Design Review Workflow

A Design Review Workflow is the structured process used to evaluate, verify, and approve solar PV system designs before they move into permitting, procurement, installation, or client delivery. It ensures each design is accurate, code-compliant, buildable, and optimized for performance—reducing costly revisions and preventing installation-stage errors.

In modern solar operations, the design review workflow is central to quality assurance. Teams use digital platforms such as Solar Designing alongside shading tools like Shadow Analysis to validate layout accuracy, structural feasibility, electrical configuration, and compliance with AHJ requirements. A solid review workflow improves turnaround time, standardization, and overall engineering reliability.

Key Takeaways

A Design Review Workflow ensures solar system designs are accurate, buildable, and code-compliant.
It prevents costly rework during installation or permitting.
Includes shading analysis, electrical review, structural validation, and AHJ compliance checks.
Automation significantly speeds up review cycles without sacrificing quality.
Critical for residential, commercial, and utility-scale PV development.

What Is a Design Review Workflow?

A Design Review Workflow is a repeatable, step-by-step quality control process that solar companies use to check every aspect of a PV system design. It typically includes:

Structural review
Electrical review
Shading and production review
AHJ and code compliance verification
Inverter and stringing validation
Layout accuracy and obstruction clearance
Customer-facing proposal alignment

This workflow acts as a safeguard between the initial design and the final approved system, helping prevent errors, reduce redesign cycles, and speed up project timelines.

How a Design Review Workflow Works

Although every organization may structure it slightly differently, most design review workflows follow these core steps:

1. Initial Design Creation

A designer or automated tool (e.g., Auto-Design) generates the first version of the solar layout.

2. Boundary and Setback Verification

Reviewers confirm that fire setbacks, parapet offsets, and usable roof areas match AHJ requirements.

See AHJ Compliance.

3. Roof Plane & Obstruction Review

Check for accurate modeling of:

Roof pitch
Azimuth
Skylights
Vents
HVAC units

Boundary mapping is often assisted by tools such as an Array Boundary Tool.

4. Shading & Irradiance Validation

Review shading losses, sun paths, and POA estimates using tools like Shadow Analysis.

5. Electrical Design Review

Verifying:

String lengths
Voltage windows
Current limits
DC/AC ratio
Inverter pairing (see Inverter Sizing)

6. Structural & Mounting Review

Ensuring compliance with:

Wind loads
Snow loads
Racking compatibility
Roof attachment requirements
See Mounting Structure.

7. Production & Performance Review

Checking annual yield, PR, and expected energy output with tools such as SurgePV’s modeling engine.

8. Permitting Readiness Check

Before final approval, reviewers confirm alignment with AHJ rules and NEC 690 system safety requirements.

9. Final Approval & Design Lock

Once approved, the project moves forward to permitting, procurement, or proposal generation.

Types / Variants of Design Review Workflows

1. Internal Engineering Review

Used by EPCs, solar installers, and design studios.

Involves multiple reviewers: junior designer → senior engineer → lead reviewer.

2. Third-Party Engineering Review

External engineering firms evaluate the design for code compliance or PE stamping.

3. Automated Design Review

AI-driven rulesets scan for:

Shading violations
Invalid string lengths
Breaker oversizing
Fire setbacks
Inverter misalignment

This greatly accelerates large-scale operations.

4. AHJ-Specific Review

Tailored workflows per jurisdiction—critical for U.S.-based solar companies.

5. Proposal Review Workflow

Ensures the design and financial proposal match capacity, equipment, and expected energy generation.

How a Design Review Workflow Is Measured

1. Review Time (Hours/Minutes)

Indicates operational efficiency.

2. Accuracy & Error Rate

Errors caught vs. errors missed.

3. Revision Cycles

How many redesigns occur before approval.

4. AHJ Approval Rate

Higher approval rates indicate better review quality.

5. Installation Change Orders

Fewer change orders = strong design review process.

6. Energy Performance Accuracy

Difference between modeled and actual production.

Typical Values / Ranges

A mature solar company typically aims for 80–95% reduction in redesign cycles through optimized review workflows.

Practical Guidance for Solar Designers & Installers

1. Standardize your review checklist

Include shading, layout, stringing, code compliance, and structural reviews.

2. Use automated tools to catch common mistakes

Platforms like Solar Designing help detect offsets, invalid strings, and layout errors.

3. Validate shading and production early

Use Shadow Analysis during the first review to avoid rework.

4. Align electrical design with inverter constraints

Verify voltage windows, DC/AC ratios, and rapid shutdown requirements.

5. Tailor workflows to AHJ rules

Different jurisdictions require different setbacks, pathways, or plan set structures.

6. Include O&M considerations

Ensure walkways and access paths are preserved in layout reviews.

7. Train your team on review criteria

Consistency reduces design errors and accelerates permit approvals.

Real-World Examples

1. Residential Design Review

Before submitting a 7 kW rooftop design, an engineer ensures:

Fire setbacks are correct
String lengths stay within inverter voltage limits
Shading losses are below 12%

Design is approved for proposal the same day.

2. Commercial Flat-Roof Project

A 250 kW system undergoes:

Walkway validation
Ballasted racking review
Structural load assessment
Electrical pathway confirmation

Reduces expected installation conflicts by 70%.

3. Utility-Scale Solar Farm

A 25 MW design is reviewed with automated tools:

Terrain optimization
Tracker row alignment
BOS routing
Grid interconnection viability

Final design is approved with minimal revision cycles.