The Hidden Costs of Cutting Corners on Solar Projects: What to Watch Out For

Solar energy is packed with benefits, from reducing electricity costs to boosting sustainability to even generating revenue. As organizations consider installing a system and begin to assess solar providers, it can be tempting to go with the least expensive option. However, this can lead to massive headaches and ultimately cost customers more in the long run. Here’s what you need to know about the risks and consequences of doing business with a cut-rate company, and why partnering with a quality partner like PowerFlex pays off.

How Some Solar Providers Cut Corners

Many solar providers compete aggressively on price, but what’s often left unsaid is how those savings are achieved. Common tactics include using substandard materials, skipping critical engineering steps, or ignoring essential safety protocols. While these shortcuts might reduce upfront costs, they can lead to expensive problems down the road.

Some of the most common areas where solar companies cut corners include:

• Materials and Equipment: Some companies use components that meet the bare minimum requirements, neglecting other factors like safety or ease of operation and maintenance. PowerFlex, however, does things differently. For example, instead of using manual circuit breakers at the POI (point of interconnection), we use motorized breakers that improve safety by reducing manual interaction with high-voltage equipment and enabling quick fault response, system automation, and real-time monitoring through remote controls. ‍
• Design and Engineering: Another way companies pinch pennies is by rushing through or skipping detailed engineering studies, which can have dire consequences. These evaluations include structural load analysis, electrical protection coordination, and arc flash studies, all of which are vital for system safety and performance. ‍
• Installation Practices: Using unqualified or poorly vetted subcontractors, failing to follow best practices, and ignoring manufacturer recommendations for equipment installation are major red flags. For example, some installers fail to use PVC conduits to protect cables in underground duct banks, neglect to install appropriate cable trays on roof-mounted installations to guard against UV and weather exposure, or do not properly secure conductors and raceways, causing them to shift over time. ‍
• Safety Measures: It’s hard to believe a company would skimp on safety, but it does happen. Overlooking surge protection, proper shutdown procedures, or regular site safety inspections are essential for protecting both workers and the finished system. Maintaining strict adherence to these protocols helps avoid serious accidents and malfunctions during the installation and beyond. ‍
• ‍Quality Assurance: Companies sometimes skip thorough quality assurance/quality control inspections or fail to document and resolve issues before project closeout. In contrast, PowerFlex is continuously improving engineering and QC processes using field knowledge. For instance, we require all quick disconnect connectors on a project to be of identical make and model, with contract drawings clearly stating what type of connectors subcontractors must use and in what locations. This avoids issues that come with mismatched mating connectors.

Poor Quality Impacts Solar Project Success

When companies cut corners, the repercussions can be significant. Poor-quality installations may lead to frequent system failures, costly repairs, and even safety hazards. Inadequate structural engineering can result in roof damage, while improper electrical work can create fire risks or void equipment warranties. These shortcuts often lead to system downtime, lost energy production, and higher insurance claims.

Costly project delays can also occur. If the work fails to meet building codes, fire codes, or other regulatory standards during inspections, rework becomes necessary, requiring additional time, resources, and expenses. These setbacks not only delay a single project milestone but also create a cascading effect that disrupts the entire schedule, delaying completion and reducing the expected return on investment.  

Choosing the Right Solar Provider

It’s imperative you choose a solar provider that emphasizes value so that your installation is compliant, efficient, and able to stand the test of time and the elements. At PowerFlex, we choose best-in-class materials, perform rigorous engineering, and adhere to strict safety protocols. Our projects are managed by experienced, certified professionals, and every step is documented and reviewed for quality assurance. For example, we use a third-party National Recognized Testing Laboratory (NRTL) for inspection and recertification of facility gear to maintain its original factory UL certification.  

We also require detailed safety plans, job hazard analyses, and method of procedure (MOP) reviews for every project. Our strict subcontractor selection and onboarding process is designed to ensure that every partner meets our high standards for safety, quality, and financial stability.

While doing things the right way comes with a higher price point, PowerFlex’s policy experts have vast experience securing the best incentives that can significantly reduce installation costs for customers. Our in-house incentive team specializes in identifying and winning available local, state, and federal funds to help offset project expenses.  

We provide you with detailed financial modeling of project economics, including all available funding sources and financing options, that can keep expenses at bay without sacrificing the long-term performance of your solar system. By leveraging various incentives and tax credits, we’ve reduced capital costs by 50–70% on customer projects.

Go Solar With PowerFlex

Commercial solar energy systems are designed to operate for 30 years or more — but not if quality is sacrificed. Working with a dependable provider like PowerFlex that won’t take shortcuts is key to the success of your system and its ability to generate return on investment through energy cost savings, as well as revenue opportunities like net metering and solar renewable energy certificates. That’s why so many of our biggest returning customers like Walmart, Target, and Prologis have trusted us to build a combined 150 large-scale solar systems to date.

If you’re considering solar for your property, reach out to PowerFlex right now. Our solar experts can walk you through the entire project process, including applying for incentive programs in your area that can offset implementation costs.