Even the smallest installation error can lead to denied warranty claims or rejected insurance coverage. In South Africa’s solar industry, compliance with both manufacturer guidelines and SANS 10160 structural standards is critical, and insurance providers increasingly expect contractors to demonstrate proper installation practices and liability cover.
As highlighted by the Electrical Contractors Association of South Africa (ECASA), professional workmanship and valid Public Liability Insurance protect installers from financial risk in the event of faulty or non-compliant installations. Read ECASA’s full article here.
Common Solar Panel Mounting Bracket Mistakes, such as using the wrong bracket for a specific roof sheeting type, clamping panels outside of their load zones, or mounting them too close to the roof surface, can all compromise performance and safety.
At Valsa Engineering, we see how these errors often occur under pressure to complete installations quickly, but with the right understanding and locally engineered components, they are entirely preventable. Below are five of the most common Solar Panel Mounting Bracket Mistakes that every installer should avoid.
Using the Wrong Bracket for the Roof Sheeting
One of the most frequent Solar Panel Mounting Bracket Mistakes is using a bracket that does not match the specific roof sheeting profile. Each roof type in South Africa, whether IBR, Kliplok, or Springlok brackets, has unique geometry, height, and load behavior. Using the wrong bracket can lead to sheet deformation, water leakage, and reduced structural integrity.
At Valsa Engineering, we design and manufacture roof-specific brackets that ensure correct engagement, watertight performance, and long-term stability. Choosing the correct bracket not only prevents warranty issues but also guarantees compliance with South African wind load and uplift standards.
Read more: Solar Panel Mounting Brackets: Choosing the Right Fit for Your Roof in South Africa
Incorrect Clamping Zone Placement
Incorrect clamping position is another major Solar Panel Mounting Mistake that can lead to serious warranty and insurance issues. Each solar panel has defined clamping zones. Refer to solar panel manufacturer’s installation manual to identify these zones, which are specific areas designed by the manufacturer to handle wind load and structural stress.
If clamps are placed outside these zones, the pressure on the module frame becomes uneven, which can cause micro-cracks, panel distortion, and, under extreme weather, complete detachment.
Important: Panel manufacturer warranties are void if the solar panels are not mounted within the correct clamping zones, and insurance providers may reject claims if an installation does not follow these guidelines.
Valsa’s brackets are precisionly engineered to align with the recommended clamping areas, ensuring even load transfer and full compliance with manufacturer standards.
Ignoring Exposure Zones and Wind Categories
A less visible but equally costly Solar Panel Mounting Bracket Mistake is overlooking the site’s exposure zone and wind category. Every region in South Africa experiences different wind pressures, and SANS 10160 loading conditions clearly define what these forces mean for roof structures and solar systems.
When installers use the same bracket spacing or mounting layout across multiple sites without considering exposure, uplift, or regional wind speed, the system can fail prematurely. Panels may loosen over time, brackets can deform, and water can enter through stressed roof seams.
To prevent this, always confirm the project’s wind category before installation. Valsa Engineering designs each bracket system to meet local load demands, providing reliable performance from coastal high-wind areas to inland regions with lighter conditions. Matching the correct bracket layout and spacing ensures both safety and compliance.
Insufficient Ventilation Between Panels and Roof Sheeting
Many installers underestimate the importance of maintaining proper clearance between the solar panel and the roof sheeting, one of the most common Solar Panel Mounting Bracket Mistakes in South Africa. When panels sit too close to the roof, heat accumulates beneath them, reducing electrical efficiency and power generation. Further accelerating material wear on both the panel and the roof.
Insufficient airflow also traps moisture, which can corrode metal sheeting and cause premature bracket deterioration. By ensuring a sufficient gap between the panel and roof surface, airflow is improved, temperature is controlled, and long-term performance is optimized. Refer to panel manufacturer’s installation manual for correct spacing between panels and the roof sheeting.
All Valsa solar mounting systems are designed with engineered standoff heights that balance structural strength and ventilation efficiency. A small adjustment in clearance can significantly extend power generation and the lifespan of both the mounting structure and the panels themselves.
Overtightening or Misalignment During Installation
The final and often overlooked Solar Panel Mounting Bracket Mistake involves overtightening bolts or misaligning brackets during installation. While installers may assume tighter means stronger, excessive torque can distort clamps, damage panel frames, and create uneven load distribution across the array.
Similarly, small misalignments across multiple rows can lead to stress points that affect both performance and aesthetics. Panels that appear slightly twisted or unevenly spaced can indicate a compromised structure beneath the surface.
Valsa brackets are precisionly engineered for quick, consistent installation. Following torque specifications and alignment checks ensures optimal performance and prevents long term fatigue or corrosion issues. Always use calibrated tools and check alignment after every few brackets to maintain accuracy throughout the project.
How to Prevent Solar Panel Mounting Bracket Mistakes
The best way to avoid Solar Panel Mounting Bracket Mistakes is through proper planning, specification, and collaboration before installation begins. Every successful solar project starts with understanding the structure, matching the right bracket to the roof profile, and verifying the correct clamping and load conditions early in the design phase.
At Valsa Engineering, we believe support does not stop at supply. Our in-house engineering and technical teams work closely with solar installers to ensure each system is built on sound mechanical principles. From helping identify the correct roof sheeting and bracket type, to reviewing structural layouts and providing guidance on SANS 10160 load compliance, we are here to help from the quotation stage to final commissioning.
Installers often tell us that having local support makes all the difference. Because Valsa designs and manufactures in South Africa, our turnaround times are faster, our stock is readily available, and our team understands local installation challenges first-hand. Whether you’re on-site needing bracket advice, or preparing drawings for tender submission, our engineers are only a phone call away.
We also provide technical documentation, pull test data, and product information sheets to assist installers in achieving full compliance and client confidence. This end-to-end support ensures that every project backed by Valsa brackets delivers lasting performance, structural integrity, and peace of mind.
Avoiding these Solar Panel Mounting Bracket Mistakes is one of the most effective ways to protect your client’s investment and maintain manufacturer and insurance compliance. Each error, though small on its own, can have major consequences – from reduced system lifespan to denied warranty claims or costly structural rework.
South Africa’s diverse roof sheeting profiles, high wind conditions, and harsh environmental factors require solar mounting systems that are engineered for strength, precision, and endurance. By combining locally manufactured brackets with verified installation practices, installers can deliver projects that meet both structural and aesthetic expectations.
At Valsa Engineering, we don’t just design and manufacture components, we partner with our installers to build success. Our products are tested under real world South African conditions, ensuring proven reliability and consistent performance. With expert guidance, local stock, and ongoing technical support, we help ensure every solar system stands strong, from the first bolt to the final inspection.
