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TECHNICAL NOTE
No.: 100VV-DE-TNO-0002 Date: 09/12/2021 Rev.: 00
STRUCTURAL BUILDING
DESIGN
CALCULATION PHYSICS
Title: Mild steel/Low carbon steel corrosion protection Discipline:
MATERIAL QA/QC HS&E

ISSUE
This note addresses the design of corrosion protection systems for mild steel / low carbon steel
components. The applicability of each corrosion protection system and their design is based on
component service life assessment. Indeed, the corrosion protection systems shall provide to the
steel component the needed (required) durability, accounting for the given (feasible) maintenance
activities and considering the specific exposure category.
A schematic method to select and design the corrosion protection system for mild steel / low
carbon steel components is proposed. The note includes a brief introduction of the concept of
service life, distinguishing between primary and secondary components; reference corrosion
categories are then reported, making direct reference to typical Permasteelisa curtain wall
applications. A table summarizing the applicability of each corrosion protection system is then
included to help designer to pre-select the appropriate system for the case specific. At the end of
the document, the procedures to design (i.e. to estimate the service life) different corrosion
protection systems are included.
This Technical Note is not meant to give a detailed overview of each corrosion protection system,
neither to specify all the information needed for correct material purchase.
The indications herewith included considers the protective treatments are correctly applied (acc.
to state of the art and reference standards) and the façade is correctly maintained (acc. to the
prescriptions included in the Operation and Maintenance Manual).
This technical note replaces and integrates DT-016 [1], IT-05 [2] and IT-02 [3].

REFERENCES

[1] DT-016 "Acciaio, trattamenti superficiali", Permasteelisa Spa.


[2] IT-05 "Resistenza alla corrosione di vari materiali", Permasteelisa Spa.
[3] IT-02 "Confronto primer bicomponente e zinco spray", Permasteelisa Spa.
[4] 100VV-DE-TNO-0004 "Galvanic_Corrosion_Provisions (latest rev.)”, Permasteelisa Spa.
[5] ISO 15686-1 "Buildings and constructed assets - Service life planning - Part 1: General
principles and framework".
[6] CWCT Standard for systemised building envelopes Part 7 "Robustness, durability,
tolerances and workmanship".
[7] ISO 9223 "Corrosion of metals and alloys - Corrosivity of atmospheres - Classification,
determination and estimation".
[8] ISO 1461 "Hot dip galvanized coatings on fabricated iron and steel articles - Specifications
and test methods".
[9] EN 10346 "Continuously hot-dip coated steel flat products for cold forming - Technical
delivery conditions".

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 1 / 14
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TECHNICAL NOTE
[10] ISO 14713-2 "Zinc coatings - Guidelines and recommendations for the protection against
corrosion of iron and steel structures - Part 2: Hot dip galvanizing".
[11] “ISO 9224 "Corrosion of metals and alloys - Corrosivity of atmospheres - Guiding values
for the corrosivity categories"”.
[12] ISO 2063 "Thermal spraying - Zinc, aluminium and their alloys".
[13] ISO 12944 "Paints and varnishes - Corrosion protection of steel structures by protective
paint systems".
[14] Qualisteelcoat, Internation quality label for coated steel "Technical Specification".
[15] EN 13438 "Paints and varnishes - Powder organic coatings for hot dip galvanised or
sherardised steel products for construction purposes".
[16] EN 15773 "Industrial application of powder organic coatings to hot dip galvanized or
sherardized steel articles [duplex systems] - Specifications, recommendations and
guidelines".
[17] Qualicoat Specifications "Specifications for a quality label for liquid and powder coatings
on aluminium for architectural applications".

NOTE
Mild steel / low carbon steel is not classified as corrosion resistant. For this reasons, all elements
composed by this material needs a protection treatment which allows to provide the component
with the required durability and the required aesthetics.
The selection of the most appropriate protection system is not always immediate, being sensitive
to durability requirements, possibility for maintenance, exposure condition and other aspects
herewith not considered (e.g. part geometry and dimensions, weights and costs).
This technical notes is meant to provide a method to help designers in selecting and designing the
most appropriate protective treatment.
The procedure consist of the following steps:
1) Clarify the design life of the curtain wall and the required service life of the curtain wall
component.
2) Check for possibility of component inspection and maintenance (repair and/or substitution)
3) Clarify the use condition of the component by identifying the corrosion category.
4) Select and design the corrosion protection system using the indication included in this
document.

Each step is addressed in the following pages.

Note: considerations included in this technical notes do not consider corrosion effects due to
galvanic coupling; for indications about correct coupling of metal components refer to [4].

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

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TECHNICAL NOTE
Design life of the component: primary and secondary components
Curtain wall shall typically achieve a design life of 50 to 60 years. Design life, i.e. “the service life
intended by the designers” (ref. to ISO 15686 [4]), is defined as the “period of time after installation
during which a facility or its component parts meet or exceed the performance requirements”. This
information is usually specified on a dedicated chapter of Project Specifications.
Not all curtain wall components can reach such long durability periods; indeed, some parts can
(need to) be designed with the possibility to be repaired and/or replaced to assure the curtain wall
service life requirements.
The CWCT Part 7 [5] provides some indications about that, distinguishing between primary and
secondary components:
- Primary components: all components with a forecast service life not less than the design life
of the envelope system, without the need for maintenance other than regular cleaning;
- Secondary components: all components with a forecast service life of less than the design life
of the envelope system. For such components, the envelope contractor shall provide guidance
on the required maintenance, replacements periods and method of replacements.
In practice, the curtain wall can be composed of parts which last “lifelong” (i.e. last for at least the
design life of the curtain wall) and by parts which can reach that duration only if are maintained
(repaired and/or replaced).
Typically Project Specifications includes service life prescriptions also for different façade
components: e.g. framing, finishes, glass, gaskets… however, the way different components are
listed is not standardized and can sometimes be interpreted in different ways. When designing a
façade component, it is recommended to have clear the required service life for such part to
proceed with a more effective design.
CWCT Part 7 [5] provides also some examples of typical primary and secondary components: with
regards to mild steel / low carbon steel typical applications, the following is reported:
Primary components Secondary components
- all framing components, their fixings and means - Exposed finishes to metal components
of attachment to the structure; - Window and door equipment
- flashing, gutters, copings and similar metal - External panels and their fixings
weathering elements;
- brackets for attachment of additional components

In principle all structural elements shall be designed as primary components when “embedded”
into the curtain wall; however, some “relaxations” might be accepted if the element is part of an
opening element (window and door) or part of an external structure holding finishing panels, i.e.
part of a substructure with a shorter lifespan than the one of the curtain wall (always double check
with Client expectations).

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
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TECHNICAL NOTE
Component inspection and maintenance possibility
CWCT Part 7 [5] states that “the secondary components shall be capable of replacement without
compromising the long-term structural or weatherproof integrity of the envelope system and
without progressive dismantling of the enveloped system”.
As a consequence:
- if a component cannot be inspected and maintained (repaired or replaced), it should be
designed as primary component.
- if a component can be inspected and maintained (repaired or replaced), it could be designed
as secondary component (depending on Project specifications)
To note that during façade design stage, this point can be seen:
- as a given condition: component can or cannot be maintained and as consequence it should
be appropriately protected against corrosion;
- or as a design input: e.g. component shall be designed to allow for its replacement.

! Attention: feasibility of component inspection and repair means that all parts of the components
should be reached, not only the visible parts. Corrosion can happen on any parts, and it’s likely to
be more severe on hidden crevices; indeed maintenance for corrosion protection shall be
distinguished from maintenance for aesthetic performance (e.g. touch up of a scratch on a visible
coated surface).

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 4 / 14
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TECHNICAL NOTE
Use condition: reference corrosion categories
The reference atmospheric corrosion categories are defined by ISO 9223 [6].

Project specifications usually include the reference corrosion category for external atmosphere,
typically C3 or C4. Building interior is in most cases (residential, office, retail, hotels) humidity and
temperature controlled and, if no different indications are provided, for such environment a
corrosion category C1 can be assumed.

Note: if no indications are provided, it’s important to promptly and properly address the request to
the Client since such parameter is required for corrosion protection system design.

While the definition of the innermost and outermost environmental condition is clear, it is not always
evident what is the reference condition for intermediate façade components. A simplified and
conservative approach fix the vapour barrier as the boundary between outer and inner

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
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TECHNICAL NOTE
environmental condition. However, such simplified approach might in some cases be too
conservative, leading to excessive overdesign of façade component.
In the following pictures, typical curtain wall sections are presented and different zones with
different exposures are highlighted.

For each zone, the following corrosion category can reasonably be considered.
Assigned Corrosion category for
Zone Description Operating condition
service life assessment

External, visible Outdoor environment, project specific


C3/C4
A External, not visible, sheltered
Outdoor environment, project specific
according to specs
but not protected from wetting.
Outside the vapour barrier, but
Unheated spaces with varying temperature and
protected from water/pollution.
B Limited wetting by condensation
relative humidity. Low frequency of condensation C2
and low pollution.
possible.
Heated spaces with low relative humidity and
Internal, not visible
insignificant pollution.
C Heated spaces with low relative humidity and
C1
Internal, visible
insignificant pollution.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
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TECHNICAL NOTE
Applicability and service life of different corrosion protection systems
Once the component required service life and the application specific corrosion category are
defined, designers can look for applicable corrosion protection systems. The following table
summarizes the applicability of the different corrosion protection systems, considering “properly
designed” corrosion protection systems and a target design life of 60 years for the curtain wall.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 7 / 14
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TECHNICAL NOTE
Hot dip galvanizing Cost €€
Hot dip galvanized coatings on fabricated iron and steel Aesthetic properties N/A
products acc. to ISO 1461 [7]. Mechanical resistance HIGH
Continuously hot dip coated steel flat products acc. to EN Protection of hollow sections YES
10346 [8]. Act as galvanic separator NO
 Aesthetic aspect: not applicable.
 There may be problems of deformation of the products during the hot dip galvanizing process;
parts might need to be straighten after the treatment.
 Threaded parts must be adequately protected or processed again after the treatment to
eliminate zinc accumulations. This can cause local losses of zinc protection which must
subsequently be restored if needed.
 Knurls can be used only when there is the possibility for a correct zinc dripping from the
affected area, otherwise grooves might be blocked by zinc and become unusable.
 Typically, continuously hot-dip galvanized sheets can be used without restoring the zinc on cut
edges for thicknesses less than or equal to 3mm, thanks to the anodic protection of zinc in
proximity.
 Design guidelines can be found on ISO 14713-2 [9].
Service life assessment
Service life is calculated by calculating the zinc total corrosion attack (according to ISO 9224 [10])
and by comparing it with the nominal minimum zinc thickness that can build up on a steel element
(according to ISO 1461 [7] and EN 10346 [8]):

with:

E.g. Service life of steel structure, 3mm thick, hot dip galvanised acc. to ISO 1461 [7] and exposed
to a C3 corrosion category: 40 ÷ >60 years.
The table below includes service life calculations for few common cases. To note that silicon (Si)
and phosphorus (P) in the steel surface can prolong the reaction between iron and molten zinc. If
an increased zinc thickness is required, refer to recommendations included in EN 14713-2.
Ref. Zinc Service life (years)
Specifications
standard thickness C1 C2 C3 C4
+Z200 14 µm >60 30 ÷ >60
+Z225 16 µm >60 35 ÷ >60
+Z275 20 µm >60 45 ÷ >60 10 ÷ 45
EN 10346
+Z350 25 µm >60 55 ÷ >60 15 ÷ 55
+Z450 32 µm >60 >60 20 ÷ >60 10 ÷ 20
+Z600 42 µm >60 >60 30 ÷ >60 15 ÷ 30
Steel ≥ 1.5mm to ≤ 3mm 55 µm >60 >60 40 ÷ >60 20 ÷ 40
ISO 1461 Steel > 3mm to ≤ 6mm 70 µm >60 >60 50 ÷ >60 25 ÷ 50
Steel > 6mm 85 µm >60 >60 >60 30 ÷ >60

! Attention: if used on primary components, consultants could require possibility of inspection.

Note: considerations above can be used (with some limitations) also with thermal spraying zinc
coatings; in particular, the Zn99,99 alloy (almost “pure” zinc) shows corrosion behaviour similar to
the hot dip galvanising according to ISO 1461. Refer to ISO 2063 for details [11].

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 8 / 14
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TECHNICAL NOTE
Liquid coating on hot dip Cost €€€
Aesthetic properties LOW
galvanised steel products Mechanical resistance HIGH
Paint systems for carbon steel according to ISO 12944 [12] Protection of hollow sections YES
and Qualisteelcoat specifications [13].
Act as galvanic separator YES
Base material hot dip galvanized according to ISO 1461 [7].
 Aesthetic aspect: depending on Client expectations, the component could be exposed in
primary view, but attention shall be paid to avoid hot dip galvanizing defects such as drops,
smudges and imperfections on visible surfaces: the coating do not cover such defects.
 There may be problems of deformation of the products during the hot dip galvanizing process;
parts might need to be straighten after the treatment.
 Threaded parts must be adequately protected or processed again after the treatment to
eliminate zinc accumulations. This can cause local losses of zinc protection which must
subsequently be restored if needed.
 Knurls can be used only when there is the possibility for a correct zinc dripping from the
affected area, otherwise grooves might be blocked by zinc and become unusable.
 Coating thickness is not very controllable and can therefore vary a lot from area to area; it
must be taken into account to calculate any coupling tolerances with other elements (joints,
reinforcements, etc.).
 Such systems are sometimes called Duplex systems: double corrosion protection (galvanizing
and coating)
 Note: liquid coating on continuously hot dip galvanised steel products according to EN 10346
[8] is not covered by ISO 12944 [12].

Service life assessment


Service life is calculated by assessing the service life of the hot dip galvanized component and by
adding the durability of the paint layer. Indeed, the durability (of the paint system) is in this case
“related to the paint system adhesion to the hot dip galvanized surface. In case of a damaged
paint system, the remaining hot dip galvanized layer delivers further protection to steel” [12]. Refer
to the related sections of this document.

E.g. Service life of a steel structure, 3mm thick, hot dip galvanised acc. to ISO 1461 and coated
with a C3-High durability paint system for exterior applications acc. to ISO 12944 and exposed to
a C3 corrosion category: (40 ÷ >60 years) + (15 ÷ 25 years) = (55 ÷ >60) years

Note: such approach might be considered conservative. Indeed, ISO 14713 [9] states that “The
total life of a zinc coating plus organic coating system is usually significantly greater than the sum
of the lives of the zinc coating and protective organic coating. There is a synergistic effect, i.e. the
presence of zinc coatings reduces under-rusting of the paint film; the paint preserves the zinc
coating from early corrosion”. However, such statement is not backed-up with a service life
assessment methodology by any international standards.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 9 / 14
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TECHNICAL NOTE
Powder organic coating on hot Cost €€€€
Aesthetic properties MID/HIGH
dip galvanised steel products Mechanical resistance HIGH
According to Qualisteelcoat specifications and EN 13438 Protection of hollow sections YES
[14]. Base material hot dip galvanized according to ISO
Act as galvanic separator YES
1461 [7] or EN 10346 [8].
 Aesthetic aspect: depending on Client expectations, the component could be exposed in
primary view, but attention shall be paid to avoid hot dip galvanizing defects such as drops,
smudges and imperfections on visible surfaces: the coating do not cover such defects.
 There may be problems of deformation of the products during the hot dip galvanizing process;
parts might need to be straighten after the treatment.
 Threaded parts must be adequately protected or processed again after the treatment to
eliminate zinc accumulations. This can cause local losses of zinc protection which must
subsequently be restored if needed.
 Knurls can be used only when there is the possibility for a correct zinc dripping from the
affected area, otherwise grooves might be blocked by zinc and become unusable.
 When organic coating shall be applied over a Continuous hot dip galvanized flat sheet,
consider sheets with “Minimized spangles” finish (M) with “skin-passed quality” (B or C) and
possibly “Oiled” (O) according to EN 10346 [8] (e.g. +Z275-M-C-O).
 Typically, continuously hot-dip galvanized sheets can be coated without restoring the zinc on
cut edges for thicknesses less than or equal to 3mm, thanks to the anodic protection of zinc in
proximity.
 Such systems are sometimes called Duplex systems: double corrosion protection (galvanizing
and coating).
 Note: EN 15773 [15] provides indications on how to manage the whole process to obtain a
high quality product, important especially if more suppliers are involved (e.g. galvanizer and
coater).

Service life assessment


Service life is calculated by assessing the service life of the hot dip galvanized component and by
adding the durability of the coating layer. The durability of the coating layer is given by the
Qualisteelcoat specifications [13]: the appropriate/certified coating system shall be selected for
the specific environment. To note that Qualisteelcoat specifications [13] only considers High
durability (15 ÷ 25 years).

E.g. Service life of a steel structure, 3mm thick, hot dip galvanised acc. to ISO 1461 and coated
according to Qualisteelcoat specifications for C3 environment and exposed to a C3 corrosion
category: (40 ÷ >60 years) + (15 ÷ 25 years) = (55 ÷ >60) years

Note: such approach might be considered conservative. Indeed, ISO 14713 [9] states that “The
total life of a zinc coating plus organic coating system is usually significantly greater than the sum
of the lives of the zinc coating and protective organic coating. There is a synergistic effect, i.e. the
presence of zinc coatings reduces under-rusting of the paint film; the paint preserves the zinc
coating from early corrosion”. However, such statement is not backed-up with a service life
assessment methodology by any international standards.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 10 / 14
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TECHNICAL NOTE
Powder organic coating on Cost €€€€
Aesthetic properties HIGH
cataphoresis coated steel Mechanical resistance MID/HIGH
products Protection of hollow sections NO
According to Qualisteelcoat specifications [13] Act as galvanic separator YES
 Aesthetic aspect: the component can be exposed in primary view.
 Mechanical protection: the cataphoresis coating provides a moderate/high scratch resistant
protection. It is anyhow advisable to pay attention not to damage the coating during assembly
or handling (no anodic protection of steel).
 The cataphoresis treatment is carried out by immersion: it is therefore possible to protect the
whole component surface (even the most hidden areas). However, it is affected by the
"Faraday Cage" effect (less than Powder coating systems), which prevents the development
of electrochemical phenomena and therefore the deposition of the paint inside cavities of long
profiles.

Service life assessment


The complete coating system (i.e. cataphoresis followed by 1 or 2 applications of powder coating)
is covered by Qualisteelcoat specifications [13].

Component service life is assessed by selecting the appropriate/certified coating system for the
specific environment. To note that Qualisteelcoat specifications [13] only considers High durability
(15 ÷ 25 years).

E.g. Service life of a steel structure, 3mm thick, with cataphoresis priming and powder coating
according to Qualisteelcoat specifications for C3 environment and exposed to a C3 corrosion
category: 15 ÷ 25 years

Qualisteelcoat specifications [13] refer to the complete coating system; the use of Qualicoat [16]
certified top coat powder is not mandatory, but reduce the testing effort required to get the
approval. Only Qualicoat class 1 and 2 powder coating are considered by Qualisteelcoat
specifications.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
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TECHNICAL NOTE
Liquid coating on steel products Cost €
Paint systems for carbon steel acc. to ISO 12944 [12] and Aesthetic properties MID
Qualisteelcoat specifications [13] Mechanical resistance MID/LOW
Protection of hollow sections NO
*excluding zinc rich primer only systems Act as galvanic separator YES*
 Aesthetic aspect: depending on Client expectations, the component could be exposed in
primary view.
 Mechanical protection: during the assembly or handling of the elements it is necessary to pay
the utmost attention not to damage the coating which is sensitive to bumps, scratches and
abrasions (no anodic protection of steel, except for zinc rich primers).
 Coating thickness is not very controllable and can therefore vary a lot from area to area, it
must be taken into account to calculate any coupling tolerances with other elements (joints,
reinforcements, etc.).
 Design guidelines can be found on ISO 12944 [12] Part 3.
Service life assessment
Component service life is assessed by specifying the desired performance of the paint system for
the given environment, in particular by specifying:
 Corrosion category: C1 / C2 / C3 / C4 / C5 / CX
 Exposure: Interior / Exterior
 Required durability*: low (<7 y) / medium (7÷15 y) / high (15÷25 y) / very high (>25 y)
*Qualisteelcoat specifications [13] always refer to high durability requirements (15÷25 y)
The paint system is then selected based on the above listed information (and any additional
requirements – e.g. colour/gloss retention, site/shop application …). The ISO 12944 [12] on Part
5 provides some paint system examples, including product typologies, thicknesses and number
of layers.

E.g. Service life of steel structure, coated with a C3-High durability paint system for exterior
applications acc. to ISO 12944 [12] and exposed to a C3 corrosion category: 15 ÷ 25 years

To note that Service life is associated to durability of the paint


system, defined as the expected time to the first major
maintenance activity. The definition of when a component would
need to be maintained is not strict: “for examples, the first major
maintenance painting would normally need to be carried out for
reasons of corrosion protection once about 10% of the coatings
have reached Ri 3, as defined by ISO 4628-3”. Looking at the
picture on the right, it can be understood that such criteria might be
too permissive for architectural applications. Keep in mind this.

! Attention: specifications could require Warranty such as Ri 1 after 10 years. These requirements
are not backed up by standards and should be checked with the Supplier.
! Attention: the expected durability/service life concerns the corrosion protection of the underneath
steel parts; no requirements on aesthetical performance is included in the standard so it can not
be excluded that a component might need an anticipated maintenance for aesthetical purpose.
! Attention: in principle, ISO 12944 [12] concerns corrosion protection of steel; the standard does
not focus on coating architectural aspects. Such aspects (e.g. colour/gloss retention) shall be
specified and discussed with the supplier.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 12 / 14
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TECHNICAL NOTE
Powder organic coating on steel Cost €€
Aesthetic properties HIGH
products Mechanical resistance LOW
According to Qualisteelcoat specifications [13]. Protection of hollow sections NO
Act as galvanic separator YES
 Aesthetic aspect: the component can be exposed in primary view.
 Mechanical protection: during the assembly or handling of the elements it is necessary to pay
the utmost attention not to damage the coating which is sensitive to bumps, scratches and
abrasions (no anodic protection).

Service life assessment


The coating system is covered by Qualisteelcoat specifications.

Component service life is assessed by selecting the appropriate/certified coating system for the
specific environment. To note that Qualisteelcoat specifications only considers High durability (15
÷ 25 years).

E.g. Service life of a steel structure, 3mm thick, with powder coating according to Qualisteelcoat
specifications for C3 environment and exposed to a C3 corrosion category: 15 ÷ 25 years

The use of Qualicoat certified top coat powder is not mandatory, but reduce the testing effort
required to get the approval. Only Qualicoat class 1 and 2 powder coating are considered by
Qualisteelcoat specifications.

! Attention: powder coating do not provide anodic protection. Moreover, the coating layer is usually
thin (thinner than liquid coating) and more sensible to damages than a cataphoresis coating. The
use of this protective treatment on corrosion categories other than C1 and C2 shall be considered
applicable only for small parts, not sensible to damages during handling, installation and operation,
where inspection and maintenance is possible.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
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TECHNICAL NOTE
Cataphoresis coating Cost €€
Process and quality assurance according to Qualisteelcoat Aesthetic properties N/A
specifications [13]. Mechanical resistance MID
Protection of hollow sections NO*
*YES on “short” hollow sections Act as galvanic separator YES
 Aesthetic aspect: not applicable. The protective treatment is generally not considered as a
finish, but as a priming coat for the subsequent application of powder coating.
 The protective treatment is carried out by immersion: it is therefore possible to protect the
whole component surface (even the most hidden areas); however, it is affected by the
"Faraday Cage" effect (less than Powder coating systems), which prevents the development
of electrochemical phenomena and therefore the deposition of the paint inside cavities of long
profiles.
 Mechanical protection: superior to a liquid or powder coating; it can be considered scratch
resistant however, it is advisable to pay attention not to damage the coating during assembly
or handling (no anodic protection of steel).

Service life assessment


It is used mostly in the automotive industry as corrosion protection coating on non-visible (not
exposed to UV) parts; as such, it complies with many automotive industries’ specifications which
prescribe accelerated corrosion tests such as Salt Spray and Humidity resistance tests.
In the construction industry, cataphoresis is treated as priming coat for subsequent powder coating
finish; while cataphoresis coating process and quality control activities are defined by standard
(e.g. Qualisteelcoat, as part of the complete coating system), no direct reference to the expected
service life of cataphoresis (alone) coated steel element can be found.

Depending on used products, Natural Salt Spray test results show performances that equal or
exceed the ones of a liquid paint system acc. to ISO 12944 [12] for C3 corrosion category with
very high durability (720 hours with maximum 1.5mm corrosion at the scribe). As such, it could be
assumed the protective treatment satisfies the design life of the building in interior, not visible and
not exposed applications (C1 corrosion category) without major maintenance operations.
However, the application of this treatment on primary components needs additional caution, since
a “referenced” service life assessment cannot be provided.

Form: 100VV-TD-TNO rev.01 dated 16 Mar 2017

Prepared by: A. Tomasi Checked by: P.F. Marton Approved by: M. Rigo
File: 100VV-DE-TNO-0002_EN_00_Mild_steel_low_carbon_protection Page 14 / 14

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