Why Missing Washers Are a Bigger Problem Than Most EPC Teams Expect
On paper, a washer looks insignificant.
On site, missing one washer can stop production.
Solar EPC teams often face project delays not because of panel shortages or structure failures, but due to something far more basic:
Incomplete fastener sets.
A common example:
The BOQ specifies:
M10 bolt + 2 washers + nut
What reaches site:
Bolt + 1 washer
The result?
Work stops.
Not because of engineering…
But because something small was forgotten.
Where Things Go Wrong
Most fastener packing failures happen during:
- • Manual packing without checklist
• Mixing sizes during bulk handling
• No double verification before dispatch
• No set-wise counting
• No labeling per kit type
When thousands of bolts are packed loosely,
even a single missing washer multiplies into hundreds of failures.
Why It Becomes a Serious Site Issue
Solar structures rely on proper clamping force.
Washers are not optional.
They:
• Distribute load
• Prevent surface damage
• Maintain torque
• Reduce vibration loosening
• Protect coatings from damage
Missing washers lead to:
• Uneven load distribution
• Improper torque
• Fastener failure during wind load
• Audit remarks
• Re-torquing cycles
• Delayed commissioning
How EPC Companies Can Prevent This
1) Demand set-based packing
Each bolt kit must include the exact washer and nut count.
2) Label cartons by size and assembly
Example:
“M10 bolt set – 2 washers + nut”
3) Verify packing before dispatch
Not on arrival.
Before loading.
4) Ask for packing photos
Simple but powerful.
5) Avoid loose bulk dispatch
Boxes without breakup create mistakes.
Final Thought
Fasteners may be small.
But packing errors cost time, money, and trust.
If your supplier cannot deliver complete kits,
your site will forever be troubleshooting.