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Technical Paper prepared by John H. Stratton Director of Technical Services
Sheet Metal and Air Conditioning Contractors’ National Association, Inc. Headquarters: 4201 Lafayette Center Drive • Chantilly, Virginia 20151-1209 Mailing Address: P.O. Box 221230 • Chantilly, Virginia 20153-1230 Phone (703) 803-2980 • Fax (703) 803-3732 www.smacna.org
The service life of both G-60 and G-90 zinc coatings in outdoor exposures is relatively short. etc.. similar coatings for the accessories (i. high humidity and chemically polluted environments. for example. Special coatings for some accessories may be available at increased costs and delivery times. is consistent with anticipated building service life of 30 years. rod hangers. coating grade G-60. access doors. 1 of 4 . Supplemental coatings are available for fasteners in outdoor exposures. product availability and cost/benefit analysis of any unusually stringent specifications.G-60 or G-90 Zinc Coatings Specifications Introduction Specifiers should exercise caution and judgment in the consideration of the coating requirements for sheet metal ductwork accessories. trade practice. Zinc coating thickness on galvanized sheet has a linear relationship to service life and for building interior service. G90 is a recommended minimum on exposed sheet and reinforcements when supplemental paint coatings are not specified. Factors To Be Considered Where ductwork exposures do not involve wet and dry cycles.e.) may not be generally available in the normal supply channels. Fire dampers that comply with UL 555 and other equipment items inserted in ducts will not categorically have G-90 coatings. Base metal thickness is reduced as zinc coating is increased. Duct system designers should be knowledgeable about construction standards. which has two-thirds the life expectancy of G-90. While the location and/or intended application for galvanized sheet metal ductwork usually dictates the requirement for G-60 and/or G-90 coating for the ductwork panels. G-60 coating weight is 0. Zinc plating on commercially available screws and rivets is about 0. G-60 zinc coating on tie rods is routinely available. the traditionally used zinc coating amounts reviewed herein have provided satisfactory service life in HVAC system service. The cost increase for G-90 versus G-60 coated sheet is small but availability varies nationally. tie rods.2 mils. Any project specification that. purports to make G-90 or G-60 coating a requirement for all steel components incorporated in ductwork and exposed to airflow is a radical departure from trade practice and will entail significant cost increases and procurement and delivery delays.34 mils.
Director of Technical Services 1. Paragraph S1. reinforcement may be uncoated steel or galvanized steel.54 mils (0. pullout and shear test data on thicker zinc-coated fasteners are not known to exist. All internal ties. renovation work has not revealed a track record problem with the customary 0. If hot-dipped. However. pipe.2 mil coated fasteners.16: The duct gage tables are based on G-60 coated galvanized steel of lockforming grade conforming to ASTM Standards A653 and A924. This exceeds the ASTM A653 G-60 coating weight (minimum one side by triple spot test) of 0. the industry has rods. Minimum yield strength for steel sheet and reinforcements is 30.16: Tie rods shall be galvanized steel. Page 1. Comment: All thread rod.2 mm) minimum galvanized steel and the smallest edge shall face the airflow. tube.32 oz/ft2). RECTANGULAR DUCT Paragraph S1.64 micrometers) and is near the G-90 minimum of 0. whether of rod. Page 1. Blind rivets using pull-through mandrels are not permitted if they leave holes for air leakage. Paragraph S1. used on positive pressure only. Where only bolts or welds are specified. they may have coatings as thick as G-90 sheet. Page 1. Polymer. values could be different. Special orders and expense would occur as a consequence if coatings equivalent to G-60 or G-90 were demanded. 8. They may be zinc or cadmium coated.16: Unless otherwise specified.8.2 mil zinc at additional expense.20 oz/ft2. or angle shall be of material having the same nature and corrosion resistance as the duct wall material. shall be 1" x 1/8" (25 x 3. Stratton. chromate or phosphate coatings could be added to the 0.11. partially threaded rod.5 mils (a mil is one-thousandth of an inch). Paragraph S1.Additional Details and Comment From SMACNA’s HVAC Duct Construction Standards.000 psi (207 kPa). Tie straps.34 mils (0. other types of fastening are not allowed. Otherwise. Standard or self-drilling sheet metal screws may be used as appropriate. tubing of pipe. 1995 John H. Page 1. Concealed components shall not be subject to nor cause galvanic corrosion.12. 2 of 4 .21. Fastenings shall not project into duct interiors more than 1/2" (13 mm). Page 1.41. The prevailing and customary plating on screws and rivets is about 0. for dry indoor environments. EMT conduit or rigid conduit grades. Comment: This specification does not require that zinc coating equivalent to G-60 be used.2 mils.8: Unless otherwise specified steel sheet and strip used for duct and connectors shall be G-60 coated galvanized steel of lockforming grade conforming to ASTM A653 and A924 standards. 2nd Edition. conduits and other structural support members that are electroplated with zinc that is about 0. ASTM A653 grade pipe and angles are routinely available in the marketplace with zinc coatings that meet or exceed the thickness of G-60 coated steel sheet. Paragraph S1. however.62: Fasteners used on steel duct shall be steel.
315 mil).5 to 4 years G-60 — 2. 4.5 to 6 years.5 to 4 years. 2.11.1: Round ducts shall be constructed in accordance with Tables 32 and 3-3. 3. Ductwork: 30 years median. Otherwise.472 mil). based on mean corrosion rate less than 0. Source: ASTM and zinc-related industry research. G-60 — 1. b) when installed. indoors: G-60 — 34 years G-90 — 54 years Source: ASTM Standard B695 Appendix. Source: ASHRAE Applications Handbook B. are as corrosion resistant as G-60 coated galvanized steel. Urban/Suburban: G-90 — 4 years. OVAL DUCT Comment: Paragraph S1. Comment: Stiffeners and fasteners are expected to have coatings as on rectangular ducts.5 years G-60 — 8 to 16 years 3 of 4 . Page 2. C. Mechanically deposited coatings per ASTM B696 come in three classes: Class 12 (0. 4.5 to 2.25: Liners shall also be installed with mechanical fastening devices that: a) are spaced in accordance with Figure 2-21. reinforcements and fasteners are expected to be zinc coated as specified for rectangular ducts. 3. Class 8 (0.0. ROUND DUCT Paragraph S3.01 mils/year. Zinc Coating. DUCT HANGERS Comment: Consult HVAC-DCS Chapter 4 for requirements and options.5 years G-60 — 1. Class 5 (0.8 applies for ducts of all shapes. SERVICE LIFE FORECASTS A.Cadmium coatings are seldom used but are available. Page 3. outdoors (to first rust): 1. 2. Zinc Coating.197 mil). Industrial: G-90 — 2. Rural: G-90 — 12 to 25 years. Table 3-2 is based on G-60 coated galvanized steel of ASTM Standards A653 and A924 grades. Paragraph S2. 5. Marine: G-90 — 2.
) Zinc-iron alloy coated steel (also known as "galvanealed") has a grey.sspc.org).galvanizeit. The life of zinc coating in a given not-severely-polluted. For extensive reporting of corrosion from outdoor atmospheres and chemicals.asm-intl.org) and the National Association of Corrosion Engineers (www.org) and the Society for Protective Coatings (www. it is not suitable for coil coating lines. however. consult the many publications available from ASM International (www. Practices for Preparation of Zinc-Coated Galvanized Steel Surfaces for Paint. Specification of G-90 coated galvanized steel is recommended for components exposed to weather.Comment: Corrosive elements present can cause significant deviation from averages. Where painting or waterproof coating of exterior insulation is applied G-60 coating may suffice.nace. (SPC was formerly known as the Steel Structures Paint Council and many codes and specifications still refer to it by its former name. outdoor atmosphere is generally considered to be linear and varying with thickness. 4 of 4 . including preventing and treating wet storage stain and touch-up and repair of galvanized surfaces with zinc-rich paint. Several publications on surface preparation and painting galvanized steel surfaces.org). are available from the American Galvanizers Association (www. The commonly used standard for phosphatizing or other treatment is ASTM D2092. unspangled A60 coating that is ready for immediate painting (with normal cleaning).
656 .0157 .0575 .1292 .0770 .270 3.5131 .2845 .004 1.1174 .05564 = minimum weight.4874 Weight Nom. .906 1.86 8.156 2.563 .656 2. 0.0236 .0516 .775 2.002 6.1771 Nom.844 . A principle international standard is ISO 3575.00153") 40. 9.1014 .5169 . or 0. Much chemical and atmospheric corrosion information is available from ASM International in Metals Park.0217 . .0120 .0172 .1233 .3404 .0356 .1382 .331 1.01 22. Minimum weight in this table is based on the following computation: Minimum sheet thickness minus 0.204 2.0316 . Based on ASTM A924/924M-9.0710 .106 1.0336 .6979 . 2.546 2. Tolerances are valid for 48" and 60" wide coil and cut length stock .138 3. per inch.0306 . Lock Forming and Drawing Qualities.8407 .4531 .1084 . Standard Specification for Sheet Steel.5755 .6274 .983 3.613 1.7591 . 3.60 oz/sf (triple spot test) total for two sides. ASTM D2092.0217 .0406 .162 2.0060 .006 1.0369 lb/sf of zinc.288 1.0516 4.2 HVAC Duct Construction Standards – Metal and Flexible Second Edition .342 2. Thickness and zinc coating class can be stenciled on the sheet. .181 1.803 1.653 1.5512 .463 1. Ohio and from NACE International in Houston. Zinc-Coat (Galvanized) or Zinc-Iron Alloy Coated (Galvanized) by the Hot-Dip Process.59 oz/sf of zinc equals 0.5931 . The steel producing industry recommends that steel be ordered by decimal thickness only.0336 .656 3.753 3.7772 .00153".6010 6772 . lb/sf . Standard Specification for General Requirements for Sheet Steel.8534 .42 5.281 4.5550 .4166 .8795 6.0814 1. per ASTM A653 and ASTM A90.594 .943 1.0934 .0266 .781 .698 .82 lb.0296 . G90 stock would be comparably calculated from: (t .0695 .1381 2.9296 1.0172 . lb/sf .994 2.90 oz/sf (triple spot test). .406 1..3607 .0376 . .64 6.0276 .061 2.222 Nom. G90 coating is 0.0650 .6481 2.2286 .832 3.21 NOTES: 1. 8.0436 .763 1. The gage designation is retained for residual familiarity reference only.0466 . A. PA.7010 .9590 1.8296 .Galvanized Sheet Thickness Tolerances1 Thickness in Inches Gage 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 12 12 11 10 9 8 Min.0202 .158 1.461 1.2038 1.4750 .1681 Min lb/sf .3569 .5274 .81 4. Practice for Preparation of Zinc-Coated Galvanized Steel Surfaces for Paint.906 1.0287 .133 4.820 .4369 .5143 .7274 .0187 .1622 .781 6.0232 .0785 .6526 1. 4.0326 .0406 .441 1.0187 . and ASTMA653/A653M-94.1442 .6312 .7534 . Zinc-Coated Carbon Steel Sheet of Commercial.305 2.020 .665 . 10.0854 .8772 .2409 .881 .0142 .121 4.953 2.0865 .8 0.5823 2.167 1.0625 . 1 oz is 0.1524 .96 16.0705 .001".0456 .376 .4712 .285 1. kg/m2 Thickness in Millimeters Min.591 1.362 3.0217 . Philadelphia.523 2.2642 .891 4.786 5. scale weight may run 2% (or more) greater than theoretical weight.040 Max.0164 . per s.1323 .0566 .8974 2.0172 . includes mill phosphatizing. 5.f.614 7.0994 .372 2.6367 . Other information is available from the National Coal Coaters Association. Magnetic gage measurement of zinc coating may have 15% error.0187 .280 3.2675 5.8725 3. per inch plus 0.394 6.311 1. ASTM A755 is the Specification for Sheet Steel.0134 .0112 . The lock forming grade of steel will conform to ASTM A653 (formerly ASTM A527).719 .0247 .525 4.408 1.0506 . Metallic Coated by the Hot-Dip Process and Prepainted by the Coating Process for Exterior Building Products.132 3.0396 .759 .8 lb per sf.4204 .740 4.other dimensions apply to other sheet widths and to strip.0017" and is 305.15 g/m2.531 5.500 Nom.530 1. Metallic Coated by the HotDip Process (formerly ASTMA525).20 3.0247 .4783 .902 3.3263 1.0104 .661 4.4331 .08 10. .1591 Max.0635 .001" of G60 coating times 40.11 28.3950 .1532 . Continuous Hot-Dip Process.875 Max.3188 .3988 .0127 .784 2.4486 1.4804 4.6505 5.1143 .028 1. TX. 6. has 0.0296 1.510 3.1472 .0157 .653 1.52 12. G60 coating.0575 . 7.0142 .0090 .8010 .0346 . However. Actual weight may be near 40.486 .9534 1.156 1.0525 .3048 .4369 .
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