USS Galvalume sheet is a cold rolled steel sheet with a coating of an aluminum - zinc-silicon alloy, applied by the continuous

hot-dip process. The coating gives Galvalume steel sheet the best properties of aluminum - coated and galvanized steel sheets. The presence of aluminum in the aluminum - zinc alloy coating provides improved barrier corrosion resistance and heat reflectivity to the cold rolled steel substrate . The addition of zinc provides a high level of galvanic protection against corrosion at cut edges, cracks and scratches. Galvalume ' s surface has a small, uniform spangle and a smooth , bright appearance that makes it attractive when used for exposed unpainted applications.

Convenient availabilityIrvin Plant

USS makes Galvalume sheet on one of the three coating lines at its Irvin Plant sheet-processing facility. The Irvin Galvalume line is equipped with modern coating equipment and its workers have years of production experience with zinc and aluminum coating. Located in the Pittsburgh area, Irvin provides a convenient shipping point for Galvalume sheet. USS Galvalume sheet is available in steel thicknesses from 0.015 inch to 0.052 inch, in widths to 48 inches, with yield strength levels to 80 ksi. (minimum) Two surface finishes are available: regular spangle (small, uniform bright spangle) and extra-smooth (matte finish for applications where critical surface finish is desired).

Coating thickness
USS offers two coating weights for most applications, 0.50 ounce per square foot (150 g/m2) and 0.55 ounce per square foot (165 g/m2) as shown in the chart below. Designations for these coatings are AZ50 and AZ55, respectively. The AZ55 coating is specified for unpainted metal buildings. The AZ50 coating, which has a thickness approximately equivalent to a G90 galvanized coating, is recommended for prepainted metal building applications, and most other applications. Lighter coating weights are available for special applications that require enhanced formability or weldability.

Long - term economy

Because of the two-way protection afforded by the aluminim-zinc coating, Galvalume sheet offers at least twice the service life of galvanized steel with the same coating thickness. In some areas, the service life is extended three to four times. This has been verified by actual atmospheric exposure corrosion tests conducted over a period of more than 17 years in environmental conditions ranging from rural to severe marine atmospheres. These test results are much more significant than laboratory accelerated tests because they show the performance in the same environments as those encountered in actual service. Observations on test panels exposed for as long as 21 years substantiate the fact that Galvalume offers long term durability. USS Galvalume costs about the same, on a per-square-foot basis, as USS G-90 galvanized sheet. Therefore, because it lasts longer, Galvalume is a low cost-peryear alternative to other coated sheet.

Triple Spot Test Coating Minimum oz./ft2 (g/m2) Designation (total both sides)

Single Spot Test

Minimum oz ./ ft2 (g /m2) Thickness, mil (total both sides ) ( per side)

Al-rich area Zn-rich area

Alloy bond layer Steel

a. Galvalume Coating Cross-Section b. Modernized exit end of the Galvalume coating line at the USS Irvin plant near Pittsburgh. The line's new

features give USS Galvalume a competitive edge in overall product quality.

Galvalume is a trademark of Bethlehem Steel Corp.

USS Galvalume sheet qualities ( ASTM A792)

Commercial Quality
Galvalume steel of this quality is intended primarily for bending and moderate forming applications. Typical applications include overhead doors, toaster parts and walk-in cooler panels. Structural (Physical ) Quality USS Galvalume steel sheet of this quality is intended for use where load-bearing capability is a consideration in design.
It is provided to meet specified mechanical test properties including yield strength, tensile strength and elongation. The minimum mechanical property requirements of the various grades when specified to ASTM A792 are shown in the table below. Typical applications include metal building roofing and siding.
71

Lock Forming Quality

Galvalume sheet of this quality is intended primarily for use in fabrication where the material will be subjected to lock forming or other bending operations that involve small bend radii. High speed forming and the tight bends involved in lock forming impose severe requirements-in excess of the formability requirements of Commercial Quality-on both the base metal and the coating. Typical applications include ductwork, downspouts, trim parts and brackets.

ASTM A792 Specification - Mechanical Properties

Yield Strength Minimum Tensile Strength Minimum MPa 230 255 275 345 345 550 (ksi) 45 52 55 65 82 MPa Elongation in 50 mm (2") Minimum % 20 18 16 12 12

Grade
Structural (Physical) Quality ASTM A792 33 37 40 50A 50 B 80

(ksi)
33 37 40 50 50 80

310
360 380 450 570

* None specified

c. In-line tension leveler provides unsurpassed uniform flatness for.better appearance in your finished products. d. Operators' console includes a microprocessorbased controller to regulate the new tension leveler. e. Galvalume coil, ready for shipping.

Corrosion resistance
USS Galvalume's unique coating composition of aluminum and zinc offers superior corrosion resistance.

Cut edge protection

The zinc causes the Galvalume coating to behave somewhat like a zinc (galvanized) coating. On exposure to water or moisture, the zinc in the Galvalume coating enters into an electrochemical reaction with exposed steel at a cut edge, crack or other break in the coating. This reaction is the critical feature that inhibits corrosion of exposed steel.

Best all-around corrosion protection

The result is long-term performance. USS offers its customers a limited 20-year, 6-month warranty against rupture, perforation or structural failure due to corrosion when Galvalume sheet is used in roofing or siding applications, exposed to normal atmospheric conditions. USS Galvalume sheet's combined protection of aluminum and zinc has been shown to provide a minimum of twice the corrosion resistance-in most atmospheric environments-and as much as four times in some environments than galvanized steel having the same coating thickness. This superior performance has been demonstrated by exposure tests conducted in a wide range of environments, as shown in the chart below.

Long - term durability

The aluminum causes the Galvalume coating to behave somewhat like an aluminum coated steel in that it helps to form an insoluble oxide film on the surface of the coating. This film shields both the coating and the steel from water and air. In this way it provides not only long-term protection of the steel but also protection against excessive corrosion of the coating itself.

Atmospheric corrosion losses of Galvalume steel and galvanized steel after 13 years ' exposure 30 to horizontal ( average top and bottom surface). Coating Loss (m) 25.0 22.5

Galvanized (G90)

Galvalume (AZ50)

2.5 0

(Severe Marine )

( Marine)

(Industrial)

(Rural)

Edge appearance of coated sheets after 13-y ear industrial exposure.

Surface protection
Unless otherwise specified, USS Galvalume sheet is chemically treated (passivated) and oiled with a vanishing oil to prevent the formation of storage stains. When properly passivated, USS Galvalume sheet is significantly more resistant to storage staining than galvanized sheet.

Galvanized (G90)

Galvalume (AZ55)

Prepainted GALVALUME SHEET

USS Prepainted Galvalume combines a superior paint system with the exceptional corrosion resistance of the aluminum - zinc alloy coating. The combination provides a prepainted sheet product that has long - term durability not previously attainable. This new standard of durability is the basis for the USS 20 - year , 6-month limited warranty against substrate perforation for Prepainted Galvalume. USS Prepainted Galvalume sheet has the same range of attractive colors and finishes as other coated steel products. For Prepainted Galvalume, the two-coat paint system includes primers formulated specifically for Galvalume to minimize edge creep and improve adhesion of the top coat paint film. In addition, USS Prepainted Galvalume receives a chromate pretreatment on the coil-coating line to

further improve corrosion resistance. These steps along with rigorously controlled processing practices and quality control on the coil paint lines result in a high-performance prepainted steel sheet.

Today's Prepainted Galvalume and prepainted galvanized sheet exhibit comparable rates of edge creep on the basis of accelerated corrosion tests and several years atmospheric exposure.

Experience shows that Prepainted Galvalume offers distinct advantages over prepainted galvanized steel: Better overall paint adhesion during roll forming. Less crazing of the paint at bends, thus reducing the amount of direct contact of the aluminum-zinc coating and steel with corrosive media. Less chance of storage staining at job sites.
Improved corrosion protection at paintdamaged areas. These advantages-combined with the improved paint systems and processing developments-make new Prepainted Galvalume an outstanding product for metal buildings.

GALVALUME SHEET...

Compatibility with other materials

Most of the fabrication and building materials used with galvanized steel can be used with Galvalume steel. Avoid lead and copper. These two metals will react with Galvalume as they do with galvanized sheet and can result in accelerated corrosion of the coating wherever contact is made. Avoid use of lead-such as lead nails, lead washers and lead flashing. Contact with copper and water runoff from copper flashing also should be avoided.

develop proper lubrication methods for your operation. To provide for effective lubrication when the product is ordered dry (no oil), it is recommended that the lubricant be applied with felt pads to both surfaces or directly applied onto the forming rolls before the material enters the forming rolls. It is also suggested that chromiumplated rolls be used to protect the coating from burnishing and scratching.
Vanishing oils are recommended for roll forming because they dry quickly without leaving a slippery surface. Bending -Laboratory tests show good adherence of the aluminum-zinc coating to the steel substrate during bending operations. As with galvanized, some crazing of the coating may occur on the outside of a 180 bend. The Galvalume coating is susceptible to flaking under very severe bending, depending on the thickness of the steel and coating. Flaking at reverse bends can be eliminated in many cases by increasing the radius of the die.

High temperature performance

Heat resistance -Galvalume sheet serves as a cost-saving substitute for aluminum-coated Type I sheet in intermediate temperature applications. When used at temperatures up to 600F, Galvalume does not discolor under continuous or intermittent exposure during prolonged periods. In some applications, Galvalume performs well at substantially higher temperatures. A special gradeGalvalume HT-is available for applications such as heat shields and gas burner grills. Heat reflectivity -Galvalume sheet has excellent heat reflectivity at temperatures up to 600F-equal to that of aluminum coated Type II sheet.

Resistance Welding (Spot & Seam) Because the aluminum-zinc coating on the sheet surface affects the flow of electric current, resistance welding of Galvalume steel requires welding currents, welding times and electrode forces higher than those for similar thicknesses of uncoated cold rolled steel. These welding parameters are similar to those normally used on galvanized steel. However, experience has shown that the welding parameters for resistance welding Galvalume are somewhat more restrictive. Soldering -We do not recommend the soldering of Galvalume steel. Like aluminum-coated steel, Galvalume steel is more difficult to solder than galvanized because of the aluminum oxide on the sheet's surface and the high soldering temperatures required for the flux to remove the oxide. Instead, the recommended practice is to use fasteners and sealants. Mechanical fasteners -Fasteners should be selected on the basis of compatibility with Galvalume steel to ensure best overall performance of the building system. The life expectancy of the fasteners should be selected to match the life expectancy of the Galvalume steel roof. Rivets and other fasteners containing lead or copper must never be used

Drawing -A Drawing Quality grade is

not available at present: therefore, deep draws with Galvalume sheet are not

recommended. However, some

draws can be achieved with special processing during production. Please check your specific requirement with a

USS Metallurgical Service Representative.

Stretching -Tests show that Galvalume steel maintains coating adhesion when

in conjunction with Galvalume steel

because they seriously reduce the corrosion resistance of the Galvalume coating. For more information, consult a fastener manufacturer or contact our Metallurgical Service Department. Sealants -A neutral cure silicone rubber sealant is recommended for forming of watertight joints. This material needs no primer. It's flexible and non-corrosive, as well as resistant to heat, cold, water and ultra-violet rays. In selecting a silicone rubber sealant, care should be taken to avoid those with acetic acid or amines, which can promote corrosion during early stages of curing. Other types of sealants, such as butyl rubber and styrene butadiene rubber, may also be considered for certain applications. For more information, consult a sealant manufacturer or contact our Metallurgical Service Department.

Formability
For many applications, Galvalume steel sheet can be formed as readily as the comparable grade (CQ, LFQ, SQ, etc.) of continuously annealed galvanized sheet. For applications that require very high levels of formability, special annealing practices have been developed. Roll forming -Galvalume can be readily roll formed... and many processors routinely roll-form products (such as roofing and siding panels) that include a number of relatively small diameter bend radii.

stretched to the point where the steel substrate fractures. However, some crazing may occur on severe stretching applications.

Fastening
A wide range of fastening techniques, similar to those used for galvanized, can be used for Galvalume steel: Welding -Galvalume sheet is readily weldable using conventional resistance and arc welding processes.

Proper lubrication prevents the coating from burnishing and picking up on the forming rolls. Solvent-based lubricants, which leave no oil residue, can be used.
Water soluble lubricants are satisfactory only if the material is allowed to dry before stacking to avoid storage stain. Contact your lubricant oil manufacturer to 6

Size range (in.) Thickness: 0.015 to 0.052

Width: 24 to 48

Typical Physical Properties-Commercial Quality Galvalume Sheet

Yield Point (ksi) Tensile Strength (ksi) Elongation (% in 2 inches) Hardness (HRB) % by volume (approximate) 80% 19% 1% 38-53 50-65 20/36 50/65

Coating composition
0 by weight Constituent ^ (nominal) Aluminum Zinc 55 43.4 1.6

Corrosion performance of Galvalume and galvanized coated steels in rural atmosphere

0,6 7E o .73
LU cn C

Silicon

(Saylorsburg , Pa.)

Coating weight and thickness AZ55-Unpainted metal building applications AZ50-Prepainted metal building and non-building applications (AZ55 may be used for non-building applications if requested by customer) The AZ50 coating has a nominal thickness of 0.8 mil (one side) which is equivalent to the thickness of a G90 galvanized coating. Surface Types Regular (small spangle) Extra smooth (matte finish) Steel sheet qualities CQ (Commercial Quality) LFQ (Lock Forming Quality) SQ (Physical Quality-Yield minimums from 33 ksi to 80 ksi)

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w C7 02 GALVANIZED SHEET

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GALVALUME SHEET

4 6 8 10 12 E XPOSU RE TIME , YEAR S

Corrosion performance of Galvalume and galvanized coated steels in industrial

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(Bethl e h em, P a.)

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A D U S S-30-8676-01 Printed in U.S.A. February, 1987

Galvalume is a trademark of Bethlehem Steel Corp.

USS is a registered trademark