North American Performance Validation

For
AESTHETICS
and
DURABILITY
the choice for buildings is
PREPAINTED
55% Al-Zn
COATED STEEL

55% Al-Zn
THE MAGIC FORMULA
FOR METAL BUILDINGS
 55% Al-Zn
THE MAGIC FORMULA
FOR METAL BUILDINGS
The range of metallic and non-metallic materials for building construction is so broad that
choosing the right materials can become confusing. By selecting modern coated steels, you
can avoid these headaches because modern coated steels are engineered materials with the
optimum combination of S•A•F•E attributes — predictable Strength, unique Affordability,
premier eco-Friendly credentials and Enduring performance.*

The durability of modern coated steels is the result of the corrosion protection that the metallic
coating provides to the steel. The most familiar example of coated steels is hot-dip galvanized
steels whose zinc coating protects the steel from corrosion and gives many years of useful
life, which in most cases far exceeds that of conventional non-metallic materials. Newer, more
advanced coatings such as 55% Al-Zn coated steels provide for even longer service life and
extend the durability of modern coated steels.

In North America, Europe and Africa, it’s generally known as GALVALUME®, ALUZINC®, Z-NAL®,
ZINTRO-ALUM® or GALVAL® and other internationally recognized trademarks. But whatever
the name, one thing is certain: 55% Al-Zn is the Magic Formula for guaranteeing the long-term
durability of prepainted metal buildings. Even in the most aggressive acid rain environments,
the 55 % Al-Zn coating continues to provide protection long after the corrosion protection of
ordinary zinc coatings has been exhausted. This means that the 55% Al-Zn coating will provide a
minimum of twice the expected life as hot-dip galvanized coatings of the same coating thickness.

It’s no surprise, then, that 55% Al-Zn coated steels are the fastest-growing coatings in the
construction market. The technology to make these advanced coatings is licensed by BIEC
International Inc. to manufacturers in more than 20 countries on six continents. The exponential
growth of these coated steels has seen more than 45 million tons produced in the last ten years,
and with licensees and the aggressive substitution of these products for other materials with
inferior S•A•F•E attributes, it is predicted that the cumulative global production of 55% Al-Zn
coated steels will exceed 100 million tons by the end of the decade. One of the fastest growing
application segments for 55% Al-Zn coated steels is in prepainted products. It is becoming
increasingly clear that the performance advantages of prepainted 55% Al-Zn coatings far exceed
those of other roofing materials. Thus, 55% Al-Zn is the Magic Formula for metal buildings.

This report covers surveys of established metal buildings utilizing both prepainted 55% Al-Zn
coated, and prepainted hot-dip galvanized, steels in the most aggressive acid rain zones of
North America.

* A recent survey by Ducker International identified service life/longevity and life cycle costs as the most important criteria
in the selection of roofing systems and indicated that the metal industry was ideally positioned based on current solutions
and offerings.
Galvalume®, Aluzinc®, Z-Nal®, Zintro-Alum®, and Galval® are internationally recognized and registered trademarks of BIEC
International Inc. or one of its licensed producers.
2
 SUMMARY OF FINDINGS
• Different areas of a building panel will deteriorate at different rates depending on
(a) the amount of strain experienced by the metal in forming the panel and (b) the time of
wetness experienced by the panel during use. In areas of high strain, such as at minor ribs,
crazing of the paint film and cracking of the underlying metallic coating allow corrosion to
initiate. The most aggressive corrosion is observed at drip edges where the increased times of
wetness mean that corrosion agents are present for longer periods of time. In other areas, with
lower strains and/or reduced times of wetness, corrosion continues to occur but usually at a
much slower rate. In these locations, material performance differences are not as noticeable and
extended exposure times are needed before the superior durability of 55% Al-Zn coated steels
becomes evident.

• On initial exposure, the rate of deterioration at the panel sites subjected to the most aggressive
corrosion – the drip edge – can be marginally lower for prepainted hot-dip galvanized steels
than it is with the more advanced prepainted 55% Al-Zn coated steels. This behavior will
persist for a period of time that depends on a number of factors, such as the specifics of the
environment and the metallic coating weight; typically it lasts 5 to 7 years. However, it is not
sustained and after about 10 years, neglible performance differences exist. Extended exposures,
beyond 10 years, increasingly show the enhanced durability of 55% Al-Zn coated steels, with
the rate of deterioration of the prepainted hot-dip galvanized substrates being more than twice
that of prepainted 55% Al-Zn steel substrates. This classical performance ‘cross-over’ effect
in the corrosion performance at the most corrosion-prone panel areas has been observed in
many studies throughout the world. In less corrosion-prone areas, the performance differences
between the coated steels are negligible and the overall performance improvements of
55% Al-Zn coated steels are evident from the initial exposure.

• When the metallic coating and the steel substrate in hot-dip galvanized steel are exposed to
corrosion agents, either through coating cracks or at cut edges, the zinc preferentially corrodes
to sacrificially protect the steel substrate. This anodic dissolution of the zinc occurs quite
rapidly. When all of the zinc has been consumed, the steel will rust and eventually perforate.
The appearance of red rust signifies that the zinc coating has exhausted all ability to protect
the steel from further corrosion. For 55% Al-Zn coatings, the zinc reservoir is smaller so that
the initial sacrificial protection provided to the steel is not as effective. But, the aluminum in
the 55% Al-Zn coating significantly modifies the corrosion process because, in this case, the
corrosion products are insoluble and restrict access of the corrosion agents to the steel, with the
result that the corrosion rate is reduced from the higher initial rate.

• These field surveys have consistently confirmed that for long-term durability, 55% Al-Zn coated
steel is a superior substrate for prepainted applications than hot-dip galvanized steel. While the
prepaint coating provides the aesthetics, it is the choice of substrate that defines the overall
product life. For both aesthetics and long-term durability, 55% Al-Zn coated steels is the superior
choice of substrate for prepainted applications.

3
 At the drip edge, the increased time of wetness produces the
most aggressive corrosion — 55% Al-Zn coatings enhance
the long term durability of prepainted steels

Drip edge of a prepainted GALVALUME roof on a 20-year old

building in an acid rain environment, Pennsylvania, U.S.A.

Drip edge of a prepainted galvanized steel roof on a 21-year old

building in an acid rain environment, Pennsylvania, U.S.A.

4
In depth evaluations of buildings with ages from 5 years to more than 25 years, located in
the most acid rain prone areas of North America, confirm three phases of relative per-
formances of prepainted 55% Al-Zn coated steel and prepainted hot-dip galvanized steel
in the most severe corrosion-prone area of the roof — the drip edge.

• In Phase I, which lasts for about 10 years the relative corrosion performance is similar;
zinc’s initially more effective sacrificial protection is not sustained and at the end of this
phase, there is no difference in relative performance.
• In Phase II, from 10 to 15 years of life – beyond the useful life of many competitive non
metallic materials – the combination of barrier and sacrificial protection of 55% Al-Zn
coatings begins to outperform the sacrificial corrosion protection mechanism of hot-dip
galvanized steels.
• In Phase III, which is the period in excess of 15 years, the enhanced durability of
prepainted 55% Al-Zn coated steels is increasingly evident and the rate of corrosion is
less than half the rate of prepainted hot-dip galvanized steel.

Phase II

Phase III

Phase I

5
 To resist corrosion initiated at panel bends and damage sites,
55% Al–Zn coated steel is a better choice of substrate for prepainting
HOT-DIP GALVANIZED
PREPAINTED
55% AL-ZN COATING
PREPAINTED

Corrosion performance at buildings in rural/acid rain Ontario:

hot-dip galvanized after 21 years; 55%Al-Zn coating after 17.5 years.
HOT-DIP GALVANIZED
PREPAINTED
55% AL-ZN COATING
PREPAINTED

Corrosion performance at a manufactured defect (scribe) on buildings

in heavy industrial Ontario after 20 years exposure.

6
 The choice of substrates for the prepaint system has a major influence
on the corrosion durability of bends in the panel.
Long-term evaluations confirm that 55% Al-Zn coated steels outperform hot-dip
galvanized at panel bends. At the more heavily-strained minor ribs, the performance
differences are even more evident with the hot-dip galvanized performance deteriorating
more than twice as fast as 55% Al-Zn coatings after 15 to 20 years exposure.

70 Hot-dip galvanized steel

open circles– minor ribs
closed circles– major ribs
60

50
Deterioration [%]

40

30

20

10
55% Al-Zn coated steel
open triangles– minor ribs
closed triangles– major ribs
0
10 15 20 25 30

Age of Building [Years]

During roll forming, the major ribs are formed first and serve as locking points for the
subsequent forming that produces the minor ribs. The minor bends are therefore more
highly strained and can cause the paint and the metallic coatings to crack. When the zinc’s
galvanic protection has been depleted, the prepainted hot-dip galvanized steel begins
to quickly corrode and the appearance of red rust at the bends indicates the corrosion
protection from the zinc has been exhausted. In contrast, the corrosion products of the
coating of 55% Al-Zn inhibit further corrosion and extend the useful life of the building.

7
 55% Al-Zn
THE MAGIC FORMULA
FOR METAL BUILDINGS
The North American field inspection surveys covered in this paper were carried out in 2004 and 2005.
They confirm the results of controlled long-term outdoor evaluations of test coupons — in aggressive
acid rain environments, the long-term durability of prepainted 55% Al-Zn coated steels is superior to that
of prepainted hot-dip galvanized steels and other roofing materials. These steels are marketed in North
America, Europe and Africa under a variety of brand names, including GALVALUME, ALUZINC, Z-NAL,
ZINTRO-ALUM, GALVAL, etc. but all products from a licensed manufacturer producing coated steels with
55% Al-Zn Magic Formula will perform similarly.
• The inspections were performed by experienced engineers from BIEC International Inc. and
from manufacturing licensees in North America.
• The buildings inspected used 55% Al-Zn coated steels designated AZ55, with a
nominal coating thickness of 20 µm [0.008] and a nominal coating weight of 165 g/sq.m
[0.55 oz./sq.ft]. The G90 hot-dip galvanized coating had the same nominal thickness and a
coating weight of 275 g/sq.m [0.9 oz/sq.ft ]
• The inspectors noted the age, location, slope, general appearance and local environmental
conditions of the buildings, in addition to measuring both the visibility and severity of
corrosion at five key component locations — flat panel, major rib, minor rib, drip edge and
longitudinal edge.
• The results described in this paper are based on the use of a consistent methodology that
rapidly determines the overall performance of the coated steels from a visible corrosion
standpoint. The results are based on close visual examination, careful measurement and
subsequent study of photographic evidence by professionals with extensive experience in
evaluating material performance. The results represent the performance to be expected in
the field and will vary with exposure environment and specific paint system used. The results
reported in this paper are, therefore, neither guaranteed nor warranted.

55% Al-Zn Coated Sheet Producers of North America, Europe and Africa
For more information and details of manufacturers and sales agencies,
visit www.steelroofing.com or www.roofsteel.com
This paper is produced by the ZAC Association
1111 Main Street, Suite 545, Vancouver, WA 98660, USA, March 2007