Universidad Nacional de Chimborazo

NOVASINERGIA 2019, Vol. 2, No. 1, diciembre-mayo (50-79)

ISSN: 2631-2654

https://doi.org/10.37135/unach.ns.001.03.06

Review Article

http://novasinergia.unach.edu.ec

Review and long-term corrosion analysis of coatings based on Zinc-

Aluminium-Magnesium alloys, as an alternative to traditional zinc-

based coatings for cable trunking systems in electrical installations

Revisión y análisis de la corrosión a largo plazo de recubrimientos basados en

aleaciones de Zinc-Aluminio-Magnesio, como alternativa a los recubrimientos

tradicionales basados en cinc, para canalizaciones eléctricas.

Ernesto Chenoll-Mora *

1

, Vicente-Agustín Cloquell-Ballester

2

1

Engineering Projects Department. Universitat Politècnica de València. Valencia, Spain, 46022

2

ACUMA Research Centre. Universitat Politècnica de València. Valencia, Spain, 46022; cloquell@upv.es

* Correspondence: ernesto.chenoll@icloud.com

Recibido 12 enero 2019; Aceptado 10 abril 2019; Publicado 06 junio 2019

Abstract:

A review of the state of the art is presented regarding metal coatings based on zinc-

aluminium-magnesium alloys, for protection against corrosion in metallic trunking

systems, as an alternative to traditional zinc-based metal coatings. This revision covers

its evolution over time, the different qualities and designations existing in the market, its

structure and composition, the international standards that regulate them, the main

commercialized brands and their characteristics, the main metallic trunking

manufacturers that offer said alloys, and finally, an analysis of the resistance to corrosion

based on field tests and accelerated corrosion tests which have been part of this

investigation. From this analysis, a mathematical model has been determined for the

estimation of long-term corrosion, in which the logarithmic behavior of the corrosion-

time function is evidenced. All in all, the article pretends, on one hand, to be a

compendium of the key aspects to consider in this type of alloys and on the other hand,

to give support to the project engineer in the decision making process, which supposes

the election of this type of coating versus zinc-based coatings, providing the most relevant

aspects to be considered, in such a way as to ensure compliance with the specifications

of the project, in terms of resistance to corrosion.

Keywords:

Atmospheric corrosion, coatings, project, trunking, ZM alloys

Resumen:

Se presenta una revisión del estado del arte en lo que se refiere a recubrimientos

metálicos basados en aleaciones de cinc-aluminio-magnesio, para la protección frente a

la corrosión, de sistemas metálicos de canalización eléctrica, como alternativa a los

tradicionales recubrimientos metálicos basados en cinc. Esta revisión contempla su

evolución en el tiempo, las distintas calidades y designaciones existentes en el mercado,

su estructura y composición, la normativa internacional que los regula, las principales

marcas comercializadas y sus características, los principales fabricantes de canalización

eléctrica que ofrecen dichas aleaciones, y finalmente, un análisis de la resistencia a la

corrosión sobre la base de ensayos de campo y ensayos de corrosión acelerada, los

cuales han formado igualmente parte de esta investigación. A partir de dicho análisis, se

ha determinado un modelo matemático para la estimación de la corrosión a largo plazo,

en el que se evidencia el comportamiento logarítmico de la función corrosión-tiempo.

Con todo y con ello, el artículo pretende, por una parte, ser un compendio de los aspectos

clave a considerar en este tipo de aleaciones y por otra, dar soporte al ingeniero de

proyectos en la toma de decisión, que supone la elección de este tipo de recubrimiento

frente a los recubrimientos basados en zinc, proporcionándole los aspectos más

relevantes a considerar, de tal forma que se asegure el cumplimiento de las

especificaciones del proyecto en lo que a resistencia a la corrosión se refiere.

Palabras clave:

Corrosión atmosférica, recubrimientos, proyecto, canalización, aleaciones ZM

http://novasinergia.unach.edu.ec 51

1 Introduction

In the last years, several types of alloy coatings

have been developed, in order to improve the

performance of the traditional zinc-based metallic

coatings, so as to have a better corrosion

resistance while reducing the cost, thanks to the

reduction of the total mass of the coating per unit

of surface. Some authors already anticipated this

evolution like CSIC in Spain: “It can be

considered that zinc as anodic material has

practically reached its limit of development, being

currently displaced gradually by aluminium alloys

of equal current efficiency (90%), but with the

advantage of having a greater real current supply

... and best electrochemical equivalent" (González

& CSIC, 1984).

Manufacturers recommend this type of alloys in

applications where traditionally, zinc-based

coating protection was used, with high

thicknesses coating (post-galvanized) to be able to

withstand corrosion effects in a harsh

environment (road/civil engineering, housing,

farming, construction, rail-roads, electric power

and equipment, automobile parts, etc.), and in

electric equipment such as metallic cable trays

and trunkings for cable routing. Other arguments

for this alternative have been claimed, like better

energy efficiency in the production, aesthetics,

better self-healing protection in cuts and hem

flanges, etc. In addition, from a safety point of

view, the typical cutting edges of traditional hot-

dip galvanizing coating disappear.

At present, there´s a large amount of scattered

information around this type of alloys, such as

specific international normatives, qualities and

designations for purchasing purposes, many types

of corrosion tests (field tests and accelerated

tests), as well as large numbers of manufacturers

and types of end users.

The aim of this article is to gather, classify and

structure all this scattered information in order to

facilitate engineers and other users, a complete

summarized review of all the key aspects of these

alloys. At the same time, a dedicated analysis has

been done about long-term corrosion resistance,

since at present, there is no specific guideline

which provides all the findings of the actual

corrosion tests or values of reference to determine

the right thickness of the coating for a specific

application.

2. Methodology

2.1 Structure characterization

Structure characterization of the zinc-aluminium-

magnesium (ZM) alloys, according to Salgueiro

(Salgueiro et al., 2015a) is represented in figure 1,

where the ternary eutectic microstructures system

is based in Zn-Al- Zn

2

Mg and binary eutectic in

Zinc-Zn

2

Mg.

(a)

(b)

Figure 1: Characterization of the uncorroded Zn-Mg-Al

coating: (a) General structure. (b) High resolution

figure representing the detailed microstructure of the

ternary eutectic. Source: Own illustration based on

reference (Salgueiro et al., 2015b).

2.2 Corrosion behaviour

Companies producing zinc-aluminium-

magnesium (ZM), zinc-aluminium (ZA) and

aluminium-zinc (AZ) alloys claim its good

corrosion performance in front of zinc (Z), mostly

based in Neutral Salt Spray tests (ISO, 2015), like

Stahl



, shown in figure 2 (Stahl, 2013).

According to this manufacturer, the zinc-

magnesium complex, forms a solid barrier layer.

Reaction of oxygen and iron is slowed and creates

a barrier effect on cut edges, as can be observed in

figure 3 (Stahl, 2013):

http://novasinergia.unach.edu.ec 52

Figure 2: NSST corrosion resistance of Z and ZM materials. Source: Own illustration based on reference (Stahl, 2013).

Figure 3: Barrier layer effects creation in ZM materials. Source: Own illustration based on reference (Stahl, 2013)

Arcelor Mittal



, one of the most relevant

manufacturers of these types of alloys, claims

those features in a similar way as well:

“Aluminium corrodes more slowly than

zinc in most atmospheres because of its

barrier layer of very passive aluminium

oxide. However, this passive layer prevents

aluminium from adequately contributing

towards cathodic (sacrificial) protection.

Cathodic protection is the strong point of

zinc coatings, so if the coating is cut or

scratched, the zinc near the exposed area

will corrode first. The zinc-aluminium alloy

combines the strength of both zinc and

aluminium, giving better passive barrier

protection than regular galvanize, and

better sacrificial protection than alloy

coatings with lower zinc composition”

(Arcelor Mittal, 2013b).

In this sense, also crucial in the corrosion process

is the protective effect of the corrosion products.

Their composition and appearance along the

process are key in determining the corrosion

resistance. According to a specific research work

to investigate corrosion products on ZM alloys

(Prosek et al., 2014a; Schürz et al., 2010), it was

determined that corrosion products on ZM coated

steel consist mainly of hydrozincite,

Zn

5

(OH)

6

(CO

3

)

2

; zinc carbonate, ZnCO

3

and

zinc hydroxide, Zn(OH)

2

; with additions of

simonkolleite, Zn

5

(OH)

8

Cl

2

.

H

2

O and a

carbonate-containing magnesium species.

In the same line, other research works (Hosking

et al., 2007; Keppert et al., 2014; Prosek et al.,

2008; Prosek et al., 2014a; Salgueiro et al.,

2015b; Schuerz et al., 2009a), stated that

“magnesium accelerates the formation of a dense

corrosion product, Zinc chloride hydroxide

monohydrate, also called simonkolleite, which is

extremely stable”. It plays a key role as a

corrosion inhibitor for the base metal.

It is proven that ZM alloys have a very good

performance in sodium chloride-containing

atmospheres, due to the transformation of the ZM

coating into a stable aluminium-rich oxide layer,

which adheres on the steel substrate and protects

it against corrosive attack (Schuerz et al., 2009b).

Autocoat

®

, in a specific research work

(Autocoat, 2013), also demonstrated this fact by

Paint

Zinc

Steel

Red rust

Fe Fe

2+

OH

-

e

-

Zn

2+

O

2

Galvanized steel sheet with organic coating

Paint

Zinc-magnesium

Steel

Stable barrier layer

Fe

OH

-

e

-

Zn,Mg

Zn

2+

, Mg

2+

O

2

Zinc-Magnesium coated steel sheet with organic coating

http://novasinergia.unach.edu.ec 53

carrying out accelerated corrosion tests based on

different standards from the automotive sector

and the regular ISO 9227 neutral salt spray test

(ISO, 2012c). As can be clearly seen in table 1,

the higher chloride load in the test, the higher ZM

performance, measured as time to reach red rust.

Table 1: Time to red rust appearance as a function of testing conditions in weeks (Autocoat, 2013).

Open

Weekly chloride

load (mg/cm

2

)

HDG

(*)

7 µm

ZM

7 µm

ZM / HDG

Volvo test

4,5

3

5

1,7

New VDA test

1,35

1,5

3

2

Renault ECC1 test

1

2

6

3

VDA test

13,6

1,5

12

8

Neutral salt spray test

90

0,6

8

13

(*)

HDG: Hot Dip Galvanized (zinc-based coating)

However, for other environments with other

types of pollutants, the behaviour varies, and the

differences in performance are not so obvious, as

will be seen later. That´s why, regular Neutral

Salt Spray test (NSS) (ISO, 2012c), which has a

very high chlorine load, at present is not

considered valid to check corrosion resistance in

general. In addition, these tests are done in a

continuous mode (continuous sprayed water

during the entire duration of the test), which

causes that corrosion products cannot be

generated.

To avoid this, other types of accelerated

corrosion tests has been developed, led mostly by

the automotive sector, such as cyclic NSS tests,

like is the case of Renault



D17 2028/--C / ECC1

cycles (Renault, 2007), Volvo STD1027,3371

(Volvo, 2010a), Volvo STD1027 (Volvo,

2010b), Volvo STD423 (Volvo, 2009). In this

way, Galvazinc and Cetim (Galvazinc & Cetim,

2014) performed this type of test, using the

referred Volvo



higher acid content test, in

which 10 cycles of 24 h each, were done in a SO

2

atmosphere and where the corrosion resistance,

measured in zinc losses (µm), was slightly higher

than standard post-galvanization. Table 2 shows

the time distribution for one cycle and the test

conditions. Table 3 shows the final corrosion

results expressed in mass loss:

Looking at the tests results, it can be stated that

ZM coatings have in general, a good

performance in harsh atmospheres with high

humidity and high chloride load, but this

performance is less obvious in SO

2

/ acid

atmospheres or with low humidity. On the other

hand, it is also important to mention that more

and more, in many countries, mostly from

advanced economies, the level of SO

2

emissions

has been drastically reduced, while NO

x

emissions have increased (Stockholm-

Environment and health administration, 2006).

Table 2: 24 h cycle time distribution in Volvo



test

according to STD1027 (Volvo, 2010b).

24 h cycle time

distribution (h)

Conditions

4

50 ºC

2

35 ºC and 100% RH

(*)

2

SO

2

cabin at 35 ºC – SO

2

injected: 2 litres

16

-30 ºC

(*)

Relative Humidity

Table 3: Corrosion results expressed in coating mass

loss for each material tested by Galvazinc & Cetim

(Galvazinc & Cetim, 2014) in Volvo



test according

to STD1027 (Volvo, 2010b).

Material tested

Coating mass loss

(m)

Regular pre-galvanized

Z275

8,16

HDG post-galvanized

10,2

HDG + Oxide

No observed losses

ZM120 Magnelis



11,52

Finally, some publications also mention that in

low CO

2

atmospheres, ZM coatings are more

affected in terms of corrosion than pure zinc

coatings (LeBozec et al., 2013; Prosek et al.,

2014b).

http://novasinergia.unach.edu.ec 54

2.3 Relevant international standards

covering ZM coatings

2.3.1 Standards to classify

environments and corrosivity

category

Arcelor Mittal



Magnelis



Steel sheets or strips (Arcelor Mittal, 2013c)

94%

3%

-

C5-15 years

C5M-20 years

>200 h/m

Arcelor Mittal



Zagnelis

 (15)

Steel sheets or strips (Rich Clausius &

Arcelor Mittal, n.d.)

93.3%

3.7%

3%

-

N.D.

1

Arcelor Mittal



Aluzinc



Steel sheets or strips (Arcelor Mittal, 2013a)

43.4%

55%

0%

1.6% Si

C4-15 years

±100 h/m

Arcelor Mittal



Crapal



2

Steel wire (Arcelor Mittal, 2013b)

95%

5%

0%

-

1000 h NSS

1

Arcelor Mittal



Crapal



4

Steel wire (Arcelor Mittal, 2013b)

95%

5%

0%

-

2000 h NSS

1

Arcelor Mittal



CrapalOptimum



Steel wire (Arcelor Mittal, 2013b)

92%

5%

3%

-

2500 h NSS

1

Arcelor Mittal



CrapalPremium



Steel wire (Arcelor Mittal, 2012), (Arcelor

Mittal, 2013b)

N.D.

1

N.D.

1

N.D.

1

N.D.

1

4000 h NSS

1

(310 g/m

2

)

Arcelor Mittal



Crapal



Color

7

Steel wire with pigmented organic coating

(Arcelor Mittal, 2013b)

92%

5%

3%

-

2500 h NSS

1

Corus Tata



Magizinc



Steel sheets or strips

ZMA100 - ZMA200 (ZMA140 replacing

Z275)

(Tata Corus, 2012), (Tata Corus, 2010), (Tata

Corus, 2016), (Tata Corus, 2009)

96.8%

(9)

1.6%

(9)

1.6%

(9)

Pure Zinc

crystals

surrounded

by

MgZn2/Zn

and Al

(8)

1000÷1200 h NSS

1

(140 g/m

2

)

Mazzoleni



Galvalid



Steel wire (Mazzoleni, 2016)

95%

5%

0%

Misch

metals

500÷600 h NSS

1

(15 µm)

Bekaert



Bezinal



Steel wire (Bekaert, n.d.)

95%

5%

-

Bekaert

know-how

1000 h NSS

1

(75 g/m

2

)

Bekaert



Bezinal



2000

Steel wire (Bekaert, n.d.)

95%

5%

-

Bekaert

know-how

2000 h NSS

1

(75 g/m

2

)

Bekaert



Bezinal



3000

Steel wire (Bekaert, 2010)

95%

5%

-

Bekaert

know-how

5000 h NSS

1

(Class

A

16

)

3000 h NSS

1

(Class

B

16

)

Salzgitter Flachstahl



Stroncoat



Steel sheets or strips (Salzgitter Flachstahl,

n.d.)

96-98%

1-2%

-

2 to 6 times higher than

standard zinc coatings

Salzgitter Flachstahl



StronSal



Steel sheets or strips (Salzgitter Flachstahl,

2016)

96-98%

1-2%

-

2 to 6 times higher than

standard zinc coatings

U.S. Steel Kosice



Zinkomag



Steel sheets or strips (U.S. Steel Kosice,

2015)

98.4-98%

0.8-1%

-

200 h NSS

1

until

appearance of red

corrosion (50 g/m

2

per

side)

http://novasinergia.unach.edu.ec 61

U.S. Steel Kosice



Zinkomag Plus



Steel sheets or strips (U.S. Steel Kosice,

2015)

96-96.4%

1.8-2%

-

>1000 h NSS

1

(150

g/m

2

per side)

Voelstalpine



Corrender



Steel sheets or strips (Voelstalpine, 2015),

(Voelstalpine, 2016)

96%

2.5%

1.5%

-

>1300 h ZM90 NSS

1

(Voelstalpine, 2016)

Voelstalpine



Colofer



Corrender

Steel sheets or strips (Voelstalpine, 2015),

(Voelstalpine, 2016)

96%

2.5%

1.5%

Organic

coating

10

-

One Steel



Zalcote



Steel wire (OneSteel, 2016)

95%

5%

0%

-

N.D.

1

Maccaferri



Galmac



4R

Steel wire (Maccaferri, 2015)

Not

referenced

Not

referenced

0%

Misch

metals

11

≈2500 h NSS

1

Posco



(group Nisshin

Steel)

PosMAC

12

Steel sheets or strips (Posco, n.d.)

94.5%

2.5%

3%

-

Superior to 120 cycles

NSS

1

(140 to 275 g/m

2

)

Wheeling Nisshin

12

(group Nisshin Steel)

ZAM

 12

Steel sheets or strips (Nisshin Wheeling, n.d.)

91%

6%

3%

-

>2500 h NSS

1

(0,3

oz/ft2 in one side)

Wheeling Nisshin

12

(group Nisshin Steel)

Galvalume

 13

Steel sheets or strips (Nisshin Wheeling, n.d.)

45%

55%

0%

-

>2500 h NSS

1

USS



(United States Steel

Corporation)

Galvalume



Steel sheets or strips (United States Steel

Corporation (USS), 2015)

45%

55%

0%

Silicon

14

N.D.

1

Stahl



WZM Wupperman



Steel sheets or strips (Stahl, 2013)

Not

referenced

Not

referenced

Not

referenced

Not

referenced

Between 800 and 1000

h for an average

coating of 20 μm

Bluescope Steel



Zincalume



Steel sheets or strips (Bluescope Steel, 2013)

43.5%

55%

0%

1.5% Si

4 times more resistant

than a standard

galvanized with the

same thickness. Tests

performed but results

not declared.

Stramit



– Building

products

ZAM

 12

Steel sheets or strips (Stramit, 2012)

91%

6%

3%

-

4 times more resistant

than a standard

galvanized with the

same thickness. NSS

and mass loss tests

performed.

Ruukki



Galfan



Steel sheets or strips

Not

referenced

Not

referenced

Not

referenced

Not

referenced

N.D.

1

SSAB



Alucinc



Steel sheets or strips

43.4%

55%

0%

1.6% Si

C4-15 years

±100 h/m

Technology derived from

the project “Galfan”

(See “Producers” in:

http://galfan.com

(3)

)

Galfan



Steel sheets or strips

Steel wire

95%

5%

0%

-

No detailed technical

information on

corrosion resistance is

cited

Magni



http://magnicoatings.com/

?lang=es

Magni



Depending on application (see Magni



webpage)

(Technology applicable to parts and

accessories)

Not

referenced

(4)

Not

referenced

(4)

0%

Not

referenced

(4)

No detailed technical

information on

corrosion resistance is

cited

http://novasinergia.unach.edu.ec 62

(1) RMM: Raw Material Manufacturer; N.D.: Not declared; NSS: Neutral Salt Spray test

(2) According to IEC 61537 Edition 3 Committee draft (IEC (International Electrotechnical Commission), 2016)

Dacromet



technology

(based in laminar zinc and

aluminium technology

(zinc/aluminium flakes))

Dacromet



Dacromet



320 (Grade A

and grade B)

16

Dacromet



500 (Grade A

and grade B)

16

Dacroblack



15 (12 µm)

Depending on the application and the

providers of this technology

5

(Group, n.d.)

(Technology applicable to parts and

accessories)

Not

referenced

Not

referenced

Not

referenced

Cr

+3

ó Cr

+6

passivated

According to NOF

Metal coatings (Group,

n.d.), for Dacromet



320:

>240 h w/o white

corrosion, >600 h w/o

red corrosion (Grade

A)

>240 h w/o white

corrosion, >1000 h w/o

red corrosion (Grade

B)

Geomet



Technology

(based in laminar zinc and

aluminium technology

(zinc/aluminium flakes))

Geomet



Geomet



321 (Grade A

and B)

16

Geomet



500 (Grade A

and B)

16

Geomet



D/360 (3 to 15

µm)

Depending on the application and the

providers of this technology

5

(Galol S.A.,

n.d.-b), (NOF Metal Coatings Group, n.d.)

Alternative Technology to Dacromet



Chrome free.

(Technology applicable to parts and

accessories)

Not

referenced

Not

referenced

Not

referenced

Chrome free

passivated

According to NOF

Metal coatings / Galol

(Galol S.A., n.d.-b),

para Geomet



321:

>240 h w/o white

corrosion, >720 h w/o

red corrosion (>24

g/m

2

)

>1000 h w/o red

corrosion (>36 g/m

2

)

Tecnología Deltatone



(based in laminar zinc and

aluminium technology

(zinc/aluminium flakes))

Deltatone



Depending on the application and the

providers of this technology

6

(Galol S.A., n.d.-

a)

(Technology applicable to parts and

accessories)

Not

referenced

Not

referenced

Not

referenced

Admits

post-

treatments

(Delta-

seal



,

Delta-seal

GZ



…)

Between 480 h and 960

h (8 and 12 µm), test

NSS ISO 9227

Deltatone



9000

(Galol S.A., n.d.-a)

BIEC International Inc

13

http://www.galvalume.co

m

Galvalume



Depending on the application and the

providers of this technology (BIEC, 2016)

45%

55%

0%

-

30 years before the first

appearance of red

corrosion, according to

BIEC (BIEC, 2016)

ThyssenKrupp



ZM Ecoprotect



Coating mass between 70 and 300 g/m

2

99%

1%

-

Salt Spray test 1000 h

ZM140

Nippon steel & Sumitomo

Metal corporation

http://www.nssmc.com/en

/product/sheet/superdyma

_introduction.html

SuperDyma

TM

Coating weight K18

86%

11%

3%

Trace

amount of

_Si

Salt Spray Test 2000 H

Cycling corrosion test

(JASO M609-

91method) 180 cycles

http://novasinergia.unach.edu.ec 63

(3) According to Galfan Technology Center “A proprietary zinc alloy coating (5% aluminium) with improved corrosion resistance and formability compared to zinc alone. Galfan has been

around since the International Lead Zinc Research Organization (ILZRO) obtained worldwide patents on this new alloy for anti-corrosion coating in 1981. This grew from an ILZRO-

organized project co-sponsored by Arbed, Cockerill Sambre, Usinor and Sacilor (and now all part of Arcelor), British Steel, Fabrique de Fer de Maubeuge (now all part of Corus), New

Zealand Steel, and Stelco (Canada) at Centre de Recherches Metallurgiques in Belgium.It was discovered that by combining 95% zinc with nearly 5% aluminium plus specific quantities of

rare earth mischmetal could be reliably used in the hot-dip coating process, and conferred substantially improved performance to the end-product. Licenses to use the revolutionary

Galfan® technology were granted to manufacturers worldwide.” (Galfan Technology Center Inc., n.d.). Of the manufacturers cited on the Galfan official website for the electrical

conduits sector, it should be noted: Grupo Arcelor, Corus Group Plc, Voest Alpine Stahl Linz, Galvstar LLC…

(4) Magni



does not specify in its technical information the detailed composition of its coatings, although the most frequent refer to zinc-based coatings with an organic "Top" layer based on

aluminium.

(5) Geomet



y Dacromet



are registered trademarks of the company NOF Metal Coatings, whose technology is applied by other companies. For instance, Geomet



321 and Geomet



500

from the company “Galol” (www.galol.com). This technology is based on a water-based coating based on sheets of zinc and aluminium, passivated inside an inorganic matrix, without

chromium (neither hexavalent nor trivalent), and which arose as an alternative to the original Dacromet



eliminating the use of Chromium, in compliance with the European Directives

ReACH and RoHS (Galol S.A., n.d.-b).

(6) For instance, Deltatone



9000 from the company “Galol” (www.galol.com). This technology is based on an organic coating based on sheets of zinc and non-hydrogenating aluminium,

which offers excellent protection against corrosion (Galol S.A., n.d.-a). It is a non-electrolytic protection system, for all types of metal parts, threaded or not, especially steel parts.

(7) Crapal



finishes coated with a layer of pigmented resin to prevent the fall of zinc oxides into the earth. Used primarily for agricultural use or to offer different aesthetics (Arcelor Mittal,

2013b).

(8) According to the only statement found in the Tata Corus bibliography about the composition of Magizinc



(Tata Corus, 2012, 2016). Also in his brochure "Magizinc - The metallic coating

of the future", a brief mention is made in this way: “MagiZinc is a zinc coating that incorporates a small fraction of magnesium and aluminium” (Tata Corus, 2010).

(9) According to the internal report of Tata Corus 2007-2008 (Tata Corus, 2009). This information is not publicized in the official Magizinc



technical brochures

(10) According to Voelstalpine brochure (Voelstalpine, 2015) for which no information is offered about the content of the additional organic coating of Colofer



Corrender.

(11) According to Maccaferri brochure (Maccaferri, 2015): The GalMac

®

4R coating also has the presence of "MischMetals" (MM) that allow a more authentic bond between Zinc (Zn) and

Aluminium (Al).

(12) PosMAC is the original brand of the Korean company Posco, for its alloys of zinc-Aluminium-Magnesium, which was later acquired by Nishin, whose brand for that product is ZAM



.

Wheeling Nisshin is a subsidiary of Nisshin Steel in the United States, following the acquisition of the wheeling company group. Stramit also markets this product.

(13) Galvalume



is a registered trademark of BIEC international, Inc. According to the BIEC website: “BIEC International Inc. is the worldwide licensor of the technology and know-how

associated with 55% Aluminium-Zinc alloy coated sheet steel (better known as GALVALUME). A measure of the success of this program is the fact that virtually all of the major steel

companies worldwide have become licensees of BIEC. Today, BIEC is the acknowledged leader in technologies associated with 55% Al-Zn coated sheet Steel”(BIEC, 2016).

(14) “A small but important addition of silicon is included in the coating alloy. It is added not to enhance the corrosion performance, but to provide good coating adhesion to the steel substrate

when the product is roll-formed, drawn, or bent during fabrication” (United States Steel Corporation (USS), 2015).

(15) Zagnelis



is the adaptation of Magnelis



to the automotive sector. This is what Arcelor Mittal indicates on its website: “Zagnelis™ has been specially designed to improve corrosion

protection of vehicles, while satisfying OEMs' specifications regarding manufacturability” (Rich Clausius & Arcelor Mittal, n.d.).

(16) Grades according to EN 10244-2(CEN (European Committee for Standardization), 2009). In this way it has that a grade A corresponds to a thickness of 5 to 8 microns, while a grade B of

8 to 10 microns.

http://novasinergia.unach.edu.ec 64

Table 10: Main trunking system manufacturers using ZM alloys (standard or wire cable trays).

CTM1

CTM1 Trade Mark

RMM2

Trade Mark

RMM2

Designation given by CTM1

RMM2

declared

corrosion

resistance class

according to

IEC 61537

Schneider Electric



Zn+

Arcelor Mittal



Magnelis



Steel sheets and strips

8

Schneider Electric



Zn+

Arcelor Mittal



Magnelis



Steel wire

8

Obo Betterman



Double Dip

Thyssen Krupp



-

Not declared

3

 8

(4)

Mavil



(Gewiss group)

High Protection HP

Arcelor Mittal



5

Unknown

5

Unknown

5

9

(6)

(1000 h)

Mavil



(Gewiss group)

Uses the trademark

(Magni



)

Magni



http://magnicoatings.com/?lang=es

Magni



Not declared

Mavil



(Gewiss group)

Uses the trademark

“Geomet



”

Geomet



technology

Geomet



Not declared

 8

(7)

Mavil



(Gewiss group)

Uses the trademark

“Deltatone



”

Deltatone



technology

Deltatone



Not declared

Legrand

8

-

Geomet



technology

Geomet



Not declared

Pemsa



Black C8



Own developed formula

-

Not declared

8

Oglaend



Systems

There is no standard offer

11

There is no

standard offer

There is no standard offer

-

Axelent

9

There is no standard offer

There is no

standard offer

There is no standard offer

-

B-Line



(Cooper

Industries – Eaton group)

There is no standard offer

There is no

standard offer

There is no standard offer

-

MP Husky



There is no standard offer

Just Aluminium

There is no standard offer

(MP Husky, 2015)

There is no

standard offer

There is no standard offer

-

Cope



There is no standard offer

Just Aluminium

There is no standard offer

(Cope, 2015)

There is no

standard offer

There is no standard offer

-

http://novasinergia.unach.edu.ec 65

(1) CTM: Cable Trunking systems Manufacturer

(2) RMM: Raw Material Manufacturer

(3) According to Obo Betterman



(Double Dip) brochure: “Double Dip” process for sheet metal is still so new that it has not yet been described in standards (Obo Betterman, 2012)

(4) A specific corrosion class is not specified in the Obo Betterman



brochure, but it is indicated that it is superior, at equivalent thickness, to conventional hot dip galvanizing: “Dip can be classified in the

highest corrosion class. In the still valid product standard DIN VDE 0639 a corrosion protection classification is described, while a revised classification will follow in the newly published IEC/EN 61537

(9:2001) (Obo Betterman, 2012).

(5) In Mavil



catalogue (Mavil (Gewiss group), 2015) it is indicated “A 4 time stronger coating than the HDG (Hot Dip Galvanized) – at equivalent thickness. Certified by Arcelor Mittal



”

(6) According to IEC 61537 standard, Edition 3 Committee Draft (IEC (International Electrotechnical Commission), 2016).

(7) According to Mavi



l catalogue: “Revêtement non électrolytique de lamelles de zinc. Le revêtement est obtenu par application de lamelles de zinc et éventuellement d'aluminium avec un apport de chaleur.

Cette finition est essentiellement utilisée pour la boulonnerie dédiée aux applications utilisant la finition GAC. L'aspect est gris argent. Geomet remplace Dacromet suite à l'interdiction d'utilisation du

Chrome 6 en France”(Mavil (Gewiss group), 2015).

(8) According to Legrand



http://www.legrand.us/cablofil/tech_resources/tg-materialsandfinishes.aspx#.V3kjf1fV6i4: Geomet is a treatment based on zinc and aluminium. As it does not contain any chromium

VI (hexavalent), it complies with the RoHS Directive. Offering protection equivalent to GC, it is used for small accessories and fixings which are difficult to hot dip galvanize.

(9) According to Axelent



technical brochure (Axelent, 2014): “Only Hot Dip galvanized will on some parts be replaced by Zinc/Nickel (DIN 50979). Zinc/Nickel is electrolytically inorganic corrosion-

resistant coatings that meet most requirements for extremely corrosive environment. Zn-Ni containing 12-15% nickel in the layer and provides good corrosion protection even in thin layers. Along with a

polished or black passivation can be more than 720 h (according to ISO 9227, NSS) to the base metal corrosion is achieved. Zinc/Nickel can be used together with aluminium”. In this way, a reference is

made to a nickel-based coating, very little used in the sector of metallic electrical conduits.

(10) According to Tolmega



catalogue, for its finish Geomet



: “Geomet components are very thin strips of zinc and aluminium into a mineral binder. This structural passivation allows a better corrosion

resistance than hot-dip galvanization (saline spray test ISO 9227: 1000 hours). In the same way, for its Zinc+ finish: “This special zinc protection process allows a better corrosion resistance than hot-dip

galvanization (saline spray test ISO 9227: 1500 hours). Appearance: silk finish. No droplets after drying” (Tolmega (Niedax group), 2015).

(11) According to Oegland



general catalogue (extract of finishes and types of materials)(Oglaend, 2016).

(12) Basor



just offers an aluminium cable tray range in its Basor Trays range (Basor Electric, 2015).

(13) According to Niedax



general catalogue, Geomet



is used for small parts and components (Niedax, 2015).

Techline

There is no standard offer

Just Aluminium

There is no standard offer

(TechLine, 2009)

There is no

standard offer

There is no standard offer

-

Tolmega



(Niedax



group)

10

Uses the trademark

“Geomet



”

Geomet



500B

(Geomet



technology)

Geomet



Not declared

 8

Tolmega



(Niedax



group)

10

Zinc+

Unknown

Not declared

 8

Basor

12

There is no standard offer

Aluminium in the range

“Basor Trays”

There is no standard offer

There is no

standard offer

There is no standard offer

-

Niedax

13

Uses the trademark

“Geomet



”

Geomet



technology

Geomet



There is no standard offer

-

Niedax

13

Aluminium

Unknown

-

http://novasinergia.unach.edu.ec 66

2.6 Accelerated and field corrosion tests

on ZM alloys

2.6.1 Accelerated and field tests

description and main conclusions

a) Patina project (de Rincón et al., 2009). This

paper presented a comparative evaluation of Al, Zn

and Al–Zn coatings on carbon steel in a very

aggressive coastal atmosphere in Venezuela, with

high wind velocities. The main conclusion of the

article was, in general, that a better behaviour is

observed with zinc coatings alloyed with aluminium,

in types of atmospheres with an aggressive coastal

environment. TLR (thickness loss rate), for the alloy

with 5% aluminium, is significantly lower than the

rest of coatings in Zn (never higher than 15 µm).

Other research works (Panossian et al., 2005),

arrived to similar conclusions, confirming that

coatings based on zinc or zinc alloys with a high

aluminium content (above 15%), only provide

effective cathodic protection against corrosion, in

atmospheres with a high concentration level of

chlorine ions, while alloys with high zinc content,

the cathodic protection acts from the beginning in all

cases.

b) Galvatech 2011 (Schouller-Guinnet et al., 2011;

Thierry et al., 2011). In this event, two-research

works were introduced related to the new zinc-

aluminium-magnesium alloys. Here, they performed

different field tests for a period of two-years in

different French environments (marine and rural).

c) Research works by N. Le Bozec et al. (LeBozec

et al., 2012; 2013). Field corrosion tests were

performed for zinc and zinc-aluminium-magnesium

alloys, in three different environments (rural, urban

and coastal) located in France, Austria and Germany.

d) Nordic Galvanizers (LeBozec et al., 2013;

Nordic Galvanizers, n.d.), performed a field test in

cooperation with Swerea KIMAB (Swerea Kimab,

2014) comparing black steel, hot-dip galvanized

(coating thickness 68 µm), ZnAlMg materials

(Zn6Al3Mg), continuous zinc coating (20 µm),

stainless steel and aluminium coupons in different

tunnels, exposed to splash from car traffic and

reference site (marine) environments during 2 years

in Sweden. Conclusions were that, in marine

reference sites, for the first and the second year of

exposure, ZnAlMg alloys have half the corrosion

rate compared to HDG. In traffic tunnels reference

sites ZnAlMg alloys showed close to 30% less

corrosion rate than HDG first year exposure and

equal results for the second year.

e) French Corrosion Institute (Autocoat, 2013;

LeBozec et al., 2013), performed a study to promote

the novel ZM coating in the automotive industry

through corrosion mechanism. It was also

investigated:

- the relation between coating composition and

microstructure in corrosion performance.

- the surface oxide on paint adhesion in order to

optimize or eliminate phosphating process.

- the corrosion stability of ZM using accelerated

corrosion test accepted by automotive industries

(VDA 621-415, N-VDA [VDA233-102] and

Volvo



STD 423-0014).

- the perforation corrosion in confined areas and

on field exposure tests (Brest - Marine, Dormund

- Industrial/Urban and Linz - Continental).

- the mechanical properties of formability and

joining.

- the long-term corrosion properties on vehicle

exposure (truck driving 2 years in Switzerland).

Different suppliers were used: Voestalpine



,

Ruuki



and TKSE



comparing different

coatings: Electrogalvanized (GE), Continuous

HDG (GI), Galvannealed (GA) and Galfan



(Galf) (7µm thickness for all).

Conclusions were that, for open panels, in marine

reference sites (Brest), ZM, after 2 years

exposure, had 20-45% less corrosion rate than

pre-galvanized. In urban references (Linz), ZM,

after 2 years exposure had 45-65% less corrosion

rate than pre-galvanized. In Industrial references

(Dortmund), ZM, after 2 years exposure had 25-

50% less corrosion rate than pre-galvanized. For

hem flanges, in marine reference sites (Brest),

ZM, after 2 years exposure, had 10-20% more

corrosion rate than pre-galvanized, with only

ZMA 1.5 showing a better corrosion rate. In

Urban references (Linz), ZM, after 2 years

exposure had much more corrosion rate than pre-

galvanized. In Industrial references (Dortmund),

ZM, after 2 years exposure had 0-40% more

corrosion rate than pre-galvanized. Finally, CO

2

content in the atmosphere had an impact on the

ZM alloys: the more CO

2

content in the

atmosphere, the lower corrosion rate.

f) Arcelor Mittal Global R&D in collaboration with

Peil, Ummenhofer and Partner (IPU, 2013), ordered

an expert’s report to test, compare and assess the

http://novasinergia.unach.edu.ec 67

corrosion resistance of the following metallic

coatings for the classification into corrosion

protection classes, according to DIN 55928-8:

• ZM - Magnelis

®

with a coating mass of 90,

120, 250 and 310 g/m

2

• AZ185 with a coating mass of 185 g/m

2

• Z275 with a coating mass of 275 g/m

2

Three types of tests were performed: (1) Resistance

against neutral salt spray test; (2) Resistance against

condensation of water; (3) humid, sulphur dioxide

atmosphere.

Conclusions were that, in NSST, ZM alloys

performed better than pre-galvanized (Z) and

aluminium-zinc alloys (AZ). In condensation of

water test, Magnelis

®

provides a higher resistance

compared with AZ. The humid and sulphur dioxide

atmosphere test showed a better corrosion resistance

effect than AZ or the pre-galvanized product.

The report recommends Magnelis

®

C4 for 15 years

maintenance plan on open surfaces, avoiding it in

confined areas, like hem flanges.

g) Galvatech 2015 (R&D, 2015), where Arcelor

Mittal presented a work, to describe to what extent

the ZM alloy, ZnMg3Al3.7, can be considered as an

alternative to standard HDG zinc-based coatings or

to AZ coatings for structural applications. It was

focused on the high level of corrosion protection of

uncoated cut edges brought by this solution and on

its potential to substitute heavier HDG-Zn coatings.

Conclusions were that on Magnelis

®

, a cut edge self-

healing phenomenon is occurring even in

environments presenting very low chloride content,

and in some cases, for high steel thicknesses, up to 5

mm in NSST. A similar result was achieved on

outdoor field exposures in the rainfall test; however,

on rural environments (chloride-free environment),

self-healing phenomenon could only be observed in

thinnest steel gauges.

In real exposure sites, Magnelis



showed a 2.3-3.1

better corrosion rate than pre-galvanized products.

h) M. Salgueiro et al. (2015a), performed a field test

to check the role of electrolyte composition in the

nature of corrosion products and relative corrosion

rate. This brought corrosion values in three different

locations: marine (France), rural (France) and urban

(USA). The main conclusions were:

• It is proven the better performance of ZM alloys

in high chloride content environments, but its

performance is lower in more neutral atmospheres,

which was evidenced by tests carried out using

distilled rain water as an electrolyte.

• The corrosion products are key for the corrosion

process and those are quite dependant on the

electrolyte, as well as on the alloy composition. This

has been proven after the analysis of the tests run.

• The performance of ZM alloys using rain water

electrolyte is much lower than using NaCl.

i) Tomandl and Labrenz (Tomandl & Labrenz,

2016), conducted a field test in Sweden, China and

Mexico to compare the performance against

corrosion between zinc and ZM alloys, in maritime

environments.

2.6.2 Summary of results

Table 11 shows a summary of all the field tests

results, while table 12 shows the accelerated tests

results. Both tables contain the sources from which

the results have been obtained.

The corrosivity category (C1 to CX) has been

determined considering the corrosion rate of zinc

finishes for the first year of exposure, according to

ISO 9223 (see table 5). In those cases, in which more

than one zinc coating is tested, the worst case (higher

corrosivity rate) has been chosen.

2.7 Long-term corrosion

To conclude, an estimation of the long-term

corrosion behaviour, based in the field tests values

referred in the previous clause is presented, with the

methodology categorized in 3 sections:

• Grouping of the field corrosion results per

corrosivity class according to ISO 9223 (C1 to

CX)

• Calculation of the long-term corrosion

expression based in equation (1)

• Corrosion graph evolution

2.7.1 Grouping field corrosion results per

category class

Table 13 groups the different corrosion rate results

for ZM alloys, by corrosivity category and

differentiating values for year 1 and year 2. An

average of these values has been calculated for each

category. These will be the values used in the next

step for the determination of the long-term corrosion

function. Values in bold letters have been considered

out of the normal range and they have been discarded

for the calculations. Table 14 gives the same

information but for ZA alloys.

http://novasinergia.unach.edu.ec 68

Table 11: Field tests results summary of the different research works analyzed.

Source

Type of Environment

(as described in the test)

Location

Corrosi

vity

categor

y

ISO

9223

Z (Post-galvanization)

Z (Cont.

galvanization)

Z (Electrogalvanized)

ZM alloy

ZA alloy

Material

Corrosión

rate (µm)

Materia

l

Corrosión

rate (µm)

Material

Corrosión

rate (µm)

Material

Corrosión

rate (µm)

Materi

al

Corrosió

n rate

(µm)

Year

1

Year

2

Year

1

Yea

r 2

Yea

r 1

Yea

r 2

Yea

r 1

Yea

r 2

Ye

ar

1

Ye

ar

2

(LeBozec et al., 2013; Nordic

Galvanizers, n.d.)

Marine - Open panels

Bohus - Malmön

C3

HDG ISO1461

(68 µm)

1.6

1.2

Zn(91%)/Mg(6%)/

Al(3%)

0.7

0.6

(Schouller-Guinnet, Allély, &

Volovitch, 2011;

Thierry, Prosek, Bozec, & E.

Diller, 2011)

Marine - Open panels

Brest - France

C3

275

g/m

2

1.2

Zn-3,5%Al-3%Mg

0.4

5

(Schouller-Guinnet, Allély, &

Volovitch, 2011;

Thierry, Prosek, Bozec, & E.

Diller, 2011)

Marine - Open panels

Brest - France

C4

275

g/m

2

2.2

Zn-(1-3)%Al-(1-

3)%Mg

1

(Autocoat, 2013; LeBozec et al.,

2013)

Marine - Open panels

Brest - France

C4

HDG ISO1461 (7

µm)

1.9

Zinc 7

µm

2.6

ZnMg1%Al1%

1.6

Zn5%

Al

1.3

(Autocoat, 2013; LeBozec et al.,

2013)

Marine - Open panels

Brest - France

C4

ZnMg1,5%Al1,5%

1.1

(Autocoat, 2013; LeBozec et al.,

2013)

Marine - Open panels

Brest - France

C4

ZnMg2%Al2%

1.3

(LeBozec et al., 2012, 2013)

Marine - Open panels

France North coast

C3

275

g/m

2

1.8

1

Zinc 7

µm

1.7

1.3

Zn-(1-3)%Al-(1-

3)%Mg

1.0

5

0.7

0.9

0.6

(de Rincón et al., 2009)

Marine extreme

La voz station-

Venezuela

CX

HDG ISO1461

(60 µm)

-

18

20 µm

18.

5

-

Zn5%

Al

14

9

(Salgueiro Azevedo et al., 2015a)

Marine - Open panels

Brest - France

C4

HDG ISO1461

(20 µm)

-

2.9

ZnMg3%Al3,7%

-

1.2

(Autocoat, 2013; LeBozec et al.,

2013)

Marine - Hem flanges

Brest - France

C5

HDG ISO1461 (7

µm)

3.5

Zinc 7

µm

> 7

ZnMg1%Al1%

4.2

Zn5%

Al

3.1

(Autocoat, 2013; LeBozec et al.,

2013)

Marine - Hem flanges

Brest - France

C5

ZnMg1,5%Al1,5%

2.3

(Autocoat, 2013; LeBozec et al.,

2013)

Marine - Hem flanges

Brest - France

C5

ZnMg2%Al2%

4

(Tomandl & Labrenz, 2016)

Marine- Open panels

Bohus - Malmön

C4

HDG ISO1461

(50 µm)

3

Zn(91%)/Mg(6%)/

Al(3%)

2

(Tomandl & Labrenz, 2016)

Marine- Open panels

Bohus - Malmön

C4

ZnMg2%Al2%

4

(Tomandl & Labrenz, 2016)

Marine- Open panels

Wanning - China

C5

HDG ISO1461

(50 µm)

5

Zn(91%)/Mg(6%)/

Al(3%)

2

(Tomandl & Labrenz, 2016)

Marine- Open panels

Wanning - China

C5

ZnMg2%Al2%

3

(Tomandl & Labrenz, 2016)

Marine- Open panels

Yucatán - México

CX

HDG ISO1461

(50 µm)

15

Zn(91%)/Mg(6%)/

Al(3%)

6

(Tomandl & Labrenz, 2016)

Marine- Open panels

Yucatán - México

CX

ZnMg2%Al2%

5

http://novasinergia.unach.edu.ec 69

(LeBozec et al., 2013; Nordic

Galvanizers, n.d.)

Traffic tunnel

Öresund

CX

HDG ISO1461

(68 µm)

9.9

5.7

Zn(91%)/Mg(6%)/

Al(3%)

6.5

5.8

(LeBozec et al., 2013; Nordic

Galvanizers, n.d.)

Traffic tunnel

Lundby

CX

HDG ISO1461

(68 µm)

10.2

6.8

Zn(91%)/Mg(6%)/

Al(3%)

7.4

5.9

(LeBozec et al., 2013; Nordic

Galvanizers, n.d.)

Traffic tunnel

Eugenia

C5

HDG ISO1461

(68 µm)

6.6

4.4

Zn(91%)/Mg(6%)/

Al(3%)

4.8

4.4

(LeBozec et al., 2013; Nordic

Galvanizers, n.d.)

Train tunnels

Öresund

C3

HDG ISO1461

(68 µm)

1.6

1.4

Zn(91%)/Mg(6%)/

Al(3%)

1

0.8

(LeBozec et al., 2013; Nordic

Galvanizers, n.d.)

Train tunnels

Strängnäs

C3

HDG ISO1461

(68 µm)

1

0.6

Zn(91%)/Mg(6%)/

Al(3%)

0.2

0.5

(Thierry, Prosek, Bozec, & E.

Diller, 2011)

Rural - Open panels

France

C3

275

g/m

2

1.9

Zn-(1-3)%Al-(1-

3)%Mg

0.9

(Autocoat, 2013; LeBozec et al.,

2013)

Urban & Industrial - Open

panels

Dormund -

Germany

C3

HDG ISO1461 (7

µm)

1.6

Zinc 7

µm

1.8

ZnMg1%Al1%

1.2

Zn5%

Al

0.6

(Autocoat, 2013; LeBozec et al.,

2013)

Urban & Industrial - Open

panels

Dormund -

Germany

C3

ZnMg1,5%Al1,5%

0.8

(Autocoat, 2013; LeBozec et al.,

2013)

Urban & Industrial - Open

panels

Dormund -

Germany

C3

ZnMg2%Al2%

0.8

(LeBozec et al., 2012, 2013)

Urban - Open panels

Germany

C3

275

g/m

2

0.7

0.8

Zinc 7

µm

1

0.8

Zn-(1-3)%Al-(1-

3)%Mg

0.4

5

0.5

Zn5%

Al

0.3

(Salgueiro Azevedo et al., 2015a)

Urban - Open panels

Chicago - USA

C3

HDG ISO1461

(20 µm)

1.4

ZnMg3%Al3,7%

0.5

(Autocoat, 2013; LeBozec et al.,

2013)

Urban & Industrial - Hem

flanges

Dormund -

Germany

C4

HDG ISO1461 (7

µm)

1.6

Zinc 7

µm

2.4

ZnMg1%Al1%

1.5

Zn5%

Al

0.8

(Autocoat, 2013; LeBozec et al.,

2013)

Urban & Industrial - Hem

flanges

Dormund -

Germany

C4

ZnMg1,5%Al1,5%

2.1

(Autocoat, 2013; LeBozec et al.,

2013)

Urban & Industrial - Hem

flanges

Dormund -

Germany

C4

ZnMg2%Al2%

2.3

(Autocoat, 2013; LeBozec et al.,

2013)

Continental (-20/+30ºC) -

Open panels

Linz - Austria

C3

HDG ISO1461 (7

µm)

0.8

Zinc 7

µm

1.1

ZnMg1%Al1%

0.5

Zn5%

Al

0.1

7

(Autocoat, 2013; LeBozec et al.,

2013)

Continental (-20/+30ºC) -

Open panels

Linz - Austria

C3

ZnMg1,5%Al1,5%

0.4

(Autocoat, 2013; LeBozec et al.,

2013)

Continental (-20/+30ºC) -

Open panels

Linz - Austria

C3

ZnMg2%Al2%

0.3

(Autocoat, 2013; LeBozec et al.,

2013)

Continental (-20/+30ºC) -

Hem flanges

Linz - Austria

C2

HDG ISO1461 (7

µm)

0

Zinc 7

µm

0.2

ZnMg1%Al1%

0.5

Zn5%

Al

0.4

(Autocoat, 2013; LeBozec et al.,

2013)

Continental (-20/+30ºC) -

Hem flanges

Linz - Austria

C2

ZnMg1,5%Al1,5%

0.9

(Autocoat, 2013; LeBozec et al.,

2013)

Continental (-20/+30ºC) -

Hem flanges

Linz - Austria

C2

ZnMg2%Al2%

1.2

(LeBozec et al., 2012, 2013)

Rural - Open panels

Austria

C2

275

g/m

2

0.5

0.4

Zinc 7

µm

0.6

0.5

Zn-(1-3)%Al-(1-

3)%Mg

0.2

0.22

5

0.0

3

0.0

9

(Salgueiro Azevedo et al., 2015a)

Rural - Open panels

Mazières - France

C3

HDG ISO1461

(20 µm)

1

ZnMg3%Al3,7%

0.3

http://novasinergia.unach.edu.ec 70

Table 12: Accelerated tests results summary of the different research works analyzed.

Source

Type of test

Z(Post-Galvanization / Continuous

galvanization)

Z (Electrogalvanized)

ZM alloy

ZA alloy

Material

Corrosion rate

(µm)

Material

Corrosion

rate (µm)

Material

Corrosion

rate (µm)

Material

Corrosion

rate (µm)

(IPU, 2013)

NSST - 1000 h

275 g/m

2

sample 1

132 g/m

2

Magnelis 90 g/m

2

sample 1

3,21 g/m

2

Aluzink

185 g/m

2

sample 1

129 g/m

2

(IPU, 2013)

NSST - 1000 h

275 g/m

2

sample 2

147 g/m

2

Magnelis 90 g/m

2

sample 2

4,03 g/m

2

Aluzink

185 g/m

2

sample 2

13,8 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 120 g/m

2

sample 1

7,2 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 120 g/m

2

sample 2

3,76 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 250 g/m

2

sample 1

4,84 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 250 g/m

2

sample 2

4,29 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 310 g/m

2

sample 1

3,7 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 310 g/m

2

sample 2

7,37 g/m

2

(IPU, 2013)

NSST - 1000 h

Magnelis 310 g/m

2

sample 3

10,3 g/m

2

(Salgueiro Azevedo et al., 2015a)

NSST - 0,1% NaCl - 100 h

HDG ISO1461 (20 µm)

5.4

ZnMg3%Al3,7%

0.5

Zn5%Al

0.6

(Salgueiro Azevedo et al., 2015a)

NSST - 1% NaCl - 100 h

HDG ISO1461 (20 µm)

6.9

ZnMg3%Al3,7%

0.3

Zn5%Al

0.5

(Salgueiro Azevedo et al., 2015a)

NSST - 5% NaCl - 100 h

HDG ISO1461 (20 µm)

11.2

ZnMg3%Al3,7%

0.9

-

(Salgueiro Azevedo et al., 2015a)

NSST - 0,4% NaCl - 400 h

HDG ISO1461 (20 µm)

14

ZnMg3%Al3,7%

2.3

Zn5%Al

4

(Salgueiro Azevedo et al., 2015a)

NSST Test VDA -1% NaCl - 5 cycles

HDG ISO1461 (20 µm)

5.8

ZnMg3%Al3,7%

0.6

Zn5%Al

2

(Salgueiro Azevedo et al., 2015a)

NSST - 1% Na

2

SO

4

- 100 h

HDG ISO1461 (20 µm)

3.2

ZnMg3%Al3,7%

0.3

-

(Salgueiro Azevedo et al., 2015a)

NSST - 0,1% Rain water - 100 h

HDG ISO1461 (20 µm)

3.6

ZnMg3%Al3,7%

1.2

-

(Salgueiro Azevedo et al., 2015a)

NSST - 1% Rain water - 200 h

HDG ISO1461 (20 µm)

8.5

ZnMg3%Al3,7%

3.1

Zn5%Al

4.5

(Salgueiro Azevedo et al., 2015a)

NSST VDA - 0,1% Rain water - 10

cycles

HDG ISO1461 (20 µm)

7.4

ZnMg3%Al3,7%

1.9

Zn5%Al

3.4

(Salgueiro Azevedo et al., 2015a)

NSST modified- 1% Rain water 200 h

HDG ISO1461 (20 µm)

4.7

ZnMg3%Al3,7%

0.7

-

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (3

weeks)

HDG ISO1461 (7 µm)

10

Zinc 7 µm

15

ZnMg1%Al1%

0

Zn5%Al

0

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (6

weeks)

HDG ISO1461 (7 µm)

40

Zinc 7 µm

30

ZnMg1%Al1%

0

Zn5%Al

10

http://novasinergia.unach.edu.ec 71

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (18

weeks)

HDG ISO1461 (7 µm)

310

Zinc 7 µm

410

ZnMg1%Al1%

190

Zn5%Al

230

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (3

weeks)

ZnMg2%Al2%

0

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (6

weeks)

ZnMg2%Al2%

0

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (18

weeks)

ZnMg2%Al2%

0

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (3

weeks)

ZnMg1,5%Al1,5%

0

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (6

weeks)

ZnMg1,5%Al1,5%

0

LeBozec et al., 2013

Cyclic test-Volvo STD 423-0014 (18

weeks)

ZnMg1,5%Al1,5%

0

(Arcelor Mittal, 2015)

Cyclic test-Volvo (10 cycles)

HDG ISO1461 (not

declared)

10.2

ZnMg3,5%3%

11.52

(LeBozec et al., 2012, 2013)

Cyclic test-N-VDA (VDA233-102) (6

weeks)

HDG ISO1461 (7 µm)

85

Zinc 7 µm

95

ZnMg1%Al1%

25

Zn5%Al

55

(LeBozec et al., 2012, 2013)

Cyclic test-N-VDA (VDA233-102)

(12 weeks)

HDG ISO1461 (7 µm)

310

Zinc 7 µm

315

ZnMg1%Al1%

260

Zn5%Al

255

(LeBozec et al., 2012, 2013)

Cyclic test-N-VDA (VDA233-102) (6

weeks)

ZnMg2%Al2%

0

(LeBozec et al., 2012, 2013)

Cyclic test-N-VDA (VDA233-102)

(12 weeks)

ZnMg2%Al2%

195

(LeBozec et al., 2012, 2013)

Cyclic test-N-VDA (VDA233-102) (6

weeks)

ZnMg1,5%Al1,5%

0

(LeBozec et al., 2012, 2013)

Cyclic test-N-VDA (VDA233-102)

(12 weeks)

ZnMg1,5%Al1,5%

170

(LeBozec et al., 2012, 2013)

Cyclic test-VDA 621-415 (6 weeks)

HDG ISO1461 (7 µm)

40

Zinc 7 µm

60

ZnMg1%Al1%

0

Zn5%Al

5

(LeBozec et al., 2012, 2013)

Cyclic test-VDA 621-415 (12 weeks)

HDG ISO1461 (7 µm)

220

Zinc 7 µm

300

ZnMg1%Al1%

5

Zn5%Al

50

(LeBozec et al., 2012, 2013)

Cyclic test-VDA 621-415 (6 weeks)

ZnMg2%Al2%

0

(LeBozec et al., 2012, 2013)

Cyclic test-VDA 621-415 (12 weeks)

ZnMg2%Al2%

0

(LeBozec et al., 2012, 2013)

Cyclic test-VDA 621-415 (6 weeks)

ZnMg1,5%Al1,5%

0

(LeBozec et al., 2012, 2013)

Cyclic test-VDA 621-415 (12 weeks)

ZnMg1,5%Al1,5%

0

http://novasinergia.unach.edu.ec 72

Table 13: Corrosion values (µm) for ZM alloys in field tests, grouped by corrosivity category.

Corrosivit

y

category

ISO 9223

Yea

r

Measurement

Averag

e

1

2

3

4

5

6

7

8

9

10

11

12

13

C1-Very

low

Y1

-

Y2

-

C2-Low

Y1

0,2

0

0,20

Y2

0,5

0

0,9

0

1,2

0

0,2

3

0,36

C3-

Medium

Y1

0,7

0

0,4

5

1,0

0

0,2

0

0,9

0

1,0

5

0,4

5

0,68

Y2

0,6

0

0,8

0

0,5

0

0,5

0

0,5

0

0,4

0

0,3

0

0,7

0

0,5

0

1,2

0

0,8

0

0,8

0

0,3

0

0,56

C4-High

Y1

1,0

0

2,0

0

4,0

0

2,33

Y2

1,6

0

1,1

0

1,3

0

1,2

0

1,5

0

2,1

0

2,3

0

1,59

C5-Very

high

Y1

4,8

0

2,0

0

3,0

0

4,80

Y2

4,4

0

4,2

0

2,3

0

4,0

0

4,20

CX-

Extreme

Y1

6,5

0

7,4

0

6,0

0

5,0

0

6,23

Y2

5,8

0

5,9

0

5,85

Table 14: Corrosion values (µm) for ZA alloys in field tests, grouped by corrosivity category

Corrosivity

category ISO

9223

Year

Measurement

Average

1

2

3

4

C1-Very low

Y1

Y2

C2-Low

Y1

0,03

Y2

0,40

0,09

0,25

C3-Medium

Y1

0,90

0,30

0,60

Y2

0,60

0,30

0,17

0,50

C4-High

Y1

Y2

0,80

1,30

1,05

C5-Very high

Y1

Y2

3,10

CX-Extreme

Y1

14,00

Y2

9,00

2.7.2 Calculation of the long-term

corrosion function

Corrosion function will be determined for each

corrosivity category, by applying equation (1), as the

general expression for corrosion processes (Chenoll-

Mora et al., 2018). These are the steps followed for

the determination:

• Identify yearly corrosion for the first year of

exposure (parameter A estimated as the average

of the different corrosion values in the tests

done).

• Identify corrosion for the second year of

exposure (estimated as the average of the

different corrosion values in the tests done).

• Calculate the cumulated corrosion for the second

year of exposure, C (2) by adding the yearly

corrosion value first year (A) and yearly

corrosion value second year.

http://novasinergia.unach.edu.ec 73

• Substitute C (2) and A in equation (1) and clear n

parameter.

• Determine the long-term corrosion function by

substituting n and A parameters in equation (1)

2.8 Graphic representation

The corrosion function will be represented

graphically for a period of 100 years.

2.9 Results

Five cases have been analyzed for ZM alloys for

corrosivity categories C2 to CX and one specific

case for ZA alloys for corrosivity category C3. The

above mentioned categories were chosen, as they

provided a large number of corrosion values of our

analysis. In that sense, according to table 13, there

are no values for category C1 in the ZM alloys. Table

14, for ZA alloys, only indicates that category C3 has

a representative amount of values to arrange the

calculation. Our methodology can thus be extended

to other categories in future works, when having

more long-term corrosion values.

As an example of our approach, the corrosivity

category C3 for ZM will be described as follows:

For C3 ZM data (table 13):

• Corrosion at first year of exposure: A. This is

calculated as the average of the recorded values

for Y1. So, A = 0,68 µm.

• Corrosion at second year of exposure. This is

calculated as the average of the recorded values

for Y2. It corresponds to 0,56 µm.

And with these data the following steps can already

be applied:

- Cumulated corrosion at second year of exposure:

C (2). This is calculated by adding year corrosion

value first year and year corrosion value second

year:

C (2) = 0,68 + 0,56 = 1,24 µm.

- Substituting C (2) and A in equation (1), n can be

cleared:

C (t) = A·t

n

; C (2) = A·2

n

; 1,24=0,68·2

n

; 2

n

=

1,823; n = log 1,823/log2 = 0,866

- And finally, the long-term corrosion expression

for ZM alloys in C3 environments is determined

by:

C (t) = 0,68·t

0,866

(3)

All results calculated for each case are presented in

table 15. The graphic representation of long-term

corrosion expression is shown in figure 10 for all ZM

alloys cases and in figure 11 for the ZA alloy.

Table 15: Long-term corrosion equations for the different corrosivity categories in ZM and ZA alloys.

Alloy

Corrosivity category

First year corrosion

(A)

Cumulated

corrosion Y2

n

Long-term corrosion function

ZM

C2

0,2

0,43

1,104

C

2

(t) = 0,2·t

1,104

ZM

C3

0,68

1,24

0,866

C

3

(t) = 0,68·t

0,866

ZM

C4

2,33

3,92

0,75

C

4

(t) = 2,33·t

0,75

ZM

C5

4,8

9

0,906

C

5

(t) = 4,8·t

0,906

ZM

CX

6,23

12,08

0,955

C

x

(t) = 6,23·t

0,955

ZA

C3

0,6

1,1

0,87

C

3ZA

(t) = 0,6·t

0,87

Figure 10: Corrosion evolution in ZM alloys for C2-CX corrosivity class (µm vs years).

1

10

100

1000

1

6

11

16

21

26

31

36

41

46

51

56

61

66

71

76

81

86

91

96

101

µm

Years

C2 C3 C4 C5 CX

http://novasinergia.unach.edu.ec 74

Figure 11: Corrosion evolution in ZA alloys for C3 corrosivity class (µm vs years).

In this way, it is possible to estimate the corrosion

resistance of a given ZM or ZA alloy, just by

knowing its thickness. For instance, for a ZM

thickness of 20 µm in a C3 environment, the

approximated corrosion resistance in years is

calculated, either using the graphs or applying

equation (3):

20 = 0,68·t

0,866

And once resolved, t = 49,6 years

3 Results and discussions

A complete review of alloys based in Zn-Al-Mg has

been made, looking at all relevant aspects of the

topic: characterization, structure and composition,

corrosion behaviour, standards and designations,

key raw material suppliers and market offer, key

electrical trunking manufacturers and market offer

and finally, field tests research and accelerated

corrosion tests.

The review has been complemented with a

methodology to estimate the long-term corrosion

resistance of these alloys. The equations calculated

with this method have to be carefully taken, since

they are based in the actual limited field tests values.

In the next years, more field tests values will be

available, and this research work should be

complemented, having much more statistical values,

so to have a better accuracy in this long-term

calculation.

In any case, our results can serve as a reference point

to project engineers and other professionals, who

need to determine the best choice of material based

on ZM alloys and can also evaluate the advantages

and disadvantages of these new alloys compared to

traditional zinc-based coatings:

- ZM finishes don´t have the issue of sharp edges

and aesthetics of traditional post-galvanized

finish.

- ZM finishes have better performance in sodium

chloride-containing atmospheres, with high

humidity or high condensation of water. In open

panels, the corrosion rate can be up to 65% lower

than for a pre-galvanized finish.

- Traditional zinc-based coatings have a better

performance in low CO

2

content atmospheres.

- In acid atmospheres or with other type of

pollutants (urban or industrial areas) the

performance of ZM alloys is less relevant, so, a

deeper analysis has to be done. This is for

instance the case of traffic tunnels, where there´s

a high component of pollutants coming from

vehicle combustion.

- The performance of ZM finishes decreases in

hem flanges for all type of environments because

of the affection of the bending process to its

chemical structure. This has to be considered

when choosing the type of metallic accessories to

use, for instance in an electrical installation.

- On cut edges, self-healing phenomenon is

occurring even in environments presenting very

low chloride content, and in some cases for high

steel thicknesses up to 5 mm in NSST. However,

on rural environments, chloride-free

environments, the self-healing phenomenon

could be only observed in thinnest steel gauges.

Thus, especial attention has to be payed when

having parts with cut edges.

- Alloys with a high aluminium content (above

15%), only provide effective cathodic protection

against corrosion, in atmospheres with a high

concentration level of chlorine ions, while alloys

with high zinc content, the cathodic protection

acts from the beginning in all cases.

- In general, the annual corrosion rate of the

second and subsequent years is lower, due to the

effect of the corrosion products. That´s very

important to be considered in the maintenance

works. Also, in places where this corrosion

products would be removed (for instance in rainy

places), it has to be considered that corrosion

resistance will be lower than in dry

environments.

0,1

1

10

100

1

6

11

16

21

26

31

36

41

46

51

56

61

66

71

76

81

86

91

96

101

µm

Years

http://novasinergia.unach.edu.ec 75

- Corrosion behaviour in this type of alloys is also

logarithmic. This has to be considered when

choosing the right thickness of the coating and

can be clearly observed in the methodology

charts.

- At the time of choosing the right type of coating,

it is very important to consider, not only the

corrosion resistance rate, but also the thickness.

For instance, even ZM alloys for specific

environments have better corrosion rates, the

current commercialized materials only offer

thicknesses up to 32 microns (430 g/m

2

). In the

end, it is up to the project engineer to make

calculations, according to the expected life

duration of the installation and the corrosion rate,

to properly choose the type of coating and its

thickness.

4 Conclusions

The rapid development and application of alloys

based on zinc-aluminium-magnesium, as an

alternative to traditional zinc-based coatings in

recent years, has generated a significant amount of

information in all areas and in a very scattered way

(composition, structure, qualities, regulations,

corrosion, etc.). This dispersion hinders their correct

understanding and application, especially in the face

of the dilemma about its usage in front of traditional

coatings. The present research work solves this

problem, gathering and structuring all this

information, and providing engineers and final users,

a complete guideline with the key features of these

type of coatings and the restrictions to use them in

different types of environments.

A specific part of this review work has been focussed

in corrosion, where there are many types of tests but

with a high dispersion. All tests found have been

consolidated and we have shown the way to

calculate long-term corrosion resistance based in the

results of this field tests, being applied in different

corrosivity categories. Included also, is the

logarithmic behaviour of the corrosion function for

corrosion products.

All in all, the decision about what type of coating

should be chosen, will depend on several aspects,

buy mostly on the conditions of the environment,

and not always is obvious that these alloys can

directly substitute zinc-based coatings. A previous

analysis has to be done based on the given

guidelines. Finally, the thickness of the commercial

products offered in the market today are also

relevant, since, even the behaviour of ZM alloys can

be better (slow corrosion speed), or sometimes it can

be compensated by the high thickness that can be

reached in traditional zinc-based coatings.

Interest Conflict

No potential conflict of interest was reported by the

authors.

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