| Aug 07, 2026
Abstract
Reusing decommissioned solar modules can extend their useful life, reduce waste and support a more circular photovoltaic industry. But good electrical performance does not necessarily mean a module is safe to put back into service.
In this work, we investigated one of the key barriers to large-scale PV module reuse: how to verify and maintain electrical insulation safety without making the qualification process prohibitively slow or expensive.
Analysis from a large-scale reuse pilot in Queensland showed why this matters. Of more than 2,200 decommissioned modules that met electrical performance requirements, around 15% still failed the IEC wet-leakage safety threshold. Performance screening alone therefore cannot reliably identify modules that are electrically safe for a second life.
We explored two complementary solutions. The first uses silicone-based backsheet coatings to restore and stabilise insulation resistance in ageing glass–backsheet modules. Accelerated environmental and electrical testing showed that coated modules maintained insulation resistance well above the IEC 61215 threshold. The second adapts conventional wet-leakage testing for higher-throughput reuse operations, including parallel testing of multiple modules.
Our results show that scalable PV reuse needs dedicated safety qualification alongside performance testing. With further automation and scale-up, both approaches could provide practical and cost-effective pathways for safely returning decommissioned solar modules to service.
In this work, we investigated one of the key barriers to large-scale PV module reuse: how to verify and maintain electrical insulation safety without making the qualification process prohibitively slow or expensive.
Analysis from a large-scale reuse pilot in Queensland showed why this matters. Of more than 2,200 decommissioned modules that met electrical performance requirements, around 15% still failed the IEC wet-leakage safety threshold. Performance screening alone therefore cannot reliably identify modules that are electrically safe for a second life.
We explored two complementary solutions. The first uses silicone-based backsheet coatings to restore and stabilise insulation resistance in ageing glass–backsheet modules. Accelerated environmental and electrical testing showed that coated modules maintained insulation resistance well above the IEC 61215 threshold. The second adapts conventional wet-leakage testing for higher-throughput reuse operations, including parallel testing of multiple modules.
Our results show that scalable PV reuse needs dedicated safety qualification alongside performance testing. With further automation and scale-up, both approaches could provide practical and cost-effective pathways for safely returning decommissioned solar modules to service.
Reference
R. Basnet, G. Nelson, I. Humphries, B. Ware, G. Beaucarne, L. Jones, M. McCann, and M. Ernst, "Electrical safety qualifications of decommissioned PV modules for scalable second-life deployment,", Solar Energy Materials and Solar Cells, vol. 307, p. 114619, 2026, doi: 10.1016/j.solmat.2026.114619.
Tags | Modules, Sustainability, Re-Use