Product Overview

Summary: This Solar Panel Installation Safe Operating Procedure sets out a clear, step-by-step method for installing photovoltaic (PV) systems safely, efficiently and in line with Australian WHS and electrical requirements. It helps your team manage high-risk work at heights, live electrical components and manual handling, while delivering consistent, high-quality installations for residential, commercial and industrial sites.

Solar panel installation involves a combination of high-risk construction work, electrical work and rooftop access, making it a critical area for robust WHS controls. This Safe Operating Procedure provides a structured, practical framework for managing each stage of a solar installation – from pre-start planning and roof access, through to mounting system installation, electrical connection, testing and commissioning. It is designed specifically for Australian conditions and regulatory requirements, including work at heights, electrical safety and environmental considerations such as heat, UV exposure and changing weather.

By implementing this SOP, solar businesses can significantly reduce the likelihood of falls from height, electrical shock, fire, dropped objects and musculoskeletal injuries. The document clearly defines roles and responsibilities, outlines mandatory pre-start checks, specifies required PPE and tools, and embeds Safe Work Method Statement (SWMS)-level controls for high-risk tasks. It also standardises quality and compliance steps – such as isolation, lock-out/tag-out, cable management, labelling and documentation – helping you demonstrate due diligence to clients, auditors and regulators while improving installation efficiency and customer satisfaction.

Key Benefits

• Ensure compliance with Australian WHS, electrical safety and working-at-heights requirements for rooftop solar installations.
• Reduce the risk of falls, electric shock, fire and manual handling injuries through clearly defined controls and safe work methods.
• Standardise installation practices across all crews, improving consistency, build quality and system performance.
• Streamline onboarding and competency assessment for new installers, apprentices and subcontractors with a clear reference procedure.
• Demonstrate due diligence to clients, regulators and insurers through documented, repeatable and auditable installation processes.

Who is this for?

• Solar Installers
• Electricians
• Electrical Contractors
• Rooftop Solar Team Leaders
• Site Supervisors
• WHS Managers
• Construction Project Managers
• Small Solar Business Owners
• Operations Managers – Renewable Energy
• Apprentice Electricians and Trade Assistants

Hazards Addressed

• Falls from height when accessing and working on roofs
• Trips and slips on pitched, fragile or wet roof surfaces
• Electric shock or arc flash from live electrical components
• Fire risk from incorrect wiring, poor terminations or damaged cables
• Dropped tools or materials striking people below
• Manual handling injuries from lifting and carrying panels, rails and inverters
• Heat stress, dehydration and UV exposure during outdoor work
• Structural failure or roof damage from incorrect mounting or overloading
• Exposure to asbestos or brittle roofing materials during roof penetrations
• Use of ladders, EWP and fall arrest systems without appropriate controls

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Abbreviations
• 3.0 Roles and Responsibilities (PCBU, Supervisor, Electrician, Installer, Spotter)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Required Competencies, Licences and Training
• 6.0 Required Tools, Equipment and Personal Protective Equipment (PPE)
• 7.0 Pre-Start Planning and Risk Assessment (including SWMS and JSA requirements)
• 8.0 Site Inspection, Access and Roof Condition Assessment
• 9.0 Working at Heights Controls (ladders, scaffolds, EWPs, fall arrest and edge protection)
• 10.0 Electrical Isolation, Lock-Out/Tag-Out and Verification of De-energisation
• 11.0 Panel and Mounting System Handling, Storage and Manual Handling Techniques
• 12.0 Installation of Mounting Hardware and Roof Penetrations
• 13.0 Solar Panel Placement, Fixing and Alignment
• 14.0 DC Cabling, String Configuration and Connector Termination
• 15.0 Inverter Mounting, AC Cabling and Switchboard Integration
• 16.0 Earthing, Bonding and Surge Protection Requirements
• 17.0 System Testing, Commissioning and Verification (insulation resistance, polarity, performance checks)
• 18.0 Labelling, Signage and Documentation Requirements
• 19.0 Housekeeping, Waste Management and Site Handover
• 20.0 Emergency Procedures (falls, electric shock, fire, extreme weather)
• 21.0 Inspection, Maintenance and Periodic Review of the SOP
• 22.0 Recordkeeping, Audit and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulation 2011 and state/territory equivalents – High Risk Construction Work and Electrical Work provisions
• Safe Work Australia – Code of Practice: Managing the Risk of Falls at Workplaces
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• AS/NZS 3000:2018 Electrical installations (Australian/New Zealand Wiring Rules)
• AS/NZS 5033:2021 Installation and safety requirements for photovoltaic (PV) arrays
• AS/NZS 1170.2:2021 Structural design actions – Wind actions (relevant to mounting systems)
• AS/NZS 1891 series: Industrial fall-arrest systems and devices
• AS/NZS 4501: Occupational protective clothing and AS/NZS 1337 / 1337.1: Eye protectors for industrial applications