Even if you don’t work in safety, you’ve probably seen them – solar fields. Stretching as far as the eye can see. Utility-scale solar projects can span hundreds – sometimes thousands – of acres and are reshaping the American energy landscape.
They may seem invasive to some, but these solar fields are actually really cool – and needed. Why? In short, solar fields generate energy from the sun – making them one of the safest and most sustainable energy sources currently available.
And these kinds of projects are getting popular. If you’re a safety manager looking for the right PPE to protect construction crews navigating risks across these massive, fast-moving job sites… this is the blog for you.
We know the hazards your crews face change dramatically as the project progresses, and we’re here to help. This blog breaks down:
- Common PPE mandates on solar projects
- Phase-specific hazards crews face + PPE recommendations
- Example PPE checklist an actual customer has used
- How HexArmor® can help
Common PPE mandates across solar projects
Why PPE is so important in solar power sites? In short – there’s a lot going on, all the time. There are typically six phases of a solar build, each with its own set of risks, challenges, and PPE needs. And while PPE requirements vary by contractor and project owner, most large utility-scale solar builds share consistent baseline standards.
Some common PPE mandates include:
- 100% glove use policies
- Cut-resistant gloves as a minimum requirement (typically ANSI/ISEA 105-2024 A4–A6)
- Safety glasses worn at all times
- Increasing adoption of Type2 safety helmets in place of traditional hard hats
- High-visibility apparel due to extensive equipment and vehicle traffic
- To improve safety, many EPC contractors (Engineering, Procurement, and Construction firms) and general contractors have moved toward mandatory glove programs and upgraded head protection requirements.
This is a great start. But it’s also important to understand how the performance requirements of PPE shift meaningfully as the work progresses.
Let’s dive into the risks and PPE required across each phase of the build.
Phase-specific hazards crews face + PPE recommendations
Hazards change as each phase of solar construction progresses. Jump to a specific section below:
Jump to:
- Phase 1: Pile driving & foundations
- Phase 2: Mechanical assembly & tracker installation
- Phase 3: Underground infrastructure & trenching
- Phase 4: Direct current (DC) cable installation
- Phase 5: Tracker wiring & electrical connections
- Phase 6: Inverter stations, substations, & grid tie-in
- Example PPE checklist for solar construction projects
Phase 1: Pile driving & foundations
Why this phase is important: Solar fields don’t begin with panels – they begin with foundations. Thousands of steel piles must be driven into the ground to support the racking systems that hold solar modules across the site.
From a safety standpoint, this phase introduces heavy mechanical exposure in an open, equipment-dense environment.
Primary hazards:
Hand hazards
- Abrasion and lacerations from handling steel piles and structural components
- Pinch points during positioning and alignment
- Impact exposure from tools and pile-driving equipment
Eye hazards
- Dust-heavy conditions that can affect visibility during pile driving and material handling
Hearing hazards
- High noise exposure from pile-driving equipment and heavy machinery
PPE recommendations
Hand protection (gloves)
- A4–A6 cut resistance for steel handling
- Back-of-hand impact protection
- High abrasion resistance for repeated contact with piles and hardware
- Strong grip performance in dusty environments
- Durable glove construction suited for repetitive material handling
Expert tip: Glove removal can become a compliance issue if dexterity or grip performance isn’t up to standard, particularly during pile alignment. Programs that balance protection with wearability tend to see better overall compliance during this stage.
Eye protection
- Safety eyewear with side shields or optional gasket systems to help protect against dust and debris
Hearing protection
- Earplugs or earmuffs designed to reduce exposure to high decibel levels from pile-driving equipment
Phase 2: Mechanical assembly & tracker installation
Why this phase is important: Once foundations are complete, the structure of the solar field begins to take shape. Mechanical crews install racking systems, torque tubes, rails, and mounting hardware that will ultimately support the solar panels.
This is one of the most hands-on and repetitive phases of the project, that requires the highest glove usage, with crews continuously assembling and adjusting steel components across large sections of the site.
Primary hazards:
Hand hazards
- Sharp edges on torque tubes and racking components
- Pinch points during alignment and bolt-up
- Crush injuries during positioning or shifting of steel materials
- Abrasion from repeated handling of galvanized steel
- Hand fatigue from extended tool use
Dropped or shifting materials
- Pipes, rails, and racking components can shift or fall during staging and assembly, creating potential impact hazards to hands, feet, and head.
PPE recommendations:
Hand protection (gloves)
- A4–A6 cut resistance
- Back-of-hand impact protection
- High abrasion resistance for repeated material handling
- Reliable grip in dusty conditions
- Dexterity for bolt tightening and torque work
Expert tip: Gloves that maintain grip and fine motor control help improve compliance, since workers are less likely to remove them during detailed assembly tasks.
Head and foot protection
- Type 2 safety helmets and safety footwear with composite or carbon toes can help reduce the risk of injuries when working around impact hazards.
Phase 3: Underground infrastructure & trenching
Why this phase is important: As mechanical assembly progresses above ground, another critical phase begins below the surface. Crews excavate trenches and install conduit systems that will carry electrical power from the solar rows back to inverter stations and combiner systems.
Primary hazards:
Hand hazards
- Abrasion and cuts from conduit materials, hardware, and construction components
- Contact with hand tools and powered equipment
- Vibration exposure from prolonged tool use
Head impact and fall hazards
- Slips, trips, and falls caused by uneven ground, loose soil, and shifting terrain
- Struck-by hazards from nearby heavy equipment or shifting materials around trenching areas
Expert tip: Because trenching work introduces constantly changing ground conditions, crews must navigate both environmental and mechanical hazards throughout the workday - and they need PPE that can keep up
PPE considerations:
Hand protection (gloves)
- A4-A6 cut resistance to protect against conduit edges and tools
- High abrasion resistance or padded palms for repeated contact with hardware and materials
- Durable material construction suited for heavier tasks
- Reliable grip performance in dirt and mud conditions
Head protection
- Type 2 safety helmets help protect against both top-of-head and lateral impacts when working around excavation zones and nearby equipment.
Foot protection
- Safety footwear designed for outdoor construction environments can help improve stability on uneven ground while protecting against dropped tools or materials.
High-visibility apparel also remains essential due to the amount of heavy equipment movement typically occurring around trenching operations.
Phase 4: Direct current (DC) cable installation
Why this phase is important: Once underground infrastructure is in place, the focus shifts to installing direct current (DC) cabling that connects rows of panels back to combiner boxes and inverter stations. These conductors form the electrical backbone of the solar field, carrying the energy generated by thousands of panels across the site.
Because cable installation involves repetitive handling and pulling operations, hand risks also remain the primary concern during this phase.
Primary hazards:
Hand hazards
- Friction and abrasion during cable pulling
- Lacerations from cable edges or cutting tools
- Hand fatigue and strain from repetitive pulling and handling
PPE recommendations:
Hand protection
- A4-A6 cut resistance to protect against cable edges and tools
- High abrasion resistance for pulling and handling materials
- Reliable grip for cable handling
- Sufficient dexterity for repetitive installation tasks
- Comfortable glove construction to support extended wear
Expert tip: Cable installation requires PPE that balances protection with dexterity so workers can safely handle cables, tools, and connectors throughout long installation runs.
Phase 5: Tracker wiring & electrical connections
Why this phase is important: As tracker systems and panel rows are installed, crews begin performing electrical connections that allow energy generated by the panels to flow through the system.
This phase requires precise hand movements and attention to detail as technicians work with connectors, wiring leads, zip ties, and small fasteners across long rows of installed equipment.
Primary hazards:
Hand hazards
- Lacerations from cable edges and tools
- Repetitive hand movements and fatigue during connector installation and wiring work
- Electrical exposure depending on the stage of system energization
- Abrasion from cable and component handling
Although full energization may not occur until later phases, electrical exposure awareness continues to increase as more systems are connected.
PPE recommendations:
Hand protection
- A4-A6 cut resistance for protection against cable edges and tools
- High dexterity for small component work
- Reliable grip for connectors and wiring
- Lightweight glove construction for comfort during extended tasks
- Arc flash + contact heat protection
Expert tip: At this stage, dexterity becomes just as important as protection. If gloves are too bulky or restrictive, workers may remove them to complete detailed work, increasing exposure risk. PPE programs that prioritize both protection and wearability tend to see higher compliance during this phase.
Phase 6: Inverter stations, substations, & grid tie-in
Why this phase is important: As construction progresses toward completion, solar energy produced by the panels must be converted and delivered to the electrical grid. This occurs through inverter stations, substations, and final grid tie-in infrastructure.
Inverter stations convert the direct current (DC) electricity generated by the panels into alternating current (AC) power that can be distributed to homes, businesses, and the broader grid. These stations often represent several megawatts of capacity in a single location, making them one of the most critical components of a utility-scale solar project.
Once testing and commissioning begin, energized systems introduce new hazards that were not present during earlier mechanical phases, and PPE requirements may shift depending on the scope of electrical work being performed.
Primary hazards:
Hand hazards
- Electrical exposure during testing and commissioning
- Tool handling around energized equipment
- Equipment installation and maintenance work
- Greater coordination between crews as energized electrical systems come online
PPE recommendations:
Electrical protection
- Electrical-rated PPE and arc-flash protection where required by the work scope
Hand protection (gloves)
- Cut-resistant gloves for general mechanical tasks and equipment handling
- Arc-rated gloves with contact heat protection
Eye and face protection
- Safety glasses or face protection when working around energized equipment
Head protection
- Continued use of Class E, Type 2 safety helmets when working around electrical infrastructure and large equipment installations
Expert tip: Strict access control, lockout/tagout procedures, and adherence to electrical safety protocols become critical during commissioning activities.
Example PPE checklist for solar construction projects
If you made it this far, we wanted to make this worth your read by sharing an example of how to put this information into practice. Below is what an actual company has been recommended from us.
But please note: While PPE requirements vary depending on the contractor, project owner, and scope of work, many utility-scale solar projects standardize equipment that can perform across multiple phases of installation.
Based on common jobsite conditions, HexArmor® recommends the following PPE when developing a solar construction safety program.
Hand protection
- Cut-resistant gloves (typically ANSI A4–A6)
- Strong abrasion resistance for steel handling and cable pulling
- Reliable grip performance in dusty environments
- Dexterity for handling tools, connectors, and hardware
Examples: Helix® 3050, Helix® 3014IMP, Chrome SLT® 4073, Helix® 1075IMP, Helix® 1075
Eye protection
- Safety glasses with anti-fog performance
- Side shields to protect against debris across large open jobsites
- Optional gasketed eyewear for dust-heavy environments such as pile driving or trenching
Head protection
- Type 2 safety helmets for both top-of-head and lateral impact protection
- Designed for environments with heavy equipment and elevated work areas
Example: Ceros® XT400E
HexTip: Helmets equipped with the Mips® safety system are designed to help reduce rotational impact forces. Options such as the Ceros® XT400 with Mips® and XT400E with Mips® provide this added protection for both general and electrical work environments.
Arm protection
- Cut-resistant sleeves for additional protection when handling steel racking systems and structural components
Examples: Helix® 2043, Helix® 2044
Safety footwear
- Composite toe or carbon fiber safety toe footwear for protection against dropped materials
- Durable outsoles for stability across uneven terrain and large job sites
- Optional metatarsal protection when handling steel components or pipes
Examples: Xbase™ met guard boots, Xbase™ BOA® models
HexArmor® can help
Utility-scale construction moves fast, and the hazards crews face evolve throughout the project.
A phase-based PPE strategy helps safety teams improve compliance, reduce injuries, and create more consistent protection across large solar job sites.
HexArmor® works with safety teams to close the gaps outlined in this guide, whether that means selecting PPE that fits the task, improving glove compliance through better comfort and dexterity, or helping develop a head-to-toe protection strategy for solar projects.
Our Solution Specialists are ready to help. Call 1-877-MY-ARMOR or send us a message.
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