Roof&Wall

ROOFING & WALLINGWE’LL MAKE YOUR DREAM A REALITY

No matter what style or structure, ZINCALUME® steel has the design flexibility that allows you to truly express your architectural creativity. Its lightweight and free-spanning capabilities help transform your vision to reality.

Be creative in your designs, whether it is a commercial, industrial or residential project. Design classic roofing styles... or simply add a touch of class to create contemporary style buildings. ZINCALUME® steel has excellent forming capabilities that can be used with striking effect to create innovative building designs.

Excellent FlexibilityZINCALUME® steel has the unique ability to complement both traditional and ultra modern architecture. It can be made to fit individual designs, allowing you to design buildings that are curved, waved, angled or straight.

Versatile, Durable, LightweightZINCALUME® steel is not only flexible, it is also versatile, durable, lightweight and cost effective. Its lightweight capability means that it is easily transported from one place to another and is also easily erected. This saves time and effort in completing a project.

DESIGNFREEDOM TO

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YOU CAN MAKE A

The coating on ZINCALUME® steel comprises 55% aluminium, 43.5% zinc and 1.5% silicon, offering high levels of corrosion resistance to buildings. Over time, you will see the difference in its performance compared to Galvanised steel (G.I.).

DIFFERENCE

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OUTPERFORMS G.I.ZINCALUME® STEEL

Performance That Lasts...After extensive research and continuous development since its launch in 1976, ZINCALUME® steel has constantly set the standards for corrosion resistance and durable performance.

The zinc/aluminium alloy coating on ZINCALUME® steel has been designed to resist environmental corrosion by up to 4 times the lifespan of Galvanised steel (G.I.). In whatever project you’re building, the durability and strength of ZINCALUME® steel will keep it looking good for years.

Better PerformanceThe rate of corrosion depends primarily on the coating material and the environment in which the product is exposed to.

The 2 common methods used to assess the anticipated corrosion performance are:

• Salt Spray Testing (Figure 1)

• Atmospheric Exposure Test (Figure 2)

Conclusion:Both of these tests prove the superior quality of ZINCALUME® steel as the ultimate defence against corrosion as compared to Galvanised steel (G.I.).

The combination of aluminium and zinc coating on ZINCALUME® steel greatly enhances corrosion resistance. Therefore, it is able to withstand harsh weather conditions.

When subjected to Salt Spray Testing or the Atmospheric Exposure Test, ZINCALUME® steel is able to withstand them all because it is manufactured using state of the art technology that has been proven with continuous years of extensive research and development.

SALT SPRAY TESTING

Galvanised steel (G.I.) ZINCALUME® steel

Conducted in accordance to the ASTM test method B117 and AS1580.

Figure 1

Figure 2

AFTER 20 YEARS OFATMOSPHERIC EXPOSURE TEST

ZINCALUME® steel = still in good condition. Galvanised steel (G.I.) = shows significant red rust.

Galvanised steel (G.I.)Galvanised steel (G.I.)

ZINCALUME® steelZINCALUME® steel

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Z I N C A L U M E ® - s t e e l - i s m a n u f a c t u r e d - f o l l o w i n g s t r i n g e n t - p r o d u c t i o n s t a n d a r d s - t o - e n s u r e - i t s superior--performance--and durability. It meets Malaysian S t a n d a r d s - M S 1 1 9 6 - a n d Australian Standards AS1397 backed by BlueScope Steel’s guarantee of quality.

SUPERIORITYUNSURPASSED

Genuine Identification

Look for the brand that identifies the long-lasting guaranteed p e r f o r m a n c e o f g e n u i n e ZINCALUME® steel. Every sheet is fully supported by BlueScope Steel.

16:18 represents the time the product was produced.

01:Dec:03 represents the date the product was produced.

11 represents the manufacturing site at which the product was produced.

AZ150 represents the coating class grade (coating mass) 150: 150g/m2 total metallic coating.

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PERFORMANCEHIGH QUALITY

Thermally EfficientZINCALUME® steel is one of the most thermally efficient roofing and walling materials available today. Research has shown that the heat reflectivity of ZINCALUME® steel is superior than that of Galvanised steel (G.I.), which tends to weather more, resulting in less reflection and more heat is absorbed and emitted into the building. (Refer to Figure 1)

A roof made from ZINCALUME® steel reflects sunlight, thus keeping the interior of the building much cooler compared to a roof made from tiles or Galvanised steel (G.I.). The level of heat radiated into the building from tiles and asbestos cement is particularly high, and tiles have a higher thermal mass which takes longer to cool in the evening. A roof made from ZINCALUME® steel helps minimise this effect. (Refer to Figure 1)

0 50 100 150 200 250 300Heat radiated into Building (W/m2)

red brown

asbestos

Galvanised steel (G.I.)

ZINCALUME® steel

concrete orterra cotta tiles

Solar radiation

Heat radiateddownward into

building

solar radiation = 850 (W/m2)zero windspeed30ºC ambient temperature

Temperature

12 midnight

External temperature

Internal temperature - metal roofing

Internal temperature - concrete/clay tiles

12 noon 12 midnight

Comfortabletemperature

26 deg.C

Comparison of temperatures insidehouses using metal roofing and

concrete/clay tiles

Research By Dr Mohd Peter (UPM)

Figure 1

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Safe and SecureOne of the advantages of having a roof or wall made from ZINCALUME® steel is its ability to deter intruders. Unlike roof tiles which can be easily lifted off or smashed, the superior strength of ZINCALUME® steel made entirely in one whole sheet makes it almost impossible for intruders to break in.

Mark ResistantThe special resin coating protects the surface from marks made during roll-forming. Wear and tear on rolls can also be reduced. The resin coating also resists marks made by dirt from sweaty hands, moisture, boots, etc. for a better-looking finish after installation.

Double ProtectionThe double protection of ZINCALUME® steel is in the metallic coating, comprising 55% aluminium, 43.5% zinc and 1.5% silicon.

The aluminium element in the coating provides a tough physical barrier against extreme atmospheric conditions.

The zinc element in the metallic coating provides sacrificial galvanic protection to the base steel. The zinc will form a zinc compound at the cut edges and on the scratched area when there is water or moisture present. The zinc compound will then slow down the rate of corrosion and thus protecting the base steel.

CONFIDENCEUSE WITH

Easy To HandleZINCALUME® steel is less slippery because it reduces the need for lubricants during roll-forming. This makes it safer to walk on and easier to handle, especially for roof fixers on steeply pitched roofs.

ZINCALUME® steel is also more cost effective as lubricants are not required, resulting in lower manufacturing costs.

Easy To FastenZINCALUME® steel can be easily fastened using integral fastener systems including seam, tab and recess, and extruded interlock systems.

Easy To JoinThe best sealed joints are made using neutral-cure silicon sealants in conjunction with recommended fasteners.

Installation and Maintenance• When installed to manufacturer’s specifications, ZINCALUME®

steel is weather tight and secure.

• Avoid direct contact with lead or copper based materials that may induce corrosion when moisture or condensation are present.

• Care should be taken so that nails, rivets, swarf and metal filings are removed at the end of each day’s work.

• Leaves, dirt, timber and rags should not be placed on the sheet surface as they can retain moisture and chemicals that may cause early corrosion.

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Storing ZINCALUME®

steelThe passivated ZINCALUME® steel minimises staining problems associated with wet storage. However, it is recommended practice to keep the sheets stored indoors and to keep it dry in transit and in storage. Where outdoor storage is unavoidable, the standard sheets should be fully covered and kept off the ground to prevent water or condensation from being trapped in between surfaces. If packs should become wet, separate the sheets, wipe them with a clean, dry cloth and allow to air-dry.

Forming ZINCALUME®

steel

The clear resin film on the surface of ZINCALUME® steel acts as a lubricant during forming operations. Roll-forming lubricant is usually not needed. However, if a lubricant is deemed essential due to the severity of the profile being formed, then Shellsol-T, Solvent 11 or an equivalent formulation is recommended. Kerosene-based lubricants must not be used.

Figure 1: Correct Storage

The benefits of not using lubricants while forming ZINCALUME ® steel include:

• Reduced clean-up after processing

• Improved final appearance

• Less slippery surface

• No lubricant cost

• Reduces roll wear

Slitting ZINCALUME®

steelWhere friction drag pads are used to maintain tension during slitting / recoiling, pickup of the passivant can occur. The following guidelines are recommended:

• If drag pads are used then appropriate pad pressures should be utilised to minimise the frictional forces.

• If resin dust is produced by the drag pads, then an appropriate and approved respiratory device is recommended for personnel working in close proximity (1 – 2 metres).

• Drag pads should be disposed of in accordance with local government regulations.

Reliability and SupportYou can always rely on us for help as every sheet is backed by an official warranty* from BlueScope Steel. We have a full range of technical bulletins that provide practical guides showing the correct usage and maintenance of our products.

*Warranty terms and conditions apply.

TIPSUSAGE

Q.1 What are the basic differences in the production of Galvanised steel (G.I.) and ZINCALUME® steel ? The most significant difference is that the coating metal bath for ZINCALUME ® steel contains a zinc/aluminium alloy rather than the near-pure zinc for galvanizing. The coating bath temperature for the former is operated at 600ºc compared to 450ºc for the latter.

Q.2 Why is the ZINCALUME® steel surface much smoother than the galvanised product and why is it a matte finish? The surface and appearance of ZINCALUME ® steel is an inherent characteristic of the coating composition.

Q.3 Are the mechanical properties of Galvanised steel (G.I.) and ZINCALUME® steel products similar? Yes, however whilst they are similar it should be noted that the actual yield strength of ZINCALUME ® steel is slightly higher than those for the equivalent Galvanised steel (G.I.) resulting in increased spring-back during forming. This is due to the inherent strength of the ZINCALUME ® steel coating.

Q.4 What is the corrosion mechanism of the coating? The coating of ZINCALUME ® steel is an alloy of zinc and aluminium consisting essentially of approximately 20% zinc-rich areas and 80% aluminium-rich areas by volume. In the initial stage of exposure, the surface corrodes preferentially at zinc-rich areas which are well dispersed throughout the coating. In atmospheric exposure, the resulting corrosion of zinc and aluminium form an adherent protective layer at the zinc-rich areas which tend to control the corrosion rate to a useful low rate capable of providing sacrificial protection. After long exposure, when the zinc-rich areas have either been removed or stifled by corrosion product formation, the aluminium-rich areas corrode, also at a low rate and provide continued protection of the steel base.

Q.5 Where does the ZINCALUME® steel coating fit in the galvanic series which is based on electrical potential measurements and galvanic tests when immersed in sea water? It fits between zinc and aluminium. However, its tendency to initially act as a zinc surface and later, after a longer immersion time, more like an aluminium surface, causes it to shift from quite close to zinc in the early stages to close to aluminium after longer periods. Its behaviour depends on the nature of the environment, which in the case of the galvanic series is sea water.

Q.6 How does metallic coating affect the base metal thickness? The table below indicates the nominal additional thickness attributed to the different coatings.

By simple ratio analysis, it can be calculated that AZ150 has a 3.5% yield advantage over Z275 zinc coating.

AZ150 has approximately a 1.0% yield advantage over Z180 zinc coating.

It should be noted that these comparisons do not compare like to like as the potential life of ZINCALUME ® AZ150 steel coating is far more superior.

Q.9 Does ZINCALUME® steel weather well? Yes, ZINCALUME ® steel weathers and dulls far more slowly and evenly than Galvanised steel (G.I.).

Q.10 Is ZINCALUME® steel resistant to acids? While ZINCALUME ® steel is slightly more resistant to an acidic atmospheric environment than Galvanised steel (G.I.), such environments should be avoided.

Therefore, for ZINCALUME ® AZ150 steel with a 25 micron coating on each side, the Total Coating Thickness is determined by adding 0.05mm to the Base Steel Thickness. It should be noted that it is only the Base Metal Thickness (BMT) that provides the steel’s structural performance; and hence BlueScope Steel products are sold on the basis of Base Metal Thickness (BMT) or Base Steel Thickness (BST).

Q.7 How does AZ150 compare with galvanised Z275 and Z180 coatings? From the table in Q.6 it can be seen that Z275 coatings have a coating thickness of 0.04mm, while the coating thickness for ZINCALUME ® AZ150 steel is 0.05mm.

For the same coating thickness, ZINCALUME ® AZ150 steel can be expected to have a potential life of up to four times that of Z275 coated zinc.

For Galvanised steel (G.I.) , the potential life is directly proportional to the coating thickness. Z180 zinc-coated product, having only two thirds of the coating of Z275 will accordingly have a potential life that is two thirds of the heavier Z275 coating.

In this case, the ZINCALUME ® AZ150 steel potential life can be as much as five to six times the expected life of the Z180 coating.

Q.8 What are the yield advantages attainable as a result of using ZINCALUME® steel? Taking 0.42mm BMT steel as an example, the area per tonne of product is:

303.3 sq metres

285.5284.3278.8288.4

Uncoated

Z180Z200Z275AZ150

ZINCALUME® steel

Coating Coating Class Thickness

AZ150 0.05mm

Galvanised steel (G.I.)

Coating Coating Class Thickness

Z100 0.02mmZ180 0.03mmZ200 0.03mmZ275 0.04mmZ450 0.07mmZ600 0.09mm

QUESTIONS &

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Q.11 Is there any difference in the strength of full hard Galvanised steel (G.I.) and ZINCALUME® G550 steel of equal base metal thickness? ZINCALUME ® steel is marginally stronger than Galvanised steel (G.I.) due to an inherent strength in the zinc/ aluminium coating.

Q.12 What are the recommended lubricants for roll-forming? Resin coated ZINCALUME ® steel does not generally need roll-forming lubricants. However, should a lubricant be required, then Shellsol-T or Solvent 11 should be used.

Q.13 Passivation is a normal process applicable to Galvanised steel (G.I.). Is ZINCALUME® steel also passivated? Yes. Its purpose is to render the surfaces inert to particular environmental conditions, thus improving resistance to early formation of corrosion. This can be due to the atmosphere exposure or under closely- stacked conditions where water is present and air circulation limited i.e. coil of packed sheets. In the case of Galvanised steel (G.I.), the corrosion forms white rust while the same effect formed on ZINCALUME ® steel is black.

Q.14 Is the level of passivation for ZINCALUME® steel the same as for Galvanised steel (G.I.)? Yes, however ZINCALUME ® steel is now sealed with an organic layer over the passivation layer (RESIN COATED) offering many benefits to users of ZINCALUME ® steel.

Q.15 Should the same care be exercised with storage of ZINCALUME® steel and for Galvanised steel (G.I.) and if damaged by water, what would be the expected effects? Yes, the same prevention procedures are applicable to both. Whilst resin-coated ZINCALUME ® steel minimises the effects of water damage, it should still be avoided. Seriousness of water damage depends on the degree of such damage and black-staining may result if recommended storage procedures are not followed.

Q.16 Is salt water damage as disastrous for ZINCALUME® steel as it is for Galvanised steel (G.I.)? Yes.

Q.17 Are Galvanised steel (G.I.) and ZINCALUME® steel products compatible in contact with each other? Yes.

Q.18 Does ZINCALUME® steel have superior reflectance of solar radiation when compared to Galvanised steel (G.I.)? When new, ZINCALUME ® steel has a similar reflectivity to Galvanised steel (G.I.) but is more diffused. However, compared to Galvanised steel (G.I.), the durability of ZINCALUME ® steel will help retain a high level of reflectivity before dulling occurs.

Q.19 What is the effect on ZINCALUME® steel of perspiration from hands and other parts of the body? The use of resin-coated ZINCALUME ® steel virtually eliminates markings resulting from perspiration from hands and other parts of the body. It is recommended for safety reasons that gloves be used in the handling of ZINCALUME ® steel.

Q.20 Will the accumulation of leaf mould, mud and general rubbish (poultice corrosion) lead to early failure of the ZINCALUME® steel coating? Yes, in the same manner as Galvanised steel (G.I.) would be affected.

Q.21 Does any of the common materials likely to be encountered have an effect on ZINCALUME® steel? The only material having an effect generally believed to be peculiar to ZINCALUME ® steel but not Galvanised steel (G.I.) is uncoated lead. Therefore, lead washers, lead-headed nails and uncoated lead flashings must not be used. However, while uncoated lead is generally believed to be non-corrosive to Galvanised steel (G.I.), many instances of interaction have been experienced. Materials that should be avoided for both include bare steel, copper and copper-treated timber as used in garden logs, roofing shakes and shingles.

Q.22 Can ZINCALUME® steel and Galvanised steel (G.I.) accessories be mixed together? Yes, but it should be avoided because it is an illogical mix of materials due to the wide difference in potential lifespan.

Q.23 Does fall-out from flue pipes of oil or wood-burning fires damage ZINCALUME® steel sheets? Yes. It also affects Galvanised steel (G.I.) and pre-painted products. If possible, the height of the flue pipe should be such that the smoke has an opportunity to drift or be blown away from the roof.

Q.24 Is the material from which the fasteners are made important? Yes. The coating must have sufficient corrosion resistance to provide rust-free performance appropriate to the life of ZINCALUME ® steel coating. The appropriate fasteners for various environments are specified in AS3566.

Q.25 With respect to the degree of preparation, how does the field-painting of ZINCALUME® steel compare with Galvanised steel (G.I.)? Similar preparation is required for both with respect to the surface being clean and dry. For Galvanised steel (G.I.) surfaces however, an additional process of etch priming is recommended prior to painting ZINCALUME ® steel does not need a primer.

Q.26 How about expansion and contraction? Any difference between Galvanised steel (G.I.) and ZINCALUME® steel? No. The coating makes no difference at all to the thermal effects on the steel base.

Q.27 How does the aging performance of ZINCALUME® steel in storage compare to Galvanised steel (G.I.)? The ‘aging’ characteristic of both ZINCALUME ® steel and Galvanised steel (G.I.) is related to the chemical composition of the base steel and the processing undergone (i.e. tension levelling), than to the attributes of the respective coatings.

QUESTIONS &

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ANSWERS

ZINCALUME® is a registered trade mark of BlueScope Steel Limited.

BlueScope is a trade mark of BlueScope Steel Limited.

Copyright © 2007 by BlueScope Steel (Malaysia) Sdn. Bhd. All rights reserved. No part of this brochure may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without written permission of BlueScope Steel (Malaysia) Sdn. Bhd.

*Warranty terms and conditions apply.

This simple checklist is your guarantee of confidence in ZINCALUME® steel.

Made by BlueScope Steel Malaysia.

Termite proof.

Non-combustible.

Dimensional stability.

Durable, strong and lightweight.

Meets relevant Malaysian building codes.

Product performance is field tested.

Supported by a BlueScope Steel warranty*.

International Building Standards

To make sure your product is from BlueScope Steel, look for the ZINCALUME® steel brand mark.

BlueScope Steel (Malaysia) Sdn Bhd (223136-P) Lot 1551, Jalan Bukit Kapar, 42200 Kapar, Selangor Darul Ehsan, Malaysia.

Tel: 603-3361 6888 Fax: 603-3361 6889/6891 Website: www.bluescopesteel.com.my