The Importance of Utilizing Third-Party QA/QC Inspectors During Solar Construction
One-way EPCs and owners can improve the quality and long-term success of their solar projects is by utilizing third-party QA/QC inspections during construction. Third-party Quality Assurance and Quality Control (QA/QC) inspections provide an expert independent set of eyes in the field to document equipment failures, installation mistakes, or poor workmanship that needs correction. By identifying deficiencies early, third-party inspectors can help EPCs and owners address problems before they lead to costly commissioning or operational problems.
What are Third-Party QA/QC Inspections?
Third-party QA/QC inspection involves an independent contractor or inspection team evaluating construction progress in the field against the project's drawings, specifications, applicable standards, and quality requirements. These inspections can take place throughout the construction lifespan, before commissioning begins, or during commissioning.
Unlike an internal construction contractor, a third-party inspector is not directly responsible for performing the installation, and their sole purpose is to provide unbiased expertise to verify the quality and workmanship of projects, as well as offer extra support on-site.
Depending on the project and support, inspections can cover areas such as:
Module installation
Racking and tracker systems
Inverters
DC wiring and cable management
Connectors and terminations
Combiner boxes
Panelboards
Raceway and Enclosures
Grounding and bonding
Medium-voltage equipment
Points of interconnection
Equipment installation
Equipment pads
Torque verification
Labeling
Trenching and underground systems
Fencing and structures
Fiber and communications infrastructure
General workmanship and installation quality
Overall site cleanliness and safety hazards
Depending on your QA/QC contractor, they may also be able to offer additional services such as creating punch lists for repairs, providing additional testing to diagnose issues, or repair support on site. Talk to your third-party QA/QC contractor about your pain points and how they can help support your projects.
Why Is QA/QC Important on Solar Projects?
Utility-scale solar projects contain thousands—or even millions—of components that all need to be installed correctly and consistently. A relatively small installation issue can have consequences beyond the individual component. An installation error can sometimes cause catastrophic damage to equipment or personnel during energization or during the operational years of a project.
For example, improper cable routing or an insufficient bend radius may place unnecessary stress on conductors. A loose electrical connection can create resistance and heat. Grounding or bonding deficiencies can create safety concerns and affect system performance.
Finding these issues during construction is generally much easier and less expensive than discovering them after the project has reached commissioning or operation.
Why use an independent third-party for QA/QC?
Timing
One advantage of utilizing a third-party contractor for QA/QC is timing and staffing. EPC crews can focus on moving along with construction, while independent inspectors can verify work and detect any deficiencies. If an installation deficiency is discovered while crews are still working in the area, the issues can often be corrected quickly. The goal is to support construction crews so they are not spread too thin and construction timelines can move along without delays.
Providing Unbiased Perspective
Construction teams have their own quality-control processes, but an independent inspection provides another level of oversight. A third-party inspector can evaluate the work without being responsible for the installation itself. This can help EPCs and owners obtain an objective assessment of construction quality and identify issues that may have been overlooked during routine internal inspections.
Expertise
Companies that focus on QA/QC and inspection work are trained and experienced in finding deficiencies in the field. They know common installation issues, where failures usually take place, and are great at comparing site drawings and specifications to what they discover in the field. QA/QC Inspectors are not only an “extra set of eyes” but an experienced expert who will greatly benefit the project’s success.
Documentation
A good third-party inspection doesn’t end when an issue is identified but must be followed up with clear documentation.
Each project may have different requirements, and it’s best to find a third-party contractor that can tailor the deliverables to the needs of the project. However, some of the deliverables in a QA/QC inspection may be:
Photographs of deficiencies
Checklist for visual inspections of all major components and equipment
Detailed description of findings
Recommended corrective action
Punch-list submittal
Verification of completed corrections
Quality documentation gives project stakeholders a clear understanding of what was found, where it was found, and whether it was corrected. It also creates a valuable record that can be referenced during commissioning, turnover, and future O&M activities.
How Third-Party QA/QC Benefits EPCs
Third-party inspections aren't just beneficial to owners. They can also provide significant value to EPCs, even to those with in-house capabilities.
A third-party QA/QC contractor can provide additional field resources when internal teams are stretched thin, help identify recurring installation issues, and give project management greater visibility into field conditions. An EPC that uses independent QA/QC support also builds trust with the project owner and stakeholders that they are committed to quality and long-term asset performance.
A third party can essentially function as an extension of the EPC's project team—providing specialized field expertise without taking over the EPC's responsibilities.
How Third-Party QA/QC Benefits Solar Owners
For owners and asset managers, independent QA/QC provides another layer of confidence that the project has been constructed according to the intended requirements.
An owner may not have personnel on-site every day throughout construction. A third-party contractor can provide independent field verification and documentation on the owner's behalf.
This can help owners better understand:
Whether installation meets project requirements
What deficiencies were identified
How deficiencies were corrected
Whether recurring issues exist
Whether the project is ready to move into commissioning
The result is greater visibility into construction quality before the asset is turned over for long-term operation.
Third-Party QA/QC Is About Risk Reduction
No solar project is going to be completely free of construction issues. The objective of QA/QC isn't to eliminate every potential problem—it is to identify issues early enough that they can be addressed efficiently.
An experienced third-party contractor brings unbiased perspective, field experience, specialized knowledge, and documentation to the project.
For EPCs and owners, that additional layer of verification can help reduce construction risk, support a smoother commissioning process, and protect the long-term performance of the solar asset.
Third-Party Solar QA/QC from Day Electric
Day Electric provides third-party QA/QC inspection services for commercial and utility-scale solar projects using our own in-house inspectors with many years of solar experience.
Our team can support projects with inspections, QA/QC documentation, system testing, third-party commissioning, troubleshooting, repairs, and other field services.
Whether you need additional support during construction and commissioning or third-party QA/QC inspections before commissioning, Day Electric can help identify issues early and provide the documentation needed to move the project forward.
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