By Melissa Romer, director of project engineering
How do we design PV systems that not only survive but thrive in an era of extreme weather? The stakes are rising as data centers, AI, and electrification drive unprecedented demand for reliable power.
At Nextpower, this question is at the core of our engineering strategy, and it was the focus of a PV Resilience Workshop hosted by Sandia National Laboratories at the University of Louisiana at Lafayette in late 2025. Sandia and Nextpower are aligned to prepare a better path forward as solar power becomes a more essential asset to the grid and our electrified future, amid the consistent threat of extreme weather events.
I was invited to speak on a panel at this Sandia workshop focused on innovative design strategies, particularly around how tracker systems and site-level design must evolve to match the realities of climate volatility.
Here are three of my key takeaways:
1 - The design life of solar assets is increasing—as is climate risk
We're now seeing projects designed for 40 years of operation, not 25. At the same time, storms are becoming more frequent and more severe. Insurance companies have noticed: for example, hail damage to solar panels accounted for $250 million in damages from 2008 to 2025, according to GCube data.
That intersection—longer exposure and higher risk—requires a shift in our approach. Historical modeling is no longer enough. We need to design with forward-looking data, longer timeframes, and proven product resilience.
Fortunately, mitigation strategies are now materially impacting loss exposure and underwriting terms. A Nextpower utility customer in Arkansas utilized NX Horizon® trackers with Hail Pro™ automated stowing capability to reduce its insurance deductible by 50 percent. In a new case study, DESRI reports the success of Hail Pro amid several hail storms across their GW-scale portfolio. Insurers are noticing this too by offering lower premiums for projects that incorporate Hail Pro 75° with automated stowing.
2 - Lab testing alone is not sufficient
I strongly support traditional methods like static and aero-elastic wind tunnel testing. But to truly understand how tracker systems respond to extreme weather, full-scale field validation is essential. Lab testing rarely captures the coupled interaction between large-format modules and tracker structures across dynamic stow configurations. With Nextpower’s Advanced Steel Frames now in our product portfolio, we are able to take an end-to-end system level engineering approach to dynamic and static loads, helping mitigate module breakage risk.
3 - Integrated intelligence drives resilience
Structural strength is essential, but true resilience emerges from intelligent integration—how hardware and software operate as a unified system across diverse site conditions. For example, Nextpower pairs the NX Horizon® solar tracker with Hail Pro™ hardware enhancements and NX Navigator™ control software to execute precision stow strategies in real time during wind, hail, and flood events.
This is where design innovations are key. Utilizing a design software that can assess all of these variables and iterate viable options for foundations, tracker height, and control strategy quickly will save time and money while reducing risks associated with any extreme weather event.
Design for resilience today
Developers, owners, and operators who want to translate resilient design into measurable project outcomes should act early. We invite our customers to explore DesignworX™, Nextpower’s collaborative front-end optimization program that empowers partners to make smarter, data-driven decisions from the start.
DesignworX brings together:
Site-specific geotechnical, hydrological, and environmental data
Forward-looking climate modeling aligned with extended asset life assumptions
Iterative foundation strategy modeling across heterogeneous soil conditions
Tracker configuration and elevation optimization for terrain and flood variability
Integrated control logic planning for dynamic stow strategies
Insurance-informed risk inputs to align engineering decisions with underwriting realities
Through DesignworX, partners will understand best practices /optimization through:
Comparing pile, helical , and ground screw solutions using scenario-based foundation modeling
Simulate tracker elevation and foundation adjustments in flood-prone or erosion-sensitive zones
Optimize row spacing, terrain-following geometry, and stow angles for site-specific wind regimes
Align tracker control logic and stow protocols with insurer performance criteria
This reduces late-stage redesign risk, shortens development cycles, and helps developers make capital allocation decisions with greater confidence.
The climate is shifting, and demand is increasing – and our design standards must stay ahead of both. At Nextpower, we’re not just designing for today—we’re engineering systems built to withstand what comes next.
Contact the DesignworX team: designworx@nextpower.com