Solar panels are built to withstand harsh weather, hail, wind, and decades of sun exposure. However, accidents happen. Falling branches, severe hailstorms, debris, or improper handling during installation can sometimes lead to cracked glass. When that happens, one of the first questions homeowners and business owners ask is: Can a cracked solar panel be repaired?
The answer depends on the severity of the damage — but in most cases, replacement is recommended over repair.
Understanding the Damage
Solar panels are made up of several layers: tempered glass, encapsulant material, photovoltaic (PV) cells, and a protective backsheet. The glass layer protects the sensitive internal components. If the outer glass cracks, moisture can enter the panel and damage the solar cells over time.
There are generally three types of cracks:
- Hairline cracks that may not immediately affect performance
- Surface cracks in the glass only
- Deep cracks that impact internal solar cells
The deeper the damage, the more likely it will reduce output and compromise safety.
Can It Be Repaired?
Technically, minor cosmetic cracks in the glass may not require immediate replacement if energy production remains stable. However, solar panels are sealed units. The glass cannot simply be swapped out like a windowpane. Attempting to reseal or patch a panel is typically ineffective and can void the manufacturer’s warranty.
Get Your Energy Independence
Because panels operate as part of a larger electrical system, a damaged panel may also create performance imbalances within the array.
In most cases, replacing the damaged panel is the safest and most reliable solution.
What Happens If You Leave It Alone?
A cracked panel may continue producing electricity for a while, especially if the internal cells are unaffected. However, over time:
- Moisture intrusion can corrode wiring
- Performance may decline gradually
- Electrical hotspots can develop
- Safety risks may increase
Ignoring visible damage can lead to larger system issues later.
Will Insurance Cover It?
Many homeowner and commercial property insurance policies cover solar panel damage caused by storms or accidents. It’s important to document the damage and contact both your installer and insurance provider promptly.
The Bottom Line
While minor cracks might not cause immediate failure, solar panels are not designed for field repair. Replacement is usually the most practical and long-term solution. If you notice visible damage or a drop in system performance, have a professional inspect your system to ensure it continues operating safely and efficiently for years to come.