the roof, including cleaners and children, until an engineer has made the string safe.
6. Gather documents: the invoice or quotation, panel serial numbers, warranty papers and any insurance policy.
7. Send it all to your installer with the inverter model and alarm text.

Cracked solar panel repair: why we recommend replacement

Repair films, resins and clear coatings are sold for cracked panels. They may slow water entry for a while, but they do not restore the panel's tested insulation, its fire and electrical safety rating, or its hail resistance, and the damage underneath usually keeps spreading. A manufacturer or insurer is unlikely to accept a patched panel. On a rooftop string running at several hundred volts DC, we recommend replacing the panel rather than patching it.

What an engineer will check

• Isolate the string and confirm it is safe before touching the damaged panel.
• Test insulation resistance of the string to confirm the fault is limited to the broken panel and not also in cables or connectors.
• Find the cause: hail, a falling object, wind uplift, over-tightened clamps, a twisting structure, or thermal stress from a shadow or a partly covered panel.
• Check neighbouring panels for cracks, chips and loosened clamps, and the structure for bent rails or loose bolts.
• Choose a replacement that matches the string. The new panel's voltage and current should be close to the others, so it does not limit the string. If the same model is no longer available, the engineer may rearrange strings. See mixing different solar panels.
• Connect it properly, with matching connectors on each joint, and re-test the string.
• Record serial numbers of the removed and new panels for your warranty file.

Replacement panels should be genuine, first-grade stock; see how to check genuine solar panels. For current replacement prices, see our solar panel price page.

Hail damage solar panel: what Punjab owners should know

Spring hail and summer storms can break panels in Punjab. In May 2025, a severe storm across Punjab left 19 people dead, and Dawn reported around two dozen incidents of solar panels and billboards falling, including damage to panels in Lahore.

Panels are certified against a basic hail test, which commonly uses ice balls of about 25 mm. Larger hail can crack or shatter panels. Research on front-glass thickness found thicker glass resisted bigger hailstones better: panels with 2.8 mm and 3.2 mm glass suffered serious cracks from 45 mm hail, while 4 mm glass withstood 55 mm hail with only micro-cracks. Larger panels with thin glass are more fragile.

What helps:

• Panel choice: check the glass thickness and any extra hail testing on the datasheet when choosing panels for an exposed site.
• Structure and clamps: a rigid structure fixed to the right torque reduces stress cracks and wind damage; see L2, L3 and elevated structures and storm and lightning safety.
• Insurance: a dedicated solar policy or a property policy that covers natural perils is the main protection against hail.

Warranty, insurance and disposal

• Warranty: manufacturer warranties cover product defects, not impact, hail, storm or handling damage. A crack caused by a manufacturing defect may be covered. Manufacturer warranty terms are given per product,; see our solar warranty guide.
• Insurance: if you have a policy, report the damage quickly, before replacing anything, with photos and serial numbers.
• Disposal: a broken panel should not go on a rubbish heap or be sold as working. See disposing of old solar panels and batteries.

How Solar Works handles broken panels

On systems we install, structures are designed in-house and carry our 3-year structure warranty. If you are a Solar Works customer, WhatsApp 0336 666 4321 with photos of the panel, its label if visible, the app data and the inverter model. Complaints are handled by our own engineering staff, and our 1-year service warranty applies under the applicable project terms. See how after-sales service works.

We can also isolate and replace broken panels on systems installed by other companies, as a chargeable service.

Frequently asked questions

Can a solar panel with broken glass still work?

It may still produce power for a while, but water gets in, insulation drops and damage spreads. It can trigger earth faults and becomes a shock risk when wet. Have an engineer isolate and replace it.

Can cracked solar panel glass be repaired?

Films and resins exist, but they do not restore the panel's insulation, safety rating or hail resistance, and the damage underneath keeps spreading. For rooftop strings, replacement is the safe choice.

Is hail damage on solar panels covered by warranty?

Usually not. Manufacturer warranties cover defects in the product, not hail, storms or impact. Insurance that covers natural perils is the usual route for hail damage.

Why did my solar panel glass break without anything hitting it?

Possible causes include over-tightened clamps, a structure that twists or flexes, thermal stress, or damage from transport that was not visible at installation. A manufacturing defect is also possible. An engineer can check the clamps and structure to find the cause.

Do I need the same model to replace a broken solar plate?

Ideally a panel with very similar voltage and current, so it does not hold back the string. If the same model is no longer sold, an engineer can choose a close match or rearrange the strings.

Is it safe to clean a broken solar panel?

No. Water on a broken panel can make the frame and structure unsafe to touch. Stop cleaning that part of the array until the panel is replaced.

Do you replace broken panels on systems installed by others?

Yes, as a chargeable service across Punjab. Send photos and the panel label on WhatsApp 0336 666 4321 first so our engineers can advise.

Sources

1. Dawn, "19 dead, over 90 injured in Punjab" (storm of 24 May 2025)
2. American Ceramic Society, "Protecting solar panels from hail: The thicker the glass, the better": https://ceramics.org/ceramic-tech-today/protecting-solar-panels-from-hail-the-thicker-the-glass-the-better/
3. SDPI, "Is our solar ready for climate extremes?" (24 Apr 2025, on hail damage and the 25 mm certification test)
4. Kiwa PVEL, "Hail Stress Sequence" (hail testing beyond the IEC 61215 baseline)