Flat Carbon Europe Aluzinc in building Guide to good on-site practices
Summary Introduction 1. What is Aluzinc? 1.1 Properties 1.2 A 25-year warranty in building 1.3 Applications 1.4 Availability 1.5 Easyfilm E 1.6 Building certifications 2. Recommendations and precautions: from transporting to installing sheets 2.1 Transportation 2.2 Unloading on site 2.3 Storage of sheets on site 2.4 Handling of sheets on site 2.5 Working Aluzinc (Cutting / Welding / Sheet marking / Adhesive bonding / Sealants / Lock seaming / Brazing / Painting / Specific situations) 2.6 Final assembly of sheets: essential precautions 2.7 Limits and constraints of Aluzinc : incompatible materials and environments 3. Choose the right Aluzinc sheet to suit the end-use application 3.1 End-use applications and choice of Aluzinc sheet 3.2 Visually innovative and architectural façades => Aluzinc Florelis 3.3 Roofs 4. Uses for Aluzinc in the construction industry 4.1 Outdoor applications 4.2 Indoor applications 4.3 Miscellaneous panels and accessories 5. Contacts Conclusions Cover photo: Stuttgart Messe Stuttgart Trade Fair (Germany) / Roof in Aluzinc / 2006 1
Introduction Sophysa plant Besançon (Brigitte Métra & Associates) Aluzinc is a flat carbon steel coated with an alloy comprising 55% aluminium, 43.4% zinc and 1.6% silicon. Aluzinc has the advantage of a long lifespan in many environments, especially in the construction sector. Its excellent corrosion resistance is the result of the properties of aluminium, present on the surface of the coating, and zinc. While aluminium-zinc alloys offer the best possible durability, a few guidelines do need to be followed in terms of building design and on-site practices in order to optimise product performance. The following instructions therefore constitute the key recommendations for ensuring that your project can take full advantage of the exceptional durability of Aluzinc. 2
1. What is Aluzinc? 1.1 Properties The main properties of Aluzinc are: Excellent resistance to corrosion and perforation Aesthetic appearance (silvery metallic spangle) Good abrasion resistance due to its surface hardness Excellent thermal and light reflectivity Excellent resistance to high temperatures (up to 315 C) Ease of working: profiling, deep drawing, bending etc Environment-friendly product (100% chromium-free passivation & Easyfilm E) Product recommended for food storage (NFA 36-712-6 standard of April 2006) 1.2 A 25-year warranty in building After more than 30 years of successful observations in different climatic conditions in Europe and overseas, exhaustive tests and research, Aluzinc now comes with a 25-year warranty against perforation when used for building purposes (only for AZ185 coating). This guarantee is provided subject to specific conditions. => http://www.arcelormittal.com/fce/repository/brochures/aluzinc_warranty_en.pdf 1.3 Applications Nowadays, Aluzinc is commonly used for construction projects, and is acknowledged in Europe as the ideal solution for a wide range of applications such as roofing, façades (traditional, architectural with the aesthetic Florelis range and industrial), interior cladding, solar shading and water drainage systems (gutters, drainpipes etc), as well as for many indoor applications (ceilings, partitions etc). Photos of Aluzinc applications: courtesy of ArcelorMittal Dudelange 3
Besides construction, Aluzinc is also used in general industry applications: electrical cabinets, HVAC (heating, ventilation and air conditioning), automotive, domestic appliances, electronic equipment, metal furniture etc. 1.4 Availability Aluzinc is made by ArcelorMittal and is available in the following coatings and grades: Coating weight (g/m 2 double-sided) 100 / 150 / 165 / 185 Coating thickness (µm/side) 13 / 20 / 23 / 25 Thickness of coated product (mm) 0.23 => 2 Width (mm) 750 => 1500 Surface finishes Standard finish (normal spangle), improved finish (skinpassed) or aesthetic finish The steel grades available are as follows: S250 S280 S320 S350 S550 H300 H380 H420 DX51 DX56. 1.5 Easyfilm syfilm E Aluzinc is usually delivered with Easyfilm E, a film applied on the assembly line as a passivation and finishing treatment. Easyfilm E is a state-of-the-art coating, as it is 100% chromium-free and capable of meeting the most stringent environmental requirements, both now and in the future. Easyfilm E also offers additional benefits: - Gives total protection against fingerprinting - Acts as a dry lubricant, improving forming performance - Offers enhanced protection against corrosion, oxidation and black rust - Provides an adhesion base for powder paints 1.6 Building certifications With regard to its use for building purposes, Aluzinc is certified in many European countries, including France, the UK, Sweden and Germany. U 4
2. Recommendations and precautions: from transporting to installing sheets 2.1 Transportation A closed, tarpaulin-covered truck is strongly recommended for transporting Aluzinc sheets. The sheet steel must be properly strapped, possibly film-wrapped and placed on a palette during transportation in order to prevent any damage (water penetration, impact, indentation etc). This applies particularly to sheets intended for façades. Care should also be taken to avoid placing other materials on the stacks of sheets. 2.2 Unloading on site > When the sheets arrive on site, unload them carefully (if possible using specialised machinery, as pictured below), without knocking them or placing them directly in contact with other materials. > Leave the protective film on and maintain the same stacking of the sheets as during transportation. Africapresse.com 2.3 Storage of sheets on site The sheets must be kept dry, if possible in a sheltered and enclosed area, protected from any humidity and openings (increased risk of corrosion or even black rust for Aluzinc without surface treatment) and from overexposure to sunlight (which would subsequently make it more difficult to remove the film, thereby increasing the risk of marks). Storage and transport conditions must be the same: covered in tarpaulin, strapped and placed on palettes or stringers. Storage outdoors and without any protection is highly inadvisable. Julien Cescon 5
On site, temporary metal shelters are still the best solution for storing sheets before installation. Below are several options for storing Aluzinc sheets under cover: Wooden or plastic wedges Metal strapping Coversys Protective film left on Ewald Giebel Dudelange If it is not possible to store all of the sheets under cover while the project is underway, we strongly advise you to have the required quantity delivered daily (in batches); these would then be assembled in one day, eliminating the need for storage on site and avoiding exposure to bad weather and other site activities. Contact your supplier and come to an arrangement if possible, in order to minimise the risk of sheet deterioration. 6
If it is not possible for you to store the Aluzinc sheets in a covered shelter, adhere to the following recommendations to avoid any nasty surprises: 1 Cover the sheet stack with a thick tarpaulin in good condition. Ensure there is an air space at ground level, between the tarpaulin and the bottom of the stack. 2 Store the stack of sheets up off the ground. Incline the stack slightly to allow any rainwater or condensation to run off. 3 Check regularly that no moisture has penetrated under the tarpaulin or between the sheets. Incorrect storage can lead to deterioration of the coating or black rust, thereby reducing its protective function. Africapresse.com 2.4 Handling of sheets on site If the sheets are strapped or film-wrapped, take the necessary precautions when cutting the strapping or removing the film. Footprints/handprints, impacts, unnecessary movement of equipment etc should be strictly avoided. 7
Make sure that workers are provided with clean gloves suitable for handling metal. Safety is always the number 1 priority! Julien Cescon Scratched sheets as a result of an impact or incorrect handling during unwrapping or unloading. The film protecting the sheet must be removed after final installation of the panel. 2.5 Working Aluzinc => Cutting: Try to minimise cutting by using sheets already cut to size. If cutting is inevitable, it is preferable to t cut the sheets on the ground, if possible using a nibbler or a power chain saw, which are both highly suitable for this kind of work. It is essential to ensure that the ground is clean, or that it is covered in some way (e.g. with a tarpaulin or board) to prevent the sheets touching the ground. Cold shearing is preferable to flame-cutting or abrasive cutting. 8
ArcelorMittal Dudelange It is essential to carefully clear r away any metal turnings and other debris at the end of the working day. => Sheet welding: Aluzinc can be welded like most other metallic coated products. Nevertheless, the welding parameters should be adjusted to match its specific properties. Several welding techniques may be used (high/low frequency, spot, laser, seam etc), but the best option is arc welding. => Sheet marking: If possible, avoid writing on the sheets using a felt-tip or a thick lead pencil, as it will be very difficult to remove the marks. Moreover, the graphite in pencils may damage Aluzinc. Marker line made before drilling and now indelible two years after completion of the job Julien Cescon Try to keep unnecessary movements of equipment on site to a minimum. => Adhesive bonding of the sheets: This is now fairly standard in the building sector and is very practical in some cases, as it avoids subsequent repair of the surfaces. For Aluzinc, we recommend using EPOXIES (for structural applications) or POLYURETHANES (for domestic applications and in mild environments). 9
=> Sealants: Be careful with sealants that release acetic acid as they cure, as there is a risk that Aluzinc will be attacked. So make sure you carefully read the composition of the product used. Badly aligned joint, which causes runout and indelibly marks the sheet Julien Cescon => Lock seaming for roofs: This has proven to be an excellent solution, primarily for standing seam roofs, in order to compensate for lateral overlaps. A properly lock-seamed roof ensures that the sheet will have a long lifespan, since the risk of corrosion will be reduced and it will retain its appearance for longer. => Brazing: Although Aluzinc can be easily welded, welding should not be confused with brazing. The difference is that in brazing, the sheets are not joined by melting the steel but by applying a tin-lead alloy or a silver-based alloy (high-temperature brazing). Regardless of the option considered, brazing is highly inadvisable! => Painting: After being installed, Aluzinc can easily be painted for aesthetic reasons. ArcelorMittal Flat Carbon Europe manages and controls the manufacture of Aluzinc without surface treatment, and issues a guarantee for this product. We recommend that you contact the paint manufacturer to find out whether the paint to be used is compatible with the properties of Easyfilm E. Examples of Aluzinc tiles painted in different colours 10
=> Specific situations: Take special precautions when installing Aluzinc around chimneys and other types of stacks. The chimney stack opening must be protected according to the specific requirements for any metallic product. We advise you to place a protective layer around the stack so as to insulate the sheet as much as possible and protect it from any deposits or the risk of leaks. This also applies for vents, glazed skylights, forced-air and any other roof outlets. Lindab Example of a protected skylight in an Aluzinc roof 2.6 Final assembly of sheets: essential precautions => Choice of fastenings: It is advisable to affix the sheet using stainless steel, nylon, aluminium or, in the best-case scenario, Aluzinc. The fasteners and screws must also be compatible with Aluzinc (with identical corrosion resistance) and, in particular, must be tightened using a power drill. ArcelorMittal Dudelange Watch out for fingerprints from using a drill! 11
Leak tight screws for affixing metal sheets Julien Cescon IMPORTANT IMPORTANT IMPORTANT IMPORTANT The insulation between the fastening used and the sheet is of crucial importance, as it ensures the sheet is well able to withstand bad weather and is securely attached to the structure on which it is resting. Poor fastenings can lead to corrosion of the Aluzinc coating, with rust subsequently discolouring ing the sheet surface. Over-tightening the fasteni f astenings ngs can lead to depressions d on the sheets, where undesirable deposits of dirt and other debris can accumulate. It may, however, be possible to assemble the sheets without using fixing components, since Aluzinc is ideally suited to bending, stamping or stapling. As a result, flat joints or standard corners can easily be created. During installation of the sheet, several key precautions must be scrupulously observed. => Avoid footprints and handprints: Wear clean gloves and make sure that safety shoes are also clean free from impregnated dirt and with no stone fragments embedded in the soles if you need to walk on the finished Aluzinc surface. => Quickly clear away drill shavings, debris and other waste generated during installation: Nails, screws, bolts, staples and other fastenings may eventually have an adverse effect on the surface appearance of the sheet if they are left behind on the worksite. 12
Clear away any debris between the ribs Lindab Buildings Nails or screws left behind in the ribs may eventually rust, damaging the Aluzinc surface EuroZAC => Avoid the formation of puddles or pools of water w on the sheets: Premature corrosion may occur very quickly if water stagnates and cannot run off easily. Dirt may also accumulate and damage the surface of the sheet in the medium term. Please note that it is also vital to ensure that your roof has a minimum slope of 2 degrees. => Cleaning of the sheets: Check that the entire Aluzinc surface is completely free of any debris upon completion of the job. For the actual cleaning, we advise you to use soap with a ph < 10 and then rinse the impregnated surface with water. It is also possible to clean an Aluzinc surface using a Kärcher high-pressure cleaner. It is highly inadvisable to rub the sheet with hard materials such as sandpaper or a metal brush! If you have any additional questions concerning the precautions to be taken during final assembly of Aluzinc sheets, we advise you to get in touch directly with your ArcelorMittal contact. 13
Metallurgy Research Centre in LIEGE (B) - Façade in Aluzinc - ArcelorMittal Dudelange Agri-food cluster in CORBAS (F) - Façade in Aluzinc - Transalliance BELGIUM - Façade in Aluzinc - Limeparts 14
2.7 Limits and constraints of Aluzinc : incompatible materials and environments It is recommended that Aluzinc sheets should not be used in direct contact c with copper or lead. Highly humid environments such as ports or seaside areas (continual spraying with fresh or salt water, constant corrosive fumes or impregnated wood) are not recommended either, as they represent a major corrosion risk for the sheets. The same applies for alkaline environments, since they are likely to adversely affect the coating. Furthermore, the use of Aluzinc is definitely not recommended in buildings housing livestock because of the ammonia fumes given off when in direct contact with animal faeces. Livestock farming France Agricole Port areas Rotterdam scanner 15
3. Choose the right Aluzinc sheet to suit the end-use application 3.1 End-use application and choice of Aluzinc sheet Applications Roofs Façades Indoor applications (ceilings, partitions etc) Accessories for water drainage systems (guttering etc) Aluzinc sheet recommended Steel grades: DX51D to DX54D+AZ and S220GD to S250GD+AZ Coating: AZ185 Thicknesses: 0.5 0.8 mm NOTE: Minimum slope of 2 degrees! NOTE: Choose the Aluzinc HFX range (DX56D) for your standing seam roofs Steel grades: DX51D to DX56D+AZ and S220GD to S550GD+AZ Coating: AZ185 Thicknesses: 0.25 2 mm NOTE: Use the Florelis range (0.6 1.2 mm) to give your building a uniform look Steel grades: DX51D to DX56D+AZ and S220GD to S550GD+AZ Coatings: AZ185 AZ150 AZ100 AZ70* Thicknesses: 0.5 0.8 mm NOTE: Use the Florelis range (0.6 1.2 mm) to ensure a uniform look for your specific application Steel grade: DX56D+AZ Coating: AZ185 Thicknesses: 0.4 2 mm NOTE: Choose the Aluzinc HFX range Photos * AZ70 on request Lindab Buildings & ArcelorMittal Dudelange 3.2 Visually innovative and architectural façades => Aluzinc Florelis Prestigious architecture requires prestigious steel. Part of ArcelorMittal s aesthetic range of flat carbon steel, Aluzinc Florelis offers a one-of-a-kind finish and can guarantee a uniform spangle size. Specifically tailored for modern and contemporary façades, the Florelis range adds a creative touch to transform a unique building into a remarkable one. Coating AZ185 Florelis + Easyfilm E (compulsory) Steel grades DX51 S220 S250 S280 S320 Surface treatment Easyfilm E (compulsory) Thicknesses 0.6 1.2 mm (0.8 1 mm for grade S320) 16
Important recommendations for the Aluzinc Florelis range => The use of Aluzinc sheets from different production runs for assembly on the same façade should be strictly avoided. There is a risk of slight differences in their appearance in terms of spangle size, which could give the façade a patchy look when viewed from a short distance away. If you have any additional questions concerning the Aluzinc Florelis range, we advise you to get in touch directly with your ArcelorMittal contact. Gallieni school in Toulouse (F) Façade in Aluzinc Florelis ArcelorMittal Dudelange 3.3 Roofs The choice of Aluzinc sheets will depend mainly on the final position of the roof and its visibility. Visible or not, an Aluzinc roof must be laid by professional roofing specialists in accordance with the following guidelines: - Minimum slope of 2 - Overlapping of identical sheets across the whole roof - Identical fastenings throughout, suitable for use with Aluzinc Gallieni school in Toulouse (F) Roof in Aluzinc Antonio Martinelli 17
Visible roofs: Great care must be taken not to mix sheets: they should all come from the same production batch. This applies for high-profile roofs that are visible to everyone, where any differences in the sheets will affect the visual impact of the building. We therefore advise you to choose Aluzinc Florelis for this type of roof to ensure that its visual appearance is as uniform as possible. NON-visible roofs: Where the roof is not visible, as in the case of industrial buildings or structures over 10 metres high, Aluzinc Florelis is not required, since the constraints will not be the same. Standard Aluzinc will amply suffice to cover the building in question. The fact that no one will be able to see the roof also means that a few minor defects in visual appearance will be acceptable. Aluzinc HFX: Aluzinc HFX (High Formability extended) for standing seam roofs and rainwater systems combines extreme steel formability with the outstanding corrosion resistance of Aluzinc. The result is a new standard in roofing, replacing pure zinc sheets and offering a cost-effective alternative to other metallic solutions. Using Aluzinc HFX makes it easier for craftsmen to manually form various accessories (guttering, mounting systems, elbows etc). Aluzinc HFX requires steel grade DX56D, particularly for standing seam roofs. Examples of applications using Aluzinc HFX (steel grade DX56D) Lindab Buildings Traditional roof in Belgium with Aluzinc (steel grade S320) Lindab Buildings 18
4. Uses for Aluzinc inc in the construction industry 4.1 Outdoor applications Sports hall in TOULON (2006) Architect: Jean CHABANNE & Partner Façade in Aluzinc Cassette panels Coating: AZ185 Thickness: 1.5 mm ArcelorMittal Dudelange School & media library in CAVAILLON (2006) Architect: AURA Agency, Marseille Façade in perforated Aluzinc Cassette panels Coating: AZ185 Thickness: 1.5 mm ArcelorMittal Dudelange Pharmaceutical plant in BESANCON (2007) Architect: Brigitte METRA Façade and solar shading in Aluzinc Slats Coating: AZ185 Thickness: 1.5 mm Julien Cescon Fire station in LIBOURNE (2009) Architect: Jean-Marie MAZIERES Façade in Aluzinc Panels with external deep drawing Coating: AZ185 Thickness: 1.2 mm Inter-Pliage 19
4.2 Indoor applications ArcelorMittal warehouse in FLORANGE (2006) Architect: Jean-Marie BOLLE Interior cladding in Aluzinc Cassette and sandwich panels Coating: AZ185 Thickness: 1.46 mm Imedia EuroAirport in BASEL (2003) Architect: Denis DIETSCHY Ceiling in Aluzinc Perforated anti-noise panels Coating: AZ150 Thickness: 0.6 mm Imedia Albert Schweitzer school in CRETEIL (2006) Architect: Gaëtan LE PENHUEL Solar shading in Aluzinc Perforated panels Coating: AZ185 Thickness: 1.5 mm Gaëtan Le Penhuel 4.3 Miscellaneous panels and accessories The panels shown below are those most commonly used in building. 20
ArcelorMittal In building projects, Aluzinc can be used for many m other applications, both visible and non- visible: => Industrial doors, garage doors, handrails, cable trays, firewalls, letter boxes, metal shutters and rolling steel doors etc. 21
5. Contacts ArcelorMittal Flat Carbon Europe 19, avenue de la Liberté L-2930 Luxembourg Website: www.arcelormittal.com/industry E-mail: fce.technical.assistance@arcelormittal.com ArcelorMittal Flat Carbon Europe agencies Website: http://www.arcelormittal.com/fce/prg/agencies_map.html ------------------------------------------------------------ Conclusions Studies carried out in recent years have shown how well Aluzinc performs, whether it is used for roofing or façades: excellent corrosion resistance, exceptionally long-lasting aesthetic appearance and remarkable formability (bending, profiling etc). ArcelorMittal Flat Carbon Europe therefore backs the Aluzinc AZ185 coating with a 25-year warranty against corrosion, in the construction sector. The aim of this document is not to prevent every problem that might occur on a worksite, but rather to offer you some guidance to help you optimise any project in which Aluzinc is used. We therefore strongly advise you to follow the instructions provided to ensure that your project is a complete success, achieving an aesthetically pleasing result that will last for many years! 22