Roof Repair With Solar Panels: A Contractor's 15-Year Perspective on Getting It Right

I have been repairing and replacing roofs in Texas for over fifteen years. Our company has completed more than 2,500 roofing projects. We hold certifications from major manufacturers like GAF and Owens Corning. We have also worked on hundreds of homes with solar panel systems. This experience gives me a unique view of this complex topic. I want to share that knowledge with you today. This article exists to solve a very specific and stressful problem for homeowners. What do you do when your roof needs repair, but it is covered in expensive solar panels? This situation creates anxiety about costs, logistics, and protecting your investment. My goal is to answer that question completely. I will give you the clear, practical information you need to make smart decisions. This guide is based on real projects we have completed for customers just like you. It uses manufacturer specifications, local building codes, and lessons learned in the field. My methodology is simple: explain the process, share real costs, and provide actionable steps. This will save you time, reduce stress, and help you protect your home and solar investment.

Understanding the Unique Challenge: Your Roof and Solar Are a System

Your roof and solar panels work together as one integrated system. The roof provides the structural foundation and weather protection. The solar panels sit on top, generating electricity. When one part needs attention, it affects the other. This is not like repairing a roof without solar. It requires specialized planning and coordination. The primary goal is to complete the roof repair without damaging the solar array. You must also ensure the solar system is reinstalled correctly to maintain its performance and warranty. This process involves multiple parties: the homeowner, the roofing contractor, and the solar installer. Clear communication between all three is critical for success. Understanding this interconnected relationship is the first step to a smooth project.

Why Solar Complicates Standard Roof Repairs

Solar panels add layers of complexity to any roofing job. First, they add significant weight to the roof structure. A typical solar array can weigh 2-4 pounds per square foot. The roofing contractor must assess if the underlying structure can handle this load after repairs. Second, the panels are connected with electrical wiring. This wiring runs across the roof surface and into your home. Disconnecting and reconnecting this system requires a licensed electrician or solar technician. Third, the mounting hardware penetrates the roof deck. These penetrations must be perfectly sealed to prevent leaks. During a repair, every single mounting point must be addressed. Finally, there is the risk of damaging the expensive panels themselves. A single cracked panel can cost over $300 to replace. These factors make planning and expertise absolutely essential.

The Step-by-Step Process: From Inspection to Completion

A successful roof repair with solar follows a proven sequence. Skipping steps or cutting corners leads to problems. We follow this method on every project to ensure quality and safety. The process begins with a thorough inspection and ends with system reactivation. Each phase has specific tasks and requires coordination between trades.

Phase 1: The Comprehensive Joint Inspection

The first step is a detailed inspection of both the roof and the solar system. This should involve the roofing contractor and the solar company. The roofer will assess the condition of the shingles, underlayment, and decking. They will look for signs of leaks, wind damage, or general wear. The solar technician will inspect the panels, wiring, and mounting hardware. They will check for micro-cracks, corrosion, or loose connections. Together, they will map the exact location of every mounting foot on the roof. This inspection determines the full scope of work. It answers key questions. Does the entire roof need replacement, or is a localized repair sufficient? Can the solar mounting hardware be reused, or does it need replacement? This phase creates the blueprint for the entire project.

Phase 2: Careful Solar Panel Removal and Storage

Once the plan is set, the solar panels must be safely removed. A qualified solar installer should always perform this task. They will first shut down the electrical system at the inverter and the main panel. This is a critical safety step. Then, they will disconnect the wiring between the panels and the racking system. The panels are then carefully unbolted from the mounting feet. Each panel is lifted off the roof and transported to a secure, designated storage area. We recommend storing them on a flat, clean surface like a driveway or garage floor. They should be covered with a breathable tarp to protect them from dust and debris. The mounting rails and feet are often left on the roof. The roofing crew will work around them during the repair.

Phase 3: Executing the Roof Repair or Replacement

With the solar panels safely stored, the roofing crew can begin their work. This phase is similar to a standard roofing project but with extra attention to detail. The crew will remove the old shingles and underlayment down to the roof deck. They will inspect the wood decking for rot or damage and make any necessary repairs. If the entire roof is being replaced, the old solar mounting feet will be removed. The roofer will then install new underlayment and the chosen roofing material. When installing new shingles, they must work around the locations where the solar feet will be reinstalled. This often involves leaving exposed areas of underlayment. Once the new roof is complete, the roofer will install new flashing or sealant around every mounting point. This is the most important step for preventing future leaks. According to the International Residential Code (IRC), all roof penetrations must be properly flashed. We follow manufacturer specifications for sealants like those from Henry Company or Geocel.

Phase 4: Solar System Reinstallation and Commissioning

After the roof is finished and the sealant has cured, the solar installer returns. They will reinstall the mounting rails and feet onto the new roof surface. They must ensure the mounting system is level and properly aligned. Then, they carefully place each solar panel back onto the racking and secure it. All electrical wiring is reconnected according to the National Electrical Code (NEC). Finally, the system is recommissioned. The solar technician will turn the system back on and test its performance. They will verify that all electrical connections are safe and that the system is producing power as expected. The homeowner should receive documentation of this final inspection. This is also the time to update any warranties with the new roof information.

Cost Breakdown: What Homeowners Really Pay

Cost is the biggest concern for most homeowners. Adding solar panels to a roof repair can increase the total project cost significantly. It is important to understand what you are paying for. The costs fall into three main categories: roofing labor and materials, solar labor, and potential upgrades. We will use real project examples from our files to illustrate typical price ranges. All costs are estimates and can vary based on your location, roof size, and system complexity.

Labor Costs for Solar Removal and Reinstallation

The single largest added cost is labor for the solar work. A solar company typically charges to remove, store, and reinstall the panels. This fee is separate from the roofing costs. For an average-sized residential system (6-8 kW), this service can cost between $3,000 and $6,000. The price depends on the number of panels, the complexity of the roof, and local labor rates. A simple ground-mounted system is cheaper to handle than a complex array on a steep, multi-faceted roof. Some solar installers offer a discount if they were the original installer. Always get a detailed written quote from the solar company before proceeding. This quote should include all labor, any needed replacement parts, and the recommissioning fee.

Material and Roofing Upgrade Costs

The roofing costs themselves may also be higher. The roofer must spend extra time working around the mounting hardware. They may need to use specialized flashing or sealants. If the solar mounting feet are old or corroded, they may need to be replaced. A new set of mounting hardware for a full system can cost $1,000 to $2,000. Furthermore, this is often the ideal time to upgrade your roofing materials. Since the panels are off, you can install a more durable, longer-lasting roof. For example, upgrading from standard 3-tab shingles to architectural shingles or even a metal roof adds to the material cost. However, this investment can extend the life of your roof and provide better protection for your solar investment. We often recommend GAF Timberline HDZ shingles for their durability and wind warranty.

Real Project Cost Example

Let's look at a real project we completed in Kingwood last year. The homeowner had a 2,000 square foot roof with a 7 kW solar system (20 panels). The roof had storm damage and needed a full replacement. Here was the final breakdown: Roof replacement with architectural shingles: $14,500. Solar removal, storage, and reinstallation by the original solar company: $4,200. Replacement of 30% of the corroded mounting hardware: $800. Total Project Cost: $19,500. The homeowner used their insurance settlement to cover the roof replacement cost. They paid the solar and hardware costs out-of-pocket. This is a very common scenario. The key is to get separate, detailed quotes for each portion of the work.

Material Considerations: Choosing the Right Roof for Solar

The type of roofing material you choose directly impacts your solar system. Some materials are better suited for solar installations than others. The ideal roof is durable, has a long lifespan, and allows for secure mounting. You must consider the compatibility between the roofing material and the solar mounting system. The goal is to create a seamless, watertight integration that will last for decades.

Asphalt Shingles: The Most Common Choice

Asphalt shingles are the most common roofing material in North America. They are also very compatible with solar panels. Most solar racking systems are designed to mount directly onto asphalt shingles using lag bolts that penetrate the roof deck. When installed correctly with proper flashing, this creates a reliable seal. The main consideration is the shingle's lifespan. Standard 3-tab shingles last 15-20 years. Architectural or dimensional shingles last 25-30 years. Since solar panels often have a 25-year warranty, it makes sense to pair them with a roof of similar longevity. Replacing a roof under solar panels after only 10 years is very expensive. Always choose high-quality shingles from reputable manufacturers like Owens Corning or CertainTeed.

Metal Roofing: A Premium, Long-Lasting Option

Metal roofs are an excellent choice for homes with solar. They are extremely durable, with lifespans of 40-70 years. This often exceeds the life of the solar panels themselves. Mounting solar on a metal roof is different. Instead of penetrating the roof with bolts, installers often use clamps that attach to the standing seams of the metal panels. This is a non-penetrating method that preserves the roof's watertight integrity. It can be more expensive than shingle mounting but offers superior leak protection. If you are replacing your roof and plan to keep solar for the long term, a metal roof is a fantastic investment. It provides a stable, long-lasting foundation for your energy system.

Tile and Slate Roofs: Specialized Installation Required

Tile and slate roofs are beautiful and long-lasting. However, they present unique challenges for solar installation and future repairs. The tiles are brittle and can break easily if walked on. Solar installers use special mounting systems that hook under the tiles or replace specific tiles with custom mounting tiles. When a repair is needed, the process is more delicate and time-consuming. Each tile around a mounting point must be carefully removed and later replaced. This requires a roofing crew experienced with these materials. The labor cost for solar removal and reinstallation on a tile roof can be 50-100% higher than on an asphalt shingle roof. If you have a tile roof, it is crucial to work with contractors who have specific experience with both tile and solar.

Insurance, Warranties, and Protecting Your Investment

Your roof and solar panels are major investments. Protecting them with proper insurance and understanding warranties is vital. The interaction between roof repairs and existing warranties can be confusing. A misstep can void valuable coverage. Let's clarify how to navigate these important protections.

Navigating Homeowners Insurance Claims

If your roof damage is caused by a covered peril like hail or wind, your homeowners insurance should cover the repair or replacement. This includes the cost to remove and reinstall the solar panels. The insurance industry recognizes this as a necessary cost to complete the covered repair. However, you must document everything. When you file your claim, explicitly state that you have a solar panel system on the roof. The insurance adjuster will need to include the cost of solar handling in their estimate. You may need to provide quotes from solar companies to justify this cost. It is your responsibility to manage this process. Do not assume the adjuster will automatically include it. For more information, review resources from the Insurance Information Institute.

Understanding Solar Panel and Roofing Warranties

Warranties are a critical concern. A roof repair can affect three main warranties: the solar panel product warranty, the solar installer's workmanship warranty, and the roofing manufacturer's warranty. The key is to use qualified, licensed professionals for each task. Most solar panel manufacturers will not void their product warranty simply because the panels were removed for a roof repair. However, if an unqualified person damages the panels during removal, that damage would not be covered. Similarly, the roofing manufacturer's warranty requires proper installation. If the solar mounting penetrations are not flashed according to the roofer's specifications, it could void the roof warranty. Always inform both the solar company and the roofing manufacturer about the project. Request written confirmation that using their certified installers will keep the warranties intact.

Practical Tips from the Field: A Contractor's Advice

After hundreds of these projects, we have learned what works and what causes headaches. Here is my best practical advice for any homeowner facing this situation. These tips come directly from our field experience and customer feedback.

• Plan for the Long Term First: Before repairing, ask yourself: How old is my current roof? If it is more than 15 years old, a full replacement is almost always the smarter choice. Paying to remove and reinstall solar twice in a short period is not economical.
• Get Multiple Quotes, But Compare Apples to Apples: Get at least three quotes from roofing contractors. Make sure each quote includes a line item for coordinating with the solar installer. Also, get two or three quotes from solar companies for the removal/reinstall work.
• Verify Licenses and Insurance: Confirm that both your roofer and solar installer are properly licensed and insured. Ask for copies of their liability insurance and workers' compensation certificates. This protects you if an accident occurs on your property.
• Create a Single Point of Contact: Designate one person, either from the roofing company or yourself, to coordinate all scheduling between the roofer and solar installer. Clear communication prevents delays and mistakes.
• Inspect the Stored Panels: Once the solar panels are removed and stored, do a quick visual inspection with the solar technician. Note any pre-existing cracks or damage. This avoids disputes later about who caused any new damage.
• Consider an Electrical Upgrade: If your electrical panel or wiring is old, this is a good time to consider an upgrade. Having the solar system disconnected makes it easier for an electrician to work on your home's electrical system.
• Review Local Permits: Most jurisdictions require a permit for a roof replacement. Some also require a permit for disconnecting/reconnecting a solar system. Your contractors should handle this, but you should ask for proof that permits are pulled and inspections are scheduled.

Frequently Asked Questions (FAQ)

Can I just repair the roof around the solar panels?

This is rarely possible or advisable. Roofing repairs require clear access to the damaged area. Solar panels and their racking cover large sections of the roof. To properly inspect, prepare, and seal the roof deck, the panels in the affected area must be removed. Attempting to work around them leads to poor repairs and almost certainly voids warranties.

Who is responsible if my solar panels get damaged during the roof repair?

Responsibility depends on who causes the damage. The roofing contractor's insurance should cover damage they cause. The solar installer's insurance should cover damage they cause during removal or reinstallation. This is why verifying insurance is so important. A clear contract stating each party's responsibilities is your best protection.

How long will the whole process take?

A standard roof replacement takes 2-4 days. Adding solar to the process can extend the timeline to 1-2 weeks. The extra time is for scheduling the solar removal, completing the roof work, allowing sealants to cure, and then scheduling the solar reinstallation. Weather delays can also affect the schedule. Plan for at least two weeks of disruption.

Will my solar panels produce less power after being reinstalled?

No, they should not. If reinstalled correctly by a qualified technician, the system should perform identically. The solar company should test the system output after reconnection to ensure it meets its original specifications. Any significant drop in production would indicate an installation error.

Should I add more solar panels while the system is down?

This is an excellent time to consider an expansion. Since the system is already being taken apart, the incremental cost to add a few more panels is lower. However, you must check with your solar installer about inverter capacity and local utility interconnection rules. Also, discuss it with your roofer to ensure the roof structure can handle the added weight.

What if my solar company is out of business?

This is a common issue. If your original solar installer is no longer available, you will need to hire a different, qualified solar contractor. They can still remove and reinstall the system. They may need to source compatible mounting hardware if parts are missing. Get references and check their experience with your specific panel brand.

Can I do any of this work myself to save money?

We strongly advise against DIY for this project. Working on a roof is dangerous. Handling high-voltage solar electrical components is extremely hazardous and requires licensing. Improper installation can cause fires, leaks, and system failure. It will also void all manufacturer and workmanship warranties. The potential cost of a mistake far outweighs the labor savings.

Conclusion: A Smart Investment in Your Home's Future

Roof repair with solar panels is a complex but manageable project. The key is knowledge, planning, and hiring the right experts. View this not just as a repair, but as an opportunity to upgrade your home's entire protective shell and energy system. By investing in a high-quality roof now, you secure the foundation of your solar investment for decades to come. The process requires coordination and has significant costs, but the long-term benefits are substantial. You will have a new, worry-free roof and a solar system that continues to save you money on energy bills. Start by getting a professional roof inspection. Then, contact your solar provider for a quote. With the information in this guide, you can approach the project with confidence. You can ask the right questions and make decisions that protect your home and your wallet. Your roof and solar panels are partners in protecting your home. Taking care of them together is the smartest path forward.