A Smart Choice for Durability in Roof & Wall Cladding Applications
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Tata BlueScope Steel
Tata BlueScope Steel is an equal joint venture between Tata Steel and BlueScope Steel of Australia, a world-leader in Zinc-Al Alloy coated steel. The venture has been formed to provide coated steel, steel building solutions and related building products. The Company operates in the South Asian Association for Regional
PAKISTAN Gurgaon
Co-operation (SAARC) region.
BHUTAN
NEPAL
The core values of Tata BlueScope Steel are Safety, Trust, Jamshedpur
Human Dignity and Excellence. The company consistently works
Kolkata
INDIA
BANGLADESH
towards “Creating Your New World in Steel!”
Mumbai Pune
Coated Steel Business
Hyderabad
The Coated Steel business manufactures and supplies 55% Al-Zn
Chennai
Alloy coated ZINCALUME® steel and pre-painted COLORBOND® steel for building and construction industry. Its state-of-the-art
SRI LANKA
manufacturing plant at Jamshedpur has an annual metal coating capacity of 250,000 t and paint line capacity of 150,000 t. The
MALDIVES
plant is accredited with ISO 9001, ISO 14001 and OHSAS 18001 Corporate Office
Regional Office
certifications - a testimony to its quality and performance.
Metal Coating and Painting Line
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Tata BlueScope Steel is proud to offer ZINCALUME® steel, a premium material with over 3 decades of proven reliability, for roof and wall cladding applications.
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Benefits of ZINCALUME® steel l l
Excellent corrosion resistance
Uniform physical appearance over longer period of time l
Long lasting lustre with excellent solar reflectivity
Assured quality with level 5 automation for excellent control on process and product l
Peace of Mind: Product details marked at regular intervals on the material
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Globally-acclaimed Brand, Manufactured Locally ZINCALUME® steel is a globally acclaimed brand which is technically proven, corrosion resistant and high on quality. Standard ZINCALUME® steel comes with a 150 g/m2 (AZ150) metal coating that lasts up to four times longer than galvanised steel with 275 g/m2 (Z275) of Zinc coating in similar environmental conditions. It has been designed to minimise differential patina development caused by the temperature difference between hot and cold areas of a roof. Thus, ZINCALUME® steel exhibits superior long-term surface appearance when compared with other metallic coated steel products.
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Time Tested Brand ZINCALUME® steel is the outcome of extensive research into the
across a wide range of climatic conditions using exposure test
methods of improving the performance and lifespan of steel.
sites in various parts
Launched in 1976, ZINCALUME® steel has stood the tests
of the world. By harnessing findings of these testings, and world-
of time. For years, it has continued to set the standard for
leading technological resources, continuous improvements have
corrosion resistance and long life.
been made to ZINCALUME® steel.
Even
today,
manufactured production
ZINCALUME® in
accordance
standards
to
steel to
be
With the dedication to continuous research and development,
most
stringent
ZINCALUME® steel now ensures that it is able to withstand harsh
its
superior
environment for a longer period of time.
continues the
ensure
to
performance and durability. In fact, for over three decades,
With the legendary performance of ZINCALUME® steel, you can
ZINCALUME® steel has been monitored for its performance
be confident that you have the right solution for your project.
ZINCALUME® steel has an alloy coating of 55% Aluminium,
ZINCALUME® steel is typically available in Base Metal Thickness
43.5% Zinc and 1.5% Silicon. The 150 g/m2 (with option of 200 g/
(BMT) ranging between 0.30 mm to 1.30 mm.
m ) coating weight is distributed equally on both surfaces of the 2
Coil width range is 914 mm to 1270 mm. Special requirements
coated strip. Metallic surface is coated with seperate layers of
in specific thickness and width combinations can be offered on
special passivation solution and resin (Figure 1).
requirement. The unique attribute of ZINCALUME® steel is the material’s inherent strength. For roofing applications, Tata BlueScope Steel
Resin Coating
is now almost exclusively supplying special high-tensile steel
Passivation
with minimum 550 MPa yield strength. For some applications
55% Al-Zn Alloy coating (AZ150 / AZ200)
where more formable grades are required, ZINCALUME® steel
Passivation
can be supplied with minimum 300 MPa yield strength.
Resin Coating
ZINCALUME® steel complies with Australian standard AS 1397, Figure 1: Typical cross section of ZINCALUME® steel
American Standard ASTM A792M, Indian Standard IS 15961 and International Standard ISO 9364.
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Remarkable Corrosion Resistance ZINCALUME® steel is manufacured by a continuous hot dipped
the rate of dissolution of the Zinc from the Zinc-rich areas of
metallic coating process. The alloy coating of ZINCALUME steel
the alloy layer.
®
provides excellent corrosion resistance and has been found to
• The Zinc-rich areas are important as they provide the product
possess greater resistance to cracking and peeling.
with galvanic protection. During the initial stages of exposure,
ZINCALUME® steel combines both the galvanic protection of
the Zinc-rich phase near the sheared edge, or areas where
Zinc and barrier protection of Aluminium. The Zinc-rich region
the steel is exposed, provides initial galvanic protection.
is locked in tiny pockets within the Aluminium-rich matrix (Figure
• The adjacent pockets of the Zinc-rich phase, which are in
2). This addition of Aluminium to the alloy coating, and the way it
electrical contact with the steel, provide continual galvanic
melds with Zinc provides the following key benefits:
protection.
• Aluminium in the coating complements the corrosion
Thus, steel at any point is not readily available for corrosion.
resistance process by providing barrier protection, reducing
AI Si Zn Alloy Layer
Figure 2: Microstructure Cross Section of ZINCALUME® steel
Figure 3: Salt Spray
Accelerated Laboratory Testing The
superior
ZINCALUME®
formulation steel,
of
coupled
the with
alloy its
coating
of
state-of-the-art
Galvanised steel Z275 after 240 hrs
ZINCALUME® steel AZ150 after 240 hrs
ZINCALUME® steel AZ150 after 2000 hrs
Significant red rust
In good condition
Dark staining only
manufacturing technology has greatly enhanced its corrosion resistance properties. ZINCALUME® steel has been rigorously tested by experts for quality assurance. Edge protected panels of Galvanised steel & ZINCALUME® steel were tested in the salt spray cabinet (Figure 3). After 240 hours the Galvanised steel panel shows significant white corrosion and red rust, but ZINCALUME® steel panel were found in excellent condition with virtually no corrosion. Even after 2000 hours, the ZINCALUME
®
steel panel showed only dark staining and some white corrosion
Figure 4: Salt Spray Performance of Galvanised steel v/s ZINCALUME® steel
product, but no red rust (Figure 4).
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2 mm
1 mm
0.75 mm
0.5 mm
0.25 mm
Sacrificial Protection ZINCALUME® steel has been tested to meet the demands of
Galvanised steel Z275
tough environments and is particularly preferred for the industrial climates and marine environments of the SAARC region.
Scribed
The adjacent picture (Figure 5) shows sample test results (to
ZINCALUME® steel AZ150
check sacrificial protection performance) after nine months exposure under industrial marine environment conditions. It can be seen that ZINCALUME® steel gives better performance at
Galvanised steel
Cut Edge
scribes of lower widths. At the cut edge, Galvanised steel is more
ZINCALUME® steel
susceptible to corrosion, as compared to ZINCALUME® steel. Figure 5: Cut Edge Performance
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Durability and Safety The base steel is coated with 55% Al-Zn Alloy with 150 g/m2 coating.
}
It combines the sacrificial benefits of Zinc with the long life barrier protection of Aluminium, and lasts upto 4 times longer than galvanised steel (Z275) in similar conditions.
Six years outdoor exposure at Bellambi Point, Australia
Outdoor Exposure Testing Outdoor Exposure Testing confirms that the corrosion performance of ZINCALUME® steel is far superior to that of Galvanised steel. After six years of severe marine exposure at BlueScope Steel’s Bellambi Point site, ZINCALUME® steel is still in good condition, while Galvanised steel shows severe loss of coating and
Test Site
significant red rust of the steel substrate (Figure 6).
Samples on Test Racks
On an average, ZINCALUME® steel (AZ150 coating) lasts up to four times longer than Galvanised steel (Z275 coating) in similar environment conditions.
Galvanised steel Z275 (Heavy sign of Rust)
ZINCALUME® steel (No Sign of Rust)
Figure 6: Outdoor Exposure Test and Product Performance after 6 years at severe marine environment
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Keeps Lustre Longer Due to the unique surface treatment, ZINCALUME® steel keeps its lustre for long, and looks great for even longer (Figure 7). ZINCALUME® steel has a clear resin coating and special passivation that complements its unique spangles and gives a satin smooth finish. It provides anti-finger print protection and looks newer for longer. It makes ZINCALUME® steel an aesthetically appealing material for use in a wide range of applications in the building and construction.
GENERAL COLOUR CHANGE AFTER 3 YEARS AT ROCKHAMPTON, AUSTRALIA
MODELLED DIFFRENCE IN COLOUR CHANGE BETWEEN HOT & COLD AREAS OF SHEET 8
Colour Change Rating
Colour Change (DE)
-25 -20 -15 -10 -5
ZINCALUME® steel AVERAGE
OTHER SURFACE TREATMENTS - ASIA
OTHER SURFACE TREATMENTS - USA
7 6 5 4 3 2 1 ZINCALUME® steel
RANGE
AVERAGE
OTHER SURFACE TREATMENTS - ASIA
OTHER SURFACE TREATMENTS - USA
RANGE
Figure 7: Change in Colour
Extraordinary Mark Resistance The resin coating on ZINCALUME® steel provides excellent mark-resistance qualities. Hand and finger prints, boot marks and water impressions caused during roll forming, handling and installation are problems which can been virtually eliminated due to this feature.
Superior Passivation Coating The special passivation treatment of ZINCALUME® steel reduces the rate of oxidation and resultant discolouration. It provides uniform weathering and improves resistance to early corrosion.
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Excellent Design Flexibility ZINCALUME® steel can be roll-formed, for a wide range of applications and end-usages, without sacrificing the coating adhesion. It has better formability when compared with conventional Galvanised steel products and can be moulded into various shapes much more conveniently when compared with other building materials. The high tensile strength of ZINCALUME® steel enables longer spans, thereby making larger open spaces possible. Laboratory tests and actual performance confirm excellent adherence of the alloy coating to the steel substrate during bending.
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Design Flexibility
Not only does ZINCALUME® steel provide more scope for interesting shapes, it also delivers a lightweight solution that gives
you the freedom to develop a design that better suits your lifestyle. It is easy to handle and can be installed faster than conventional materials.
High Yield Strength The high yield strength (minimum 550 MPa) of ZINCALUME® steel makes it suitable for various applications requiring durability and long service life. Its strength to weight ratio is higher than any other building material. When compared to softer and brittle materials, it has greater resistance to dents and damages. It is an excellent alternative to thicker and heavier materials as well.
Yield Advantage ZINCALUME® steel has 55% aluminium by weight. Since Aluminium is lighter than Zinc, it makes 80% of the volume. This means that alloy coating weighs less, giving more surface area per tonne of finished product than galvanised sheet of equivalent base metal and coating thickness.
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Proven Thermal Efficiency Thermal efficiency is an important consideration in building design and would influence the choice of roofing and wall cladding material. Considering the manner in which energy costs
850 Watt/m2
are rising, it has become increasingly important to explore options for reducing expenses on environment control in buildings. ZINCALUME® steel has a lower thermal mass as compared to conventional building materials, so it does not hold heat for long. The primary source of this heat is sunlight. The fine spangle and special surface treatment of ZINCALUME steel (with SRI value ®
57) results in higher solar reflectivity. This enables it to reflect a
65 Watt/m2 Heat Transmission
120 Watt/m2 Heat Transmission
150 Watt/m2 Heat Transmission
ZINCALUME® steel Roof
Galvanised Roof
Terracotta Tile Roof
Based on a weather-worn roof where the level of reflectivity had stabilised and which were exposed to solar radiation of 850 W/m2
greater portion of the sunlight, without transmitting the energy
850 Figure 8: Thermal Watt/m2 Efficiency
into the building (Figure 8).
{
65 Watt/m2 Heat Transmission ZACS® steel Roof
Thermal Efficiency
The higher solar reflective index (SRI value:57) of ZINCALUME® steel enables it to keep the internal environment cool during summer. The high solar reflectivity index and lower thermal mass of ZINCALUME® steel, combined with insulation makes it an energy efficient roofing solution.
}
120 Watt/m2 Heat Transmission
150 Watt/m2 Heat Transmission
Galvanised Roof
Terracotta Tile Roof
ZINCALUME® steel combined with proper insulation makes a cost effective, energy efficient roofing system. Results from a study conducted by the CSIRO division of Building Construction and Engineering suggest that on a hot day the maximum temperature inside a building with a roof made of ZINCALUME® steel is significantly lower than an equivalent construction with tile roofing, thereby offering greater occupant comfort and ongoing cost savings as well. Other factors that impact the thermal efficiency are location, orientation, shape of the building, and the pitch & slope of the roof.
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Environment Friendly ZINCALUME® steel is reusable and recyclable. It is manufactured in a factory environment and can be installed in a shorter time frame. It does not disturb the ecology or damage the local flora, since there is no mixing or wastage at site. It is easy to clean and maintain - without the use of harmful chemicals and processes. Better thermal efficiency of ZINCALUME® steel not only lowers cooling and heating cost, it also reduces greenhouse emissions due to lower fossil fuel consumption.
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Environment Friendly ZINCALUME steel is easy to clean and maintain - without the use of harmful chemicals and processes. Moreover, being ®
steel, the products are recyclable and reusable.
}
Quality Assurance When purchasing any product, it is good to know that the manufacturer stands behind it. We are proud of Grade
ZINCALUME® steel and want you to know that.
Alloy Coating
Product Name
ZINCALUME® steel is supplied with a brand mark at regular
Total Mother Time & Date Coated Thickness Coil No. of Produce
Base Metal Thickness
intervals on the reverse side of the strip (as shown in Figure
Brandmark on the reverse of ZINCALUME® steel
9). The brandmark includes - name of the product, grade, alloy
Figure 9: Brand Mark
coating, base metal thickness (BMT), total coated thickness
Warranty*
(TCT), manufacturing time, date and coating line number.
Tata BlueScope Steel takes a professional approach to product
The brandmark enables the product you purchase to be tracked
warranties, which are treated as an important part of our product
through our production and quality control processes.
offer and after-sales service. Our warranties are developed after
You can be assured that it is of the highest quality every time,
thorough review and are not just sales tools. ZINCALUME®
produced and backed by our team of qualified and experienced
steel will have life prior to corrosion to perforation in the natural
personnel at Tata BlueScope Steel.
elements up-to 20 years . * Warranty is subjected to terms and conditions.
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Applications and End-Usages ZINCALUME® steel is widely used in the construction industry
Wall Cladding
where long life is critical. The excellent corrosion and weather
ZINCALUME® steel is an attractive, durable and economic wall
resistance of ZINCALUME steel makes it a durable and reliable
cladding solution for most environments.
®
solution for a wide variety of applications.
In addition to the practical benefits and aesthetic appearance, it
Roofing
also acts as an impenetrable barrier to intruders and pests.
From classic corrugated sheeting to contemporary profiles and
Gutter, Flashing and Accessories
architectural panels, ZINCALUME® steel is the natural choice
To ensure equal durability for gutter, flashing, ridge capping and
for roofing applications. Various design options are possible as
other accessories, it is always recommended that these are
a result of higher strength and excellent flexibility. Being light-
manufactured out of the same product system used for main roof
weight, it reduces the amount of framing required in roofing
and wall cladding.
design. Longer spans enable economic truss design.
Handling and Maintenance ZINCALUME® steel, while in coil or sheet pack, should be kept clear off the ground. If ZINCALUME® steel becomes or remains wet whilst stacked, storage corrosion may result, which is both unsightly and can result in reduced corrosion protection at the affected areas. The effected area should be cleaned, dried at earliest. As the need for lubricants during roll-forming is reduced, ZINCALUME® steel is safer to handle, especially for roof fixing on steep pitch roofs. To avoid localised corrosion during /post installation, remember to remove nails, rivets, loose metal filings, leaves, rags and other refuse from roofs, gutters and valleys at the end of each work-day. Areas not subject to the natural washing action of rain should be cleaned using water regularly to avoid accelerated corrosion. 14
ZINCALUME® steel guttering suitable for all roofing material
Compatibility The correct selection of roofing and wall cladding materials is the first stage in achieving the maximum service life of a building. Due to a phenomenon known as galvanic or bi-metallic corrosion, some commonly used materials in construction can cause accelerated corrosion in metal sheets used for roof or wall cladding applications. For example Copper, Lead, treated Timber are incompatible with ZINCALUME® steel. Water flowing from these onto ZINCALUME® steel is likely to cause rusting
Run-off Effects from Inert Catchments Run-off from inert catchments is a problem for galvanised gutters but not for ZINCALUME® steel
of the latter. Zinc and Aluminium are most compatible with ZINCALUME® steel. Zinc coated steel can also be used with
Figure 10
ZINCALUME® steel but its lower life makes it a less practical option particularly in severe environments (Figure 10).
Bare steel, if it is used with coated steel, needs to be painted to
For ZINCALUME® steel, the recommended fasteners are
avoid direct contact and the likelihood of corrosion.
as per AS 3566.2, Class 3. This is a standard specifying the
As far as sealants are concerned, only natural-cure silicone
requirements for corrosion resistant self-drilling screws used in
sealants should be used with coated steel sheets. Other silicone
the building and construction industries.
sealants often have a vinegar or ammonia smell, an aggressive
The washers also should be compatible with the material used
by-product during curing, which is detrimental to steel sheet.
and should not contain high level of conducting elements. Use
Fasteners along with washers are used to fix and join the metal
of EPDM (Ethylene Propylene Diene Monomer) washers is
sheets.
recommended for ZINCALUME® steel.
These are an important part of coated steel roof and wall
When considering structures adjacent to industrial activity
applications. The life of the fastener needs to match that of the
involving acids, chemicals, fossil fuel consumption, etc., please
sheeting material. Stainless steel fasteners & washers are not
contact Tata BlueScope Steel for specific recommendations.
suitable for ZINCALUME® steel.
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Project: Rangsit School, Thailand Segment: Institutional
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Environment Friendly
Regional Offices North - Gurgaon: 3rd Floor, Tower A, Millenium Plaza, Sushant Lok –II, Sec -27, Gurgaon – 122002. Telephone: +91 124 4712800 / 4263051 West - Navi Mumbai: 702/3 , 7th Floor , Maithili, Sector - 30A, Vashi, Navi Mumbai – 400705. Telephone: +91 22 66743329 East - Kolkata: Tata Centre, 3rd Floor, 43, Jawaharlal Nehru Road, Kolkata – 700071. Telephone: +91 33 65502335
- Jamashedpur: Coated Steel, BARA, AGRICO, Jamashedpur - 831009. INDIA. Telephone: +91 9771487317
South - Chennai: AC 69, Shanthi Colony, Anna Nagar, Chennai - 600 040. Telephone: +91 44 42693319/50/60
Tata BlueScope Steel Ltd. CIN : U45209PN2005PLC020270, Regd. Office: The Metropolitan, Final Plot No. 27, Survey No. 21, Wakdewadi, Shivaji Nagar, Pune - 411005. INDIA. Tel: +91 20 6621 8000, Email:
[email protected] Website: www.tatabluescope-cs.com
- Hyderabad: Lotus Residency, MLA Colony, Road No 12, Banjara Hills, Hyderabad. Mobile: +91 9676626161
Note: “©2013 Tata BlueScope Steel Ltd. All rights reserved. This brochure and its content is copyright of Tata BlueScope Steel Ltd. No part of this brochure may be reproduced or transmitted in any form or by any means, electronic or mechanical including photocopy, recording, or any information storage and retrieval system, without permission in writing from Tata BlueScope Steel Ltd “ ZINCALUME® steel and COLORBOND® steel are the registered trademarks of BlueScope Steel Limited under license to Tata BlueScope Steel Limited.
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CS/PM/6.4/0513/VY
