The Hidden Dangers of PoorlyInstalled Caravan Solar Panels

Solar panels are one of the most popular upgrades for caravan owners. They offer independence, convenience, and reliable off-grid power—when installed correctly.

However, mounting solar panels to a caravan roof is far more complex (and dangerous) than many people realise. A poor installation isn’t just a financial risk for the caravan owner—it can become a deadly hazard for other road users.

A Tragic Reminder of the Risks

A recent investigation in Tasmania highlighted the seriousness of improper solar panel mounting. A fatal accident occurred when a solar panel mount failed, sending the panel airborne at high speed. It struck the vehicle travelling behind, leading to a devastating outcome.

This incident shows just how critical it is to ensure roof-mounted solar panels are secured to the highest safety standards.

Why Silicone and a Screw Are Not Enough

Many DIY installers—and even some caravan repairers—treat solar panels like simple rooftop accessories. A dab of silicone and a screw might seem to hold a panel in place, but when you consider the forces at play, it’s completely inadequate.

When travelling at 100 km/h, you’re facing continuous wind pressure for hours at a time. Add in a road train coming the opposite direction, also doing 100 km/h, and you’re suddenly dealing with cross-draft forces exceeding 200 km/h.

Expecting a screw and a blob of sealant to withstand that pressure is not only unrealistic—it’s dangerous.

Positioning Matters More Than You Think

Where your solar panels sit on the caravan roof is just as important as how they’re secured.

• Mounting too far forward means the panel is constantly hit by the uprush of air from the tow vehicle, putting enormous pressure on the brackets.
• Incorrect spacing makes access for inspection difficult.
• Poor cable routing means joints and connectors can’t be serviced without removing the entire system.

Most installations never consider these essential factors.

The Problem With Stick-On Solar Panels

Stick-on or flexible solar panels may seem like a neat solution—but they come with serious drawbacks:

• Once bonded, they cannot be removed without destroying the roof surface.
• If installed on a fibreglass roof, removal will likely destroy the fibreglass itself.
• If placed across a floating roof joint, they can cause significant water ingress issues over time.
• They trap heat, reducing panel efficiency and shortening their lifespan.

What appears to be a quick upgrade can quickly turn into a major structural repair.

How Solar Panels Should Be Installed

A safe solar panel installation requires:

• Brackets tall enough to allow airflow underneath, helping panels stay cool and operate efficiently.
• Mounting brackets aligned north to south to reduce wind load while driving.
• A design that prevents debris buildup and allows access for inspection and maintenance.
• A secure fixing method that doesn’t just meet—but exceeds—cyclonic safety conditions.

Our Approach: Built for Strength and Safety

At Caravan Waterproofing WA, we don’t take chances with roof-mounted solar systems.

We remove all existing brackets and replace them with our own engineered mounting system, installed:

• North to south for optimal airflow and reduced wind pressure
• Glued and screwed for maximum security
• Integrated into the waterproofing system for complete structural protection

Our installations are designed to exceed cyclonic conditions, ensuring your solar panels stay firmly in place no matter where you travel.