Solar Site Survey Checklist (Free Download)

A poor site survey is the most expensive mistake you can make in solar sales. Everything downstream, system sizing, proposal pricing, DISCOM application, PM Surya Ghar eligibility, structural design, is built on the data you collect in that first 90-minute visit. Miss one critical item and you are making a second trip, revising your quote, or worse, discovering the problem after installation is complete.

This guide presents the full 24-point checklist, explains why each item matters, and highlights the 6 items that most installers skip, and regret. The QuickEstimate mobile app includes a built-in site survey module that captures all 24 points digitally, with photo capture and auto-fill to proposal.

Why most site surveys miss critical items

Walk with any sales engineer through a site survey and you will see the same pattern: they photograph the roof, count the panels that will fit, take a picture of the electricity bill, and leave. That takes 20–25 minutes. What they miss takes the next 3 weeks to discover.

The four most common expensive misses:

Sanctioned load not checked. The customer says they want a 5 kWp system. The EPC quotes a 5 kWp system. At DISCOM application, the sanctioned load is 3 kW, the system exceeds the allowed ratio and the application is rejected. The EPC now needs to either resize or wait 4–6 weeks for a load enhancement approval. Per Central Electricity Authority (CEA) technical standards, the solar system capacity for LT residential connections must not exceed the sanctioned connected load without a formal load enhancement approval.

Roof structural issue missed. Old RCC roofs in tier-2 cities sometimes have load-bearing constraints. A 3 kWp system adds 250–350 kg of dead load (panels + structure). On a roof with compromised structural integrity, this is a liability problem. A 5-minute walk on the roof and tapping hollow spots would have revealed it.

DISCOM feeder moratorium. Some DISCOM feeders are at capacity for net metering connections. This information is available at the local DISCOM subdivision office, but most EPCs never check. They install the system and then find out at Phase 6 inspection that the feeder is blocked for new net metering until capacity is upgraded. MNRE's rooftop solar guidelines require DISCOMs to process net metering applications within 30 days, but feeder capacity constraints can override this timeline in practice.

Customer documents not collected. PM Surya Ghar requires Aadhaar-linked bank account, PAN, and property ownership proof. If the customer's Aadhaar mobile number is not linked or the property is in a different family member's name, the subsidy application fails. Collecting and checking documents at the site survey saves 3–5 days of back-and-forth later.

Category 1, Structural (6 points)

The structural assessment determines whether the roof can support the system, where the panels can be placed, and what structural components are needed.

1. S1

   Roof type and material

   Note: RCC flat, metal (GI/colour-coated), clay/Mangalore tile, asbestos cement (AC sheet), or GI corrugated. Each requires different mounting hardware. AC sheet roofs require specialist support channels, never drill directly through AC sheets. Photograph the roof material closeup.

2. S2

   Usable roof area (sq ft)

   Measure the usable shadow-free area, excluding areas blocked by water tanks, parapet walls, staircase structures, and AC outdoor units. Mark it on a rough sketch. Rule of thumb: 100 sq ft per kWp of capacity needed.

3. S3

   Roof orientation and existing slope

   Note the compass orientation (south, south-west, east-west) and existing slope angle. Use a compass app on your phone. South-facing is optimal in India; east-west split is acceptable for larger systems. Note if the roof is flat (0–5° slope) or sloped (5–45°).

4. S4

   Roof structural condition and age

   Walk on the roof and tap hollow spots. Check for visible cracks, water seepage stains, or crumbling concrete. Ask the customer the age of the roof. For roofs over 20 years old or showing visible damage, recommend a structural assessment before proceeding. This protects both the customer and your liability.

5. S5

   Access and logistics

   How will the installation crew get panels to the roof? Is there a staircase wide enough for a 2.2m panel? Is there a terrace landing area? For 3rd floor and above without a staircase, rope-and-pulley or crane access adds ₹3,000–8,000 to the installation cost. Note this in your BOM at Phase 2.

6. S6

   Inverter mounting location

   Identify where the inverter will be wall-mounted. It must be in a shaded, ventilated location (a covered veranda wall, staircase landing, or meter room). Avoid direct sunlight, which reduces inverter efficiency and lifespan. Measure the cable run distance from the planned inverter location to the main distribution board (MDB).

Category 2, Electrical (4 points)

7. E1

   Sanctioned load and meter rating

   Read the sanctioned load from the latest electricity bill (typically shown in kW or kVA). This is the maximum solar system size most DISCOMs allow without a load enhancement application. Most DISCOMs cap solar system capacity at 100% of sanctioned load. Also note the meter rating (5A, 10A, 30A), undersized meters may need replacement.

8. E2

   Phase configuration (single or three-phase)

   Single-phase connections (most residential) accept single-phase inverters. Three-phase connections (large homes, commercial) require three-phase inverters or multiple single-phase inverters balanced across phases. Confirm by looking at the incoming supply cable, single-phase has 2 wires (phase + neutral), three-phase has 4 wires.

9. E3

   MDB location and earthing condition

   Note the location of the main distribution board (MDB) relative to the planned inverter location. Check whether an earth pit exists and if it appears maintained. Test earth resistance if possible with a clamp meter, readings above 10 ohms will cause a DISCOM inspection failure per CEA Safety Regulations.

10. E4

    Existing cable condition and space in DB

    Check whether the existing main cable entering the DB is rated for the additional solar generation current. Also check if there is space in the DB for an additional 32A or 63A MCB for the solar AC connection. If the DB is full, a new sub-panel or DB replacement needs to be factored into the BOM and quoted price.

Category 3, Shading (4 points)

Shading assessment is the most technical part of the site survey and the most commonly skipped. Even 5–10% shading on one panel in a string can reduce output by 25–30% due to the series string effect.

S7, Shadow sources: Photograph all shadow-casting objects visible from the roof: water tanks, parapet walls, staircase structures, antenna masts, cell towers, neighboring buildings, trees. Record their approximate height and direction relative to the proposed panel area.

S8, Seasonal shadow path: Note whether the shadow source is north, south, east, or west of the panel area. Objects to the north cast shadows that shift dramatically between summer and winter in India. An object that casts no shadow in May (high solar altitude angle) may cast a 3-metre shadow across the panel area in December (low solar altitude angle). For anything more than a quick visual check, use a free solar pathfinder app. Solar radiation data for Indian cities is available from MNRE's solar resource atlas and the Council on Energy, Environment and Water (CEEW).

S9, Tree shading risk: Trees grow. A tree that is currently 10 metres from the panel edge and casting no shadow may become a shading problem in 3–5 years. If there are trees within 20 metres to the south of the roof, note their height, species, and growth rate. Flag this in your proposal as an "annual shading review" AMC item.

S10, Panel orientation for shading avoidance: Given the shadow sources identified, determine the optimal panel orientation and layout. For roofs with unavoidable partial shading, recommend microinverters or power optimisers to limit the string mismatch penalty. This is a ₹8,000–15,000 upcharge on a 3 kWp system but can recover 15–20% of lost generation in partially shaded installations.

Category 4, DISCOM (4 points)

For detailed guidance on navigating DISCOM applications, see our DISCOM approval time benchmark guide. For the full net metering process by state, read what is net metering in India.

Category 5, Customer Documents (4 points)

PM Surya Ghar subsidy requires specific documents, and collecting them at the site visit eliminates a 3–5 day delay later. Check each of the following and photograph them (with the customer's consent).

CD1, Aadhaar card: Must be linked to the customer's mobile number. The PM Surya Ghar portal sends OTP verification to the registered Aadhaar mobile. If the mobile number is not linked, the OTP fails and the application stalls. Ask the customer to verify their Aadhaar-mobile linkage by calling the UIDAI helpline (1947) before you submit the application.

CD2, PAN card: Required for all PM Surya Ghar applications. If the property owner does not have a PAN, they can apply online at Income Tax India (incometax.gov.in), instant e-PAN is available with Aadhaar in 10 minutes. Note this is a blocker; you cannot submit the PM Surya Ghar application without PAN. The PM Surya Ghar application process is detailed at PM Surya Ghar National Portal.

CD3, Electricity bill (latest, with account number): Photographs the complete bill, not just the front page. The DISCOM application requires the account number, consumer name, and tariff category (LT Residential, HT Commercial, etc.) to match exactly. A mismatch between the name on the bill and the name on the Aadhaar delays the application by 5–10 days.

CD4, Bank account and property proof: Bank account details must match the name on the Aadhaar for PM Surya Ghar direct-benefit-transfer (DBT). Property proof, property tax receipt, registry copy, or registered rental agreement, is needed to confirm the customer is the occupant/owner of the property being solar-ised. For rented properties, the landlord's consent letter is also required.

Category 6, Commercial (2 points)

CM1, System size and type confirmed: Before leaving the site, confirm the kWp and system type (on-grid vs hybrid) with the customer. Use the 3-Step Residential Sizing Formula from our residential sizing guide to validate the size on-site. If the customer wants to compare on-grid vs hybrid pricing, note both configurations. For system type guidance, see our on-grid vs off-grid vs hybrid guide.

CM2, Work order and payment terms: Get a signed work order before leaving the site. Even a one-page letter of intent with the agreed system size, total cost, and payment milestones (advance + at installation + at commissioning) protects both parties. EPCs who skip this step lose 15–20% of confirmed leads to competitors who visit a second time.

The complete 24-point checklist, at a glance

How to get this as a PDF

The checklist above is the complete 24-point list. To use it in the field:

1. Screenshot or print this page and laminate it, a durable field reference your team uses on every site visit.
2. Use the QuickEstimate mobile app's built-in site survey module, it walks your field team through all 24 points with photo capture prompts, auto-saves to the cloud, and auto-populates the proposal form so you generate the quote directly from the survey without re-entering data.

The QuickEstimate site survey module was built specifically for Indian residential solar EPC teams. It includes DISCOM-specific prompts (which DISCOM are you working with?), captures geo-tagged photos, and flags PM Surya Ghar document gaps before you leave the site.

Common site survey mistakes, and the cost of each

How QuickEstimate fits

Imran runs a one-person solar installation business in Aurangabad. He does 8–10 site visits a month. Until he started using a structured checklist, he was making second trips to 3–4 sites every month, either for missed documents or to re-measure the roof because his original estimate was off.

• Proposal Generator, the site survey data feeds directly into the proposal template; Imran sends the quote from his phone within 30 minutes of completing the site visit, before he even leaves the parking area.
• Lead Capture, each site survey is automatically linked to the lead record so Imran can see, three weeks later, whether that Aurangabad customer got their DISCOM application submitted and where it stands.
• WhatsApp Follow-up, automatically sends the customer a WhatsApp message with their proposal PDF and a document checklist for PM Surya Ghar, so they start gathering their Aadhaar and PAN the same evening.

Try QuickEstimate free, 10 proposals/month, no card. The site survey module is available on the free plan.

What to do this week

1. Print or save this 24-point checklist and use it on your next site visit. Time yourself, a structured 90-minute survey using this checklist is faster and more complete than an unstructured 45-minute visit because you do not have to go back. Every check point takes 2–4 minutes; the whole checklist takes 60–90 minutes total.
2. Identify your top 3 missed-check-point patterns from recent projects. Look at your last 5 projects: at which phase did a problem emerge that could have been caught in the site survey? DISCOM rejection, wrong inverter specified, missing documents, each one traces back to a specific check point on this list.
3. Train your site engineers using this checklist before their next field visit. Role-play a 15-minute mock site survey in your office. The first time most engineers see the DISCOM feeder eligibility check (D2), they do not know how to verify it. Teach them which number to call at the local DISCOM subdivision office to get a 2-minute answer.

Frequently asked questions

How long should a solar site survey take?

A thorough residential solar site survey covering all 24 points takes 60–90 minutes on-site, plus 30–45 minutes for documentation and report filing afterward. Fast, 20-minute surveys are tempting but consistently lead to rework, second visits, and DISCOM application rejections. The extra 40–50 minutes spent on a complete survey saves 3–5 hours of rework downstream.

What is the most important item on the solar site survey checklist?

For PM Surya Ghar projects, the single most important check is E1 (Sanctioned Load) because it caps the maximum system size the DISCOM will approve. Getting this wrong means either a rejected application or an undersized system that does not meet the customer's savings target. D2 (Net Metering Feeder Eligibility) is equally critical, installing on a capped feeder wastes the entire installation cost.

Do I need special equipment for a solar site survey?

For a basic site survey, you need a smartphone (for photos and compass app), a measuring tape (for roof dimensions and cable run distances), and a copy of the customer's latest electricity bill. For more thorough surveys, a clamp meter for earth resistance testing, a solar pathfinder app for shading analysis, and a spirit level for roof tilt measurement add significant accuracy. Advanced tools like thermal cameras and IV curve tracers are used for AMC inspections, not initial surveys.

Can I do a solar site survey remotely using satellite imagery?

A preliminary assessment using Google Maps satellite view can estimate roof area, orientation, and obvious shadow sources. But it cannot replace a physical survey for: structural condition assessment, actual electrical measurements, document collection, and DISCOM feeder eligibility check. Use satellite imagery for pre-qualification (is this roof large enough to bother visiting?) but always do a physical survey before generating a proposal.

What documents does the customer need for a solar installation in India?

For PM Surya Ghar residential installations: Aadhaar card (Aadhaar-linked mobile number must be active), PAN card, latest electricity bill with account number, bank account details (Aadhaar-linked account), and property ownership proof. For non-PM Surya Ghar on-grid installations: latest electricity bill is sufficient for the DISCOM net metering application. Collect all documents at the site visit to avoid 3–5 days of back-and-forth.

How do I check if a DISCOM feeder is accepting new net metering connections?

Call the customer care number of your DISCOM and ask specifically about the feeder zone for that consumer number. Some DISCOMs also publish feeder status on their portals, MSEDCL has an online portal where you can check net metering application status by feeder. Alternatively, visit the local DISCOM subdivision office with the consumer number, the junior engineer (JE) at the sub-division typically knows which feeders are at capacity.

What is the difference between the site survey checklist and the installation checklist?

The site survey checklist covers what to assess before quoting and before installation begins. The installation checklist covers what to verify during each phase of the installation process. Both are covered in the solar installation process step-by-step guide. The site survey checklist is used by the sales/pre-sales engineer; the installation checklist is used by the installation crew and electrical contractor.

How does shading affect solar panel output?

In a string inverter system, the output of an entire string is limited by the weakest panel. If one panel in an 8-panel string is 50% shaded, the entire string may operate at 50% or less of rated output, not just 1/8 of the system. This is why shading analysis is critical. Microinverters and power optimisers eliminate this string mismatch effect by giving each panel independent MPPT. For roofs with unavoidable partial shading, these technologies recover 15–25% of generation compared to a standard string inverter setup.