Customer Communication

CORROSION
February 2005 UPDATE
Customer Communication

Presentation content

• What is Corrosion?
• Where do you find corrosion?

• Protection of Metals from Corrosion

• Compatibility of Metals in Service

• Australian Standard AS3566

• The Buildex Solution.

• The Buildex Warranty

Customer Communication

What is corrosion?

Corrosion is the natural process

of reverting the metal to the ore
from which it came.

• Corrosion is normally associated with non-precious metals such as steel, zinc,

aluminium and to a lesser extent copper
• These metals only exist because we refine them from their ores by heat and
smelting
• In the presence of air, water or salt, these metals will corrode
• The level of corrosivity in the atmosphere will determine the rate at which the
metal corrodes
• Levels of corrosivity vary from one location to another
• Exposing metal to any form of corrosive environment will cause oxides to form
which gives the metal a disfigured appearance and eventually will cause it to
be unsafe or useless
Customer Communication

Where do you find Corrosion?

Locations of Corrosive Areas within Australia.

• Australia is mostly a Chloride

environment, Chloride is usually
associated with marine influences.
The southern hemisphere has a sea to
land ratio of 3 to 1 unlike the northern
hemisphere which is closer to equal.

Corrosive parts of Australia

Customer Communication

Where do you find Corrosion?

Types of corrosive environments

• The corrosion found in the Northern

hemisphere is caused by a Sulpher and
Acidic environment. (Heavy industry)

• Chloride usually associated with marine

influences but can be found commonly in
such places as swimming pools

• Sulpher generally associated with industrial or

high emmission environments

• Acidic usually associated with processing or

storage of chemicals
Customer Communication

Where do you find Corrosion?

Level of corrosivity in the atmosphere

The level of corrosivity is affected by the following factors

• Proximity or distance from the corrosive source

• Prevailing wind direction
• Topography of the land
• The type of corrosive source
• Frequency of wash down ( natural rain or washing )
• Vegetation density
Customer Communication

Where do you find Corrosion?

Proximity or
distance from the
corrosive source

WIND
Stainless.Zone

Climaseal 4 & Zacs 4 Zone

VERY SEVERE
CLIMASEAL 3 ZONE
SEVERE

MODERATE
MILD
CORROSIVITY
LEVEL

OVER 2 KILOMETERS
Customer Communication

Where do you find Corrosion?

Prevailing wind
direction
20 KTS 5 KTS

Cliffs
FALLOUT ZONE
10 KTS

Climaseal 4 & ZACS 4 ONLY

Customer Communication

Where do you find Corrosion?

Topography of the land

FALLOUT ZONE

20 KTS Trees

10 KTS

CLIMASEAL 3

Climaseal 4 & ZACS 4

Customer Communication

Protection of metals from Corrosion

Methods commonly used.

• Barrier coats such as paints

• Electro deposited coatings eg ‘E’ coat ( climacoat )
• Passivation coatings eg patina effect
• Galvanic protected coating systems eg sacrificial
• Combinations of above
Customer Communication

Protection of metals from Corrosion

• Galvanic or sacrificial protection of steel is the most

common form as it gives the longest service life.

• The principle of protection is using dissimilar metals

in contact, where one will corrode to protect the
other.

• This is called galvanic ( sacrificial ) protection

Customer Communication

Protection of metals from Corrosion

Galvanic scale for metals
Noble ( cathodic )
Gold
Silver
Stainless steel
Monel
Brass
Tin
Lead
Carbon steel
Cadmium
Zinc
Magnesium
active ( anodic )
Customer Communication

Protection of metals from Corrosion

• The more active metal will give sacrificial protection to
the less active material when in contact.

• The alloying of two metals together to protect a third acts

differently giving better protection and sacrificing more
slowly

• Zinc & aluminium over steel = zincalume

• Zinc & tin over steel = alloyplate

Customer Communication

Compatibility of metals in service

Compatibility of coating to sheeting material

Material:
COLORBOND
STEEL

GALVANIZED CLIMASEAL 3

Results from Real World Test after 6 months exposure

Customer Communication

Compatibility of metals in service

Results from the Same test after 2 years.

GALV. PATINA FORMED ---- SHEET STEEL CORRODES

Customer Communication

Compatibility of metals in service

Compability Results from Real World Test after 2 years.

Material:

XSE

GALV. Z4 SS
Customer Communication

Compatibility of metals in service

Stainless steel screws into colorbond steel

SHEH FUNG BI METAL

MARUTEX

POWERS

BX Stainless

Compatibility after 18 months exposure

Customer Communication

Australian Standard AS 3566

AS 3566 is the Australian Standard for

Self Drilling screws used in the building and
construction industries

Part 2. Corrosion resistance requirements

Qualification is by ‘Deemed to Comply’

Or
Real World Testing
Customer Communication

Australian Standard AS 3566

What isWhat
Deemed To Comply ?
is deemed to comply ?
Deemed to Comply relates to Table 2 below that states the levels of Zinc and Tin-Zinc that is required to
meet the this standard. All major industry groups have been working on Real World Testing as their
preferred method for achieving AS3566.
Customer Communication

Australian Standard AS 3566

Example of Deemed To Comply minimum requirement

To Table 2
CLASS 3 ZINC TIN

25 um
Customer Communication

Australian Standard AS 3566

Sectioned pieces of material indicating porosity rating of
mechanical plating
( as per Deemed To Comply Table 2)
Customer Communication

Australian Standard AS 3566

Example of Buildex Class 3 Cross Section

STEEL SUBSTRATE

ZINC/TIN LAYER

CLIMASEAL
TOPCOAT
Customer Communication

Australian Standard AS 3566

C3 Competitor Sample (April 2004 )

Porosity Rating between 1 - 4

Required to be 8 to obtain Standard for Compliance
(as per Deemed To Comply Table 2)
Customer Communication

Australian Standard AS 3566

Real world corrosion testing
Real World Test Sites
In order to test the actual corrosion performance of our
products, Buildex operates and supports a research,
development and testing program. Buildex pioneered the use
of “real world” outdoor exposed testing, operating since 1994
three outdoor testing stations and using a further four sites
controlled by BHP & CSIRO. These stations are built in known
corrosively aggressive locations around Australia, such as
Bellambi Point (NSW), Flinders (VIC), King Island (TAS), and
Newcastle (NSW) in order that Buildex can obtain the test
result quickly. The severe conditions at these sites will give an
indication of the product performance after approximately one
year. Unlike traditional “accelerated” laboratory testing only
outdoor test sites expose the fasteners to the combinations of
corrosive influences that exist in the “real world” eg:

• Chlorides (Marine)
• Humidity (Condensation)
• Acid Rain (Industrial)
• Ultra Violet (UV) Zinc Coupons used to measure
corrosion rate / time
Customer Communication

Australian Standard AS 3566

Buildex have been involved with real
world test for almost 15 years
Panels representing sections of
roofing, complete with screws, are
exposed to the elements and the
results are monitored twice yearly.
This is done independently by the
CSIRO. From theses results
Buildex can pinpoint which coatings
perform best, regularly putting out
new panels with new coatings, as
well as panels for checking the
consistency of our existing coating CLASS 4 EXPOSURE
process over time. We also put out
42 um ZINC LOSS
comparative panels of competitor
products on a regular basis. CLASS 3 EXPOSURE
21 um ZINC LOSS
Customer Communication

Australian Standard AS 3566

Competitor comparison 2003

BF A M B BX

Results 18 months after exposure k.I. ( C3 ) samples obtained 2001

Only A and BX pass Real World Test (product A now imported)
All claimed to meet Table 2 Deemed To Comply
Customer Communication

Australian Standard AS 3566

Real world test sites are everywhere
Unfortunately for some owners

House location
Como Perth W.A.
2004
Customer Communication

Australian Standard AS 3566

Real world test sites are everywhere
Unfortunately for some owners

House location
Como Perth W.A.
2004
Customer Communication

Australian Standard AS 3566

Real world test sites are everywhere
Unfortunately for some owners

House location
Hocking Perth W.A.
2003
Customer Communication

Australian Standard AS 3566

Real world test sites are everywhere
Unfortunately for some owners

House location
Hocking Perth W.A.
2003
Customer Communication

The Buildex® Solution

Established Buildex finishing systems

• Climaseal 3® / ZACS 4® and Climaseal 4® are all protected with a sacrificial coating
of zinc/tin alloy over which a further coating of aluminium rich polyester ( Climaseal )
is added

• Climaseal 3® has a coating thickness of 25um of zinc tin and a further 15um of
climaseal making a total of 40um

• ZACS 4® has a coating thickness of 45um of zinc/tin with a further 25um of blue
climaseal making a total of 70 um

• Climaseal 4® combines a sacraficil base coat with a new environmentally friendly

passivation system and then overcoated with a new processing system for
climaseal.
Customer Communication

The Buildex® Solution

Climaseal 3 ®
Climaseal 3® is an unique anti-corrosive coating system consisting of 3 distinct
layers which combine to give exceptional corrosion protection:
1. A mechanically deposited zinc alloy coating giving excellent galvanic
protection.
2. A chromate conversion coating to passivate the zinc alloy, further inhibiting
coating loss.
3. An aluminium filled polyester coating with good all-round corrosion and
long-term weathering resistance.
Designed to conform to AS3566 Class 3, real life atmospheric testing has
confirmed that the performance of Climaseal 3® far exceeds the standard!

Climaseal 3® should be used for general external

use in mild and moderate industrial, and mild marine
Applications
Customer Communication

The Buildex® Solution

ZACS 4 ®
• Buildex ZACS 4® fasteners and cyclone plates don’t just satisfy
AS3566
• Class 3, but meet and exceed AS3566 Class 4 specifications.
• ZACS 4® is a unique coating system comprising of an alloy
combination
• which gives exceptional galvanic protection. The coating thickness
exceeds
• 50 µm, which is twice the thickness of an equivalent Class 3 product.
• Twice the thickness doubles the protection and doubles the
performance!
• ZACS 4® should be used in coastal areas where salt, wind, U.V. and
moisture are prevalent, in tropical zones, in industrial areas subject to
acid rain fall-out, where agricultural spraying is carried out, or
anywhere high performance cladding material is specified.
• It is particularly recommended for use in moderate and severe marine
Customer Communication

The Buildex® Solution

Climaseal 4 ®
• Climaseal® 4, the new coating finish from Buildex, is the end-
result of over ten years of “real world” testing, providing a
thorough understanding of corrosion and its prevention.

• The new Climaseal® 4 coating is a layered system, combining

both a high density sacrificial coating substrate, over which a
passivation coat has been applied. The Climaseal® 4 is then
applied by a new, environmentally friendly, processing system.

• Climaseal® 4 meets and exceeds AS3566 Class 4

specifications. It should be used in coastal areas where salt,
wind, UV and moisture are prevalent, in tropical zones and
industrial areas. It is particularly recommended for use in
moderate and severe marine environments.
Customer Communication

The Buildex® Solution

Under roof corrosion of roofing fasteners is the great hidden

danger. All protective coatings are subject to damage during
installation. This damage is a scratching by the roof sheeting
along the shank of the fastener.

In this picture the protective

coating on the shank was
damaged during installation
allowing the corrosive
environment to attack the
exposed metal of the fastener
shank.
Customer Communication

The Buildex® Solution

ShankGuard® is a revolutionary patented design

feature, specifically developed by Buildex to guard and
protect fastener shanks from scratching and scouring
that can occur when crest fixing metal roofing.

ShankGuard® actually cuts a slightly larger hole in the

roofing profile than the shank diameter, guarding and
protecting it against scratching and scouring from the
sharp edges of the pierced hole in the metal roof.

ShankGuard® allows the fastener shank

to remain unscuffed and scratch free during installation,
which in turn keeps the corrosion coating intact and
fully functioning.
Customer Communication

The Buildex® Solution

The ShankGuard® feature is constructed of small knurls

rising above the surface of the shank. When these contact
the roofing profile and enlarge the hole, a small amount of
protective coating is removed from the crest of the knurl.
The surrounding corrosion coating protects these exposed
points by galvanic action.

The underside of this roof clearly demonstrates the

superiority of the Buildex product with ShankGuard®.
The imported competitor product on the left is in an
advance stage of deterioration due to corrosion.
The Buildex roofing screw with ShankGuard® on the right
is in perfect condition. Without With
ShankGuard ShankGuard
The site where these pictures were taken is classed as
moderate marine, protected by a breakwater. All
competitors fasteners on this site are failing after 18
months, requiring costly repair and replacement.
Customer Communication

The Buildex® Warranty

Buildex® is so confident that it

can guarantee the highest
quality and performance of its
fasteners that it has backed it
up with the Buildex® Warranty,
an industry first.

Buildex Warranties are based

on real world test results.
Customer Communication

The Buildex® Warranty

Buildex® is so confident that it

can guarantee the highest
quality and performance of its
fasteners that it has backed it
up with the Buildex® Warranty,
an industry first.

Buildex Warranties are based

on real world test results.
Customer Communication

Mission Statement

“Buildex® is committed to being the leading Australian

manufacturer and marketer of construction fastener
solutions based on:
Innovative products, outstanding quality and
uncompromising service”.