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Verification of the load introduction

and permissible compression of the
insulation by solar systems installed on flat roofs

notice paper
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introduction
Due to their size and location, flat roofs are often
predestined for the installation of solar systems. The
majority of the solar systems are installed and
ballasted on flat roofs.
An important advantage is that there is no
penetration of the roof membrane.
In addition to the load capacity reserve of the roof
construction, the local load capacity of the roof
structure must also be taken into account. In the
case of flat roofs, this is often designed as a "warm
roof" (insulation above the base layer), as shown in
Figure 1 as an example. Most of these roofs have
been planned as unused roofs.
Especially in the area of an ascent or exit,
insulation is deformed and damaged if there are no
suitable load-distributing paths.
A special focus of this information paper is the
compressive stress on the insulation under the
base rails of the PV system placed on the roof
(linear support) or point supports. The snow load
and the necessary ballasting are the decisive factors
for the pressure below the supports. Where there
were previously flat effects, the roof structure and
especially the thermal insulation is loaded by point or
linear supports of the PV system.

The installation and operation of solar systems place

a strain on the roof waterproofing and the other
functional layers. The functionality of each individual
functional layer must be maintained permanently. In
addition to the constant loads caused by the PV
system, which are the subject of this information
paper, temporary loads must also be taken into
account during installation and maintenance.
The compressive stress on the insulation and the
resulting compression/deformation can cause
damage, e.g. B. in the seal.
This must be prevented by careful planning and
installation. This information paper deals with the
planning and the measures derived from it.

Image 1: Schematic
Roof structure
(“warm roof”) with attached
PV flat roof system

1 The insulation material standard DIN 4108-10 specifies for polystyrene insulation with the mean compressive strength "dm" for
polystyrene rigid foam (EPS) 100 kPa and for polystyrene extruded foam (XPS) 200 kPa. In DIN 4108-10, no insulation with medium
compressive strength "dm" is listed for rigid polyurethane foam (PU) and cellular glass insulation materials (CG) for the application area DAA.

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Figure 2: Snow cover on a PV flat roof system (source: IBC Solar)
Normative requirements
Solar systems are subject to the respective specialist
standards and guidelines and those of structural engineering.
According to DIN 18531:2017-07 (“Sealing of roofs and
balconies, loggias and access balconies”), roofs with ballasted
solar systems or the relevant roof areas are considered used
roofs. The technical rule for waterproofing (flat roof guideline)
also defines roofs with solar systems as used areas. The
insulation requirements on flat roofs are higher for used roofs
than for unused roofs. Specifically, both of the standards/
guidelines relevant to flat roofs refer to DIN 4108-10 (“Thermal
protection and energy saving in buildings – Part 10: Application-
related requirements for thermal insulation materials – factory-
made
Table 1: Requirement for compressive strength of insulation when used
Roofs in the DAA application area (according to the flat roof directive)
manufactured thermal insulation materials"). There, the
application area "DAA" with the product property "dh" (high
compressive strength) is named for used flat roofs with a warm
roof structure (insulation under roof waterproofing), while
insulation DAA-dm (medium compressive strength) is often
used for unused roofs 1
.
This means that the values from Table 1 apply to the
compressive strength of insulation made of expanded
polystyrene (EPS), extruded polystyrene (XPS),
polyurethane rigid foam (PU) and cellular glass (CG). It
should be noted that these values are the result of laboratory
tests with Short-term loads are (DIN EN 826) and are used to
classify insulation within a material group.
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DIN 4108-10 for the application category DAA (external
roof insulation under roof waterproofing) does not
specify any compressive strengths for dm (medium
compressive strength) or dh (high compressive strength)
for thermal insulation materials made of mineral wool.
Accordingly, no indication of the compressive
strength for used roofs with mineral wool insulation can
be obtained. Here specifically
However, the flat roof guideline sates the recognized
rules of technology as described in the information box.
In addition to the flat roof guideline, DIN 18531 in Part
1: "Unused and used roofs - requirements, planning
and execution principles" in Chapter 6.13 Solar systems
lists further planning information that must be observed.

Flat roof guideline

Thermal insulation materials made of mineral wool according to DIN EN 13162 with a
12-2016 part 3.4
thermal insulation (6)
compressive strength/stress of at least 70 kPa at 10% compression are suitable for roof areas
that are used exclusively for solar systems or other technical systems. A load-distributing layer
must be arranged above the thermal insulation/sealing, which is already required when installing
the solar system or technical system. The insulation material must be approved by the
manufacturer for this application.

Recommendations from professional

associations of insulating materials and manufacturer

In the data sheets of the insulating material
manufacturers, the pressure loads according to EN
826 (CS(10)) for a 10% compression of the thermal
insulation are given as standardized information for
Germany (laboratory value).
translated practice. According to DIN 13163, Annex
F, a compression of 2% or less can be expected to
occur after 50 years when subjected to a permanent
compressive stress of 0.3 · CS(10).

However, in order to comply with the permissible XPS

compression of the thermal insulation for the special
loads with PV systems, additional recommendations are
given by insulation material manufacturers and
professional associations.
polystyrene
EPS
The Industry Association for Hard Foam eV (IVH) also
specifies a permissible compressive stress of ÿ 2%
compression in its physical properties of EPS hard foam
(e.g. Styropor®). Here, only 30% (approx. 1/3) of the
compressive stress may be applied for a 10%
compression (see Table 2).
In the case of EPS, the results from the
Laboratory tests in the product standard directly for
The XPS rigid foam has a very high compressive
strength (see table 1, values for CS(10)).
With a continuous load of 50 years and a compression
of < 2% (long-term creep behavior under compressive
stress, CC(2/1.5/50)), product-specific long-term
compressive strengths determined according to EN
1606 are given in the data sheets.
These values are usually > 100 kPa.
Mineral wool insulating material
or mineral wool
The professional association for the mineral wool industry points
out that the permissible compressive stresses must be requested
from the individual manufacturers, as these vary from
manufacturer to manufacturer or from one manufacturer to the next.

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Table 2: Permissible bearing pressure for EPS (source IVH, 4-2020)

vary from type to type. Information from selected
manufacturers is presented as an example in the
appendix.
polyurethane
Studies by the Industrial Association for Rigid
Polyurethane Foam (IVPU) show that the
compression of the insulating layer should not
exceed 2%. If the insulation is subject to greater
stress, there is a risk that the roof waterproofing
will be damaged and leaks can occur. At this
pressure load of 2%, according to the IVPU, “the
The building material is ideally elastic, i.e. the
insulating material returns to its original thickness
after it has been relieved.” In order not to exceed
the 2% compression of the thermal insulation under
the constant load, only 1/5 of the permissible
compressive strength may be assumed (Table 3 ),
while this increases to 3/5 for the variable loads.
For the PU hard foam, this means that the
pressure below the supports must not exceed the
value of 20 kPa with a constant load and 60 kPa
with a variable load (100 kPa with 10%
compression).

Table 3: Load cases and property values of insulating materials made of rigid polyurethane foam (PUR/PIR) (source IVPU 2 , as of March 17, 2015).

2 https://daemmt-besser.de/fileadmin/user_upload/IVPU_Whitepaper_2015-02_AnDemand_Waermedaemmung_von_Solardaechern.pdf, access: May 20, 2020

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Note on inventory
roofs
Since neither the condition nor the type of thermal
insulation is known on older flat roofs, this should be
checked by means of test openings when planning
an installation. Since a PV system stays on the roof
for at least 20 years, the functionality of the roof
structure must be guaranteed for this period.

It must be weighed up whether a renovation before the

construction of a PV system makes sense. Image 1: Open roof skin with mineral wool insulation (source: IBC Solar).

calculations
Safety factors: Since
the bearing pressure is verified according to the
serviceability limit (SLS), the partial safety factor
can be set to ÿQ = 1.0.
Insulation is not part of the load-bearing
building structure. Therefore, they are to be
evaluated statically according to the serviceability
limit state (SLS). This means that a partial safety
factor ÿG = ÿQ = 1.0 must be applied for both
permanent loads and variable loads.
Permanent loads:
These include the dead weight of the solar
modules or solar collectors, the mounting system
and the weighting or ballasting.
Variable loads: These
include wind, snow and walking loads.
As a rule, the snow load is to be regarded as the
decisive influence for the verification of the insulation
under solar systems.
The snow load is determined from the form factor
ÿ and the base value of the ground snow load
3
according to DIN EN 1991-1-3 NA_2019-04 . If If
snow can accumulate locally between rows of modules
or collectors, these snow accumulations must be
reduced by applying the form factor ÿ5 according to
DIN EN 1991 -1-3_NA_2019-04 to be considered.
This is particularly the case if the system is not
completely snowed in at the maximum snow load
to be assumed and no level snow surface is
formed. In the case of low system heights of < 30
cm, a form factor of ÿ= 0.8 can generally be
assumed.
The snow load to be applied to a front and rear
support corresponds to the snow load on an entire
module (see middle base rail in Figure 2 and the
following calculation examples).
Further information on calculating the snow load in
solar thermal systems can be found in the BDH/ BSW
worksheet for determining snow loads in solar thermal
systems 4.

In the case of aerodynamically optimized Figure 2: Effect of snow loads on individual base rails
(linear supports). A colored block equals 1/4 of the
mounting systems for PV systems in particular, Gross area of a PV module or a solar collector.
the wind pressure loads on the insulation are so
low that they hardly play a role, taking into account
the short duration of action and the combination
coefficient ÿ to be added according to DIN EN 1990.

Walking loads do not have to be combined with

the snow loads on the modules, as there is no
additional load under the contact area of the solar
system.

3 National Annex for Germany to Eurocode 1: Actions on supporting structures - Part 1-3: General actions - snow loads 4 https://
www.bdh-koeln.de/fileadmin/user_upload/ISH2019/Infoblaetter/Infoblatt_Nr_49_Mai_2012_Ermittlung_von_Schneelasten_ Solarthermie.pdf

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Surface pressure [kN/m2 ]=[kPa] incl. snow load under the protective layer of the
base rail Decisive for proof of thermal insulation

Figure 3: Support pressure with an interrupted protective layer for water drainage
(Source: BayWa re SES)

When connecting the base rail to the trapezoidal sheet

bearing surface
Linear systems: Since in
most systems it can be assumed that the load is
distributed due to the rigidity of the base rails, the
row spacing of the system multiplied by the rail width is
used as the load transfer width for continuous rail
systems.
metal bead, the load from the PV system and snow load
are concentrated on a single trapezoidal sheet metal
bead via the base rail.
With narrow base rails that run parallel to the
corrugation, there is also a risk that the insulation will
give way if the base rail runs over the corrugation
trough of the trapezoidal sheet.

In the case of linear systems perpendicular to the roof

slope, safe water drainage must be ensured.
If lateral drainage is necessary, the protective layers avoid sharp
under the rails must be interrupted (Fig. 3). In this case,
edge
the bearing surface is reduced by the gaps.
Sharp edges can injure the skin of the roof and lead to
leaks.
Punctual systems: The Therefore, protection of the roof skin should be e.g. B.
area of the punctiform support is applied be guaranteed by protective layers or edge protection.
here.

Sharp edges can be: • the end

avoidance of of floor rails • corners or edges

load concentrations of selective supports • intermediate joints, e.g. B. with

sawn floor rails • ballast trays • ridge couplings • or similar
In the case of flat roofs with trapezoidal sheet
metal, the base rail should preferably run across the
trapezoidal sheet metal. Otherwise, in parallel arrangement

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Calculation examples

Calculation example 1:
Snow load 5 with 12 cm wide base rail: 85 kg/m² (corresponds The total load on a module is calculated
to 0.85 kN/m²) 10° 262
as a sum of:
Module area = length x width = 1.65 m x 0.992 m = 1.63 m²
1600
Snow load of 111 kg
Taking into account the safety level for proof of suitability for Dead weight module v 18 kg (data sheet module manufacturer)
use (SLS) ÿQ = 1.0 and the Weight mounting system v 2 kg
Shape coefficient µ5 = 0.8 6 the snow load results in a (Indication of mounting system manufacturer)
Module to: 1.0 0.8 85 kg/m² 1.63 m² = 111 kg Ballast (maximum) v 25 kg
Max. ballast on a base rail within a (specification calculation mounting system manufacturer)
Row: 25 kg Load per module v 156 kg

10°
262

1600

Image 4: South elevation 10° with a row spacing of 1.60 m and a continuous protective layer under the base rail

For a continuous base rail with a width of 0.12 m
with a continuous protective layer and a row spacing of 1.6
meters results in:
Bearing pressure on the insulation* 156
kg / (0.12 m x 1.6 m) = 813 kg/m² 813 kg/
m² = 8.1 kN/m² = 8.1 kPa
If the mineral wool comes from the manufacturers named in
the chapter above, then depending on the type, the
permissible bearing pressure is between 9 and 13 kPa, and the
bearing pressure would still be maintained for this calculation
example.

Calculation example 2: For two point supports with the dimensions 0.2 m x
Snow load 7,200 kg/m², 2 point supports, 0.2 m, the result is:
Dimensions 0.2m x 0.2m Bearing pressure on the insulation* 306
Snow load on a module: 1.0 x 0.8 x 200 kg/m² x 1.63 m² kg / (2 0.2 m 0.2 m) = 3825 kg/m² 3825 kg/
= 261 kg m² = 38.3 kN/m² = 38.3 kPa

Snow load of 261 kg For a polystyrene of type EPS 035 DAA dh, according to
Dead weight module v 18 kg (data sheet module manufacturer) Table 3, the permissible bearing pressure is 45 kPa at 2%
Weight mounting system v 2 kg compression and would be complied with in this case.
(Indication of mounting system manufacturer)
Ballast (maximum) v 25 kg
(specification calculation mounting system manufacturer) For a polystyrene type EPS 035 DAA dm, according to
Load per module v 306 kg Table 3, the permissible bearing pressure is only 30 kPa and
would not be complied with in this case.
Additional measures will be required.

*)
For reasons of simplification, the module inclination was neglected and the conversion from 1 kN to 100 kg was
applied . 5 85 kg/m² is an example used here. The actual value at the installation site must be taken into account.
6 The value can increase up to 1.0, see DIN EN 1991-1-3:2019-04
7 200 kg/m² is an example used here. The actual value at the installation site must be taken into account.

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suggested solutions
If the permissible bearing pressure is exceeded, the following possible solutions
arise:

1. Enlargement of the bearing surface

a. Third base rail or additional supports b. Additional
protective layers if these are interrupted. c. Load distribution
elements under the base rail d. Ballast pans in areas with very
high ballast for distribution
of the ballast weight over a larger area

2. Reduction of the snow load to an average return period of 50 years to 25 years - only in
consultation with the structural engineer and the building owner

3. Roof renovation with more pressure-resistant thermal insulation

Introduction of horizontal forces

Experience has shown that horizontal forces that are introduced from the installation of typical
ballasted solar systems can be transferred to the supporting structure via the roof structure.
Explicit proof can be omitted if the following requirements are met:

• Roof pitch ÿ 5° •
°
Elevation angle of the photovoltaic modules ÿ 15 •
Maximum height of 50 cm between the upper edge of the modules and the roof membrane

Note on the interpretation of DIN 18531:

When formulating the wording, the employees of the working committee were only concerned
with the bonding of solar systems to the roofing membrane, which is undesirable. Although
these installation situations are possible, they must prove their functionality, reliability, etc. with
the respective individual verifications. Ballasted systems are not affected by the wording; the
working committee did not see the need for regulation here.
The forces introduced by ballasting were classified as low.

Conclusions
Installing ballasted solar systems on flat roofs increases the pressure on the individual
functional layers. In existing buildings, unused flat roofs are often converted into roofs with a
PV system. In any case, the insulation must also be considered as one of the necessary tests.

Their condition must be examined during the usage phase (20 to 35 years) to avoid damage
or leaks in the roof waterproofing due to excessive deformation. With new buildings, you can
still influence both the load-bearing capacity and the materials to be used.

In the case of rigid foam insulation on flat roofs, there are hardly any problems in
complying with the permissible pressure below the systems, while with mineral wool
insulation it should be checked whether the insulating wool is approved for the selected
system and whether the permissible pressure is observed.

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Appendix

Information from selected

mineral wool manufacturers
rockwool
Permissible loads on ROCKWOOL flat roof insulation panels from photovoltaics
Rockwool roof
(Dead weight and panels
snow) Table 4: using photovoltaics
Permissible load of (Source: Rockwool Germany, STATUS 01/2020) 8

flat load small-area/linear load up to 0.50×0.50 m or point loads up to 0.20 m ÿ

up to 0.15 m width

ÿÿÿÿÿÿÿÿÿÿÿÿÿÿÿÿ ÿÿÿÿ ÿ

product permissible surface load Permitted small-area/ at e.g. at eg permissible point at eg

linear load 0.40×0.40 m 0.10 m width load 0.15 m ÿ

kN/m² [kg/m²] kN/m² [kg/m²] kN [kg]/support kN [kg]/running metre kN/m² [kg/m²] kN [kg]/support

megarock 6.0 [600] 12.0 [1200] 1.9 [190] 1.2 [120] 60 [6000] 1.1 [110]

Hard Rock 040/038

Geo skirt 038
Bond Rock 040 MV 5.0 [500] 11.0 [1100] 1.7 [170] 1.1 [110] – –
Georock 040 MV
bitrock

Duration:
Durock 040/037 4.0 [400] 10.0 [1000] 1.6 [160] 1.0 [100] – –
Geo skirt 037

Note: Rockwool gives different values under different product names for other countries, e.g. B. the BENELUX countries (Table 5)

STATUS 01/2020

Table 5: Permissible load of Rockwool for BENELUX (Source: ROCKWOOL BV, STATUS 05/2020)

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Paroc

Table 6: Permissible load from Paroc solar systems (status: ÿ11/2017)

knob

Table 7: Information from Knauf Insulation (status: 03/2019)

STRESSABILITY OF
KNAUF INSULATION ROOF INSULATION BOARDS – RESISTORS RK

Distributed load applied Distributed load with power Line load with Line load with Distributed load at power
over the entire surface load-distributing panel per load-distributing load-distributing plate load-distributing plate Ø = 15 cm in per load-distributing
product PL(5mm)
[N] [kPa] [W/
CS(10) stone
mÿK]
wool
ÿD
in [kPa] [kN/m²] [40 x 40 cm] in [kPa] [kN/m²] plate [40 x 40 cm] in [kN] [40 cmÿrm] in [kN/rm] [10 cmÿrm] in [kN/rm] [kPa] [kN/m²] plate at Ø = 15 cm in [N]

knob insulation
0.037 ÿ 70 ÿ 700 3.6 6.4 1.0 2.2 0.8 9.0 165
Roof insulation board DDP2-U PLUS

knob insulation
0.039
Roof insulation panel DDP
ÿ 70 ÿ 650 4.5 8.0 1.2 2.8 1.0 11.0 190
knob insulation
0.038
Roof insulation panel SmartRoof Top

knob insulation
0.039 ÿ 90 ÿ 800 5.0 8.5 1.3 2.9 1.1 13.0 230
Roof insulation board DDP-X

knob insulation
0.039 ÿ 90 ÿ 2000 7.0 14.0 2.5 4.0 2.0 35.0 650
Roof insulation panel DDP-MAX

knob insulation
0.039 ÿ 90 ÿ 800
Roof insulation board
3.3 13.3 2.1 3.9 1.9 30.0 500
DDP-X with top layer Knauf
Insulation
Roof insulation board DDP-MAX in 60 mm0.039 ÿ 90 ÿ 2000
› ›
Rule of thumb: 1 kN=100 kg | 1N 0.1kg
=

Calculated for insulation materials laid in one layer except for the combination
Knauf Insulation GmbH
Knauf Insulation roof insulation board DDP-X with Knauf Insulation roof insulation board DDP-MAX in 60 mm as top layer*
Heraklithstrasse 8
Suitable non-sharp-edged load-distributing plates must be used
D-84359 Simbach am Inn
Dynamic loads are to be excluded
phone +49 (0)8571 40-0 fax
Determination of the effects according to DIN EN 1991
rk = rk = Rk +49 (0)8571 40-231
For verification in the serviceability limit state, ÿ =1 applies Rd
=ÿ 1.0
*The calculations are based on a full-surface application of the insulating material on the substrate info@knaufinsulation.de
The information in this document corresponds to our level of knowledge and our experience at the time of printing (see printer's note). The level of knowledge and experience is
constantly evolving. Please ensure that you always use the current edition of this document. The description of the product uses cannot take special conditions and circumstances
into account in individual cases. Therefore, check our products for their suitability for the specific purpose. 03/2019 www.knaufinsulation.de

Note: The different loads result from the fact that the fibers of the mineral wool are more stable with point loads than with linear systems.

8 If no information is given in the table, it is recommended to contact the manufacturer.

9 Until 2019, Rockwool Benelux used the values from static load tests with even surface loading according to "MOAT 92" for their flat roof
products as reference values for calculations regarding loads and PV systems. For load-distributing panels (e.g. 30 cm x 30 cm) a maximum of 550
kg/m² is recommended for applications in the Benelux.
10 In 2019, Rockwool Benelux investigated long-term compression creep according to EN 1606. This test, carried out by the testing institute
SGS Intron in Sittard (Netherlands), has shown that a maximum load of 33 kPa leads to a maximum deformation of 2.0 to 2.8 mm over a service
life of 10 years. A loading area of 187.5 cm² was used for these tests, the equivalent of a round or rectangular solar system base commonly used
in the Benelux countries.

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This information paper was created by the Federal Association of Solar Industry e. V. (BSW Solar)
Bundesverband Solarwirtschaft eV (BSW-Solar) German Solar Association
Department of Civil Engineering Lietzenburger Str. 53 10719
Berlin | Germany
1st edition, May 2020

Publisher: Bundesverband Solarwirtschaft eV phone +49 30 2977788-43

fax +49 30 2977788-99
Contact: Maria Roos roos@bsw-solar.de

bsw.li/39RfrDZ twitter.com/BSWSolareV bsw.li/2usud3D www.solarwirtschaft.de/feed/

www.solarwirtschaft.de