Colorcoat HPS200 Ultra Technical - Euroclad...EN 10143:2006 to ensure that the cladding performs as...

Colorcoat HPS200 Ultra® technical detailsSuper durable, guaranteed performance pre-finished steel

CI/SIB (4-) Nh2August 2015

Introduction

Colorcoat HPS200 Ultra® is a superdurable pre-finished steel productfrom Tata Steel. It offersexceptional and proven weatherresistance and long-term colourand gloss retention. Itsperformance characteristics,together with the results of itsrigorous testing, are detailed inthis technical brochure.

Contents

Colorcoat® pre-finished steel 3

Super durable Colorcoat HPS200 Ultra® 4

Robust paint technology 5

Product of sustained evolution 6

Steel substrate 8

Double-sided Colorcoat HPS200 Ultra® 9

Unrivalled Galvalloy® corrosion protection 10

Product performance 12

Abrasion resistance 13

Corrosion resistance 14

Interior performance - corrosion resistance 18

Chemical resistance 21

UV resistance 22

Solar reflectivity 26

Fire performance 28

Confidex® Guarantee 30

Sustainability 32

Colour reassurance 34

Colorcoat® services 35

Colorcoat HPS200 Ultra® Introduction

2 Copyright Tata Steel UK Limited 2015 www.colorcoat-online.com

Colorcoat®pre-finished steelExpertiseTata Steel has been developing andmanufacturing the Colorcoat® range of pre-finished steel for five decades. Over the years,our developments have been at the forefrontof new advances in pre-finished steel resultingin longer lasting products and unprecedentedcolour ranges.

We continue to apply our knowledge andunderstanding to ensure that Colorcoat®remains a market-leading brand. We activelyengage with architects and other specialists tobuild on our experience and detailedknowledge of the construction market and tolead the way in developing new products.Sustainability is a key driver for theConstruction industry with an increasingdemand to build with this in mind. Tata Steelhave an in depth knowledge of theenvironmental impacts of not only Colorcoat®products but also the various roof andcladding systems that they are part of. Thisunderstanding means that we are able tosupport you in designing sustainable buildingenvelope solutions.

At Tata Steel we are committed to makingproducts that meet the needs of the marketand to making them in the most responsibleway. Our commitment to sustainability alsomeans we actively manage our impacts andcontribution throughout the full life of ourproducts - with our suppliers, within our ownoperations, through the supply chains weserve and by taking responsibility for recyclingsteel. Colorcoat HPS200 Ultra® has achievedBES 6001 responsible sourcing certificatewhich reinforces our commitment tosustainability.

QualityWith a world-class reputation in steel, TataSteel products and services are widely used inthe construction market. Utilising steelproduced by Tata Steel in the UK, ColorcoatHPS200 Ultra® is manufactured to exactingstandards at Shotton in North Wales.

Our products are subject to carefullymonitored processes and comprehensive,independent testing to ensure compliancewith the highest and most demandingEuropean standards. The superior and provenlong-term performance of our pre-finishedsteel products means we are able toguarantee Colorcoat HPS200 Ultra® for up to 40 years for industrial and commercial buildings. Colorcoat HPS200 Ultra® is also supported by a comprehensive range of services, technical advice and guidance.

Colorcoat HPS200 Ultra® Introduction

Colorcoat Connection® helpline +44 (0) 1244 892434 Copyright Tata Steel UK Limited 2015 3

Super durable Colorcoat HPS200 Ultra®

Colorcoat HPS200 Ultra® pre-finished steelcombines outstanding performance withexceptional durability. The product is builtto last – and exhaustive testing proves that itdoes. With its market-leading guaranteesand excellent sustainability credentials,Colorcoat HPS200 Ultra® is suitable for manydifferent construction applications.

The choice of a pre-finished steel product isfundamental to both the long-termperformance and visual appearance of thebuilding envelope. Colorcoat HPS200 Ultra® isdesigned to withstand the most demandingand aggressive environments – both externaland internal, providing exceptional corrosionresistance and outstanding colour and glossretention.

It has been subjected to comprehensivenatural and accelerated testing, often waybeyond the required standards. ColorcoatHPS200 Ultra® is used in a wide range ofindustrial and commercial buildings and thesereal-life scenarios provide further evidence ofthe product’s super durable qualities.

Colorcoat HPS200 Ultra®features and benefits:• Optimised Galvalloy® metallic coating for

exceptional corrosion resistance and cutedge protection.

• Surpasses requirements of RUV4 and RC5 asper EN 10169:2010 providing excellentcolour and gloss retention and corrosionresistance.

• Scintilla® embossed as a mark ofauthenticity from Tata Steel.

• Made in the UK for a lower carbon footprintand certified to BES 6001 ResponsibleSourcing standard.

• Confidex® Guarantee for up to 40 years forthe weatherside of industrial andcommercial buildings with no inspection ormaintenance to maintain its validity.

• Can be used under photovoltaic (PV) framemodules with no reduction in guaranteelength ensuring all parts of the roof arecovered for the same duration of theConfidex® Guarantee.

• A project based warranty outside Confidex®zones may be available on a case by casebasis for standard cladding applications.

• Exceeds requirements of CPI5 as per EN 10169:2010 demonstrating excellentbarrier properties when used internally.

• Available with Confidex Sustain® to offerthe world’s first CarbonNeutral® buildingenvelope.

• Standard sizes are available on shortproduction lead times.

• BBA certified for durability in excess of 40years.

• Double-sided option providing a robustbarrier on the reverse side of the steelsubstrate for buildings with demandinginternal and external environments.

• Fully recyclable with full producttraceability and REACH compliance.

Colorcoat HPS200 Ultra® Super durable


The multi-layered structure of ColorcoatHPS200 Ultra® incorporates a uniqueprotective layer and the latest polymertechnology. This means that ColorcoatHPS200 Ultra® is strong, super durable andmaintains its appearance for longer.

Pre-finished steel comprises a number of paintlayers and treatments that are applied to thesteel in an automated and carefully controlledprocess. Each layer has a particular function.The synergistic effect of these various layersensures a material that is robust, versatile andaesthetically pleasing.

Multi-layered functionalityThe functional layers of Colorcoat HPS200Ultra® combine to deliver super durability androbustness. The Galvalloy® metallic coating,pre-treatment and primer provide unrivalled corrosion resistance even at the cut edges.

The unique topcoat formulation (nominal 200microns) utilises leading polymer technology,which provides abrasion, chemical and UVresistance.

Unique Scintilla® embossUnique to Colorcoat HPS200 Ultra® theScintilla® emboss has been developed with adepth of only nominal 50 microns, whichmakes it less likely to trap dirt than deeperleathergrain embosses therefore making thepre-finished steel easier to clean whilst beingmore robust.

Unlike standard leathergrain patterns theemboss is subtle and does not detract fromthe overall appearance of the building,looking smooth and creating a modernbuilding appearance from a distance. TheScintilla® emboss provides a unique guaranteeof authenticity, and an overall thickerprotective topcoat from Tata Steel.

Key

Top coat with unique Scintilla® emboss by Tata Steel

Corrosion resistant primer

Pre-treatment

Galvalloy® metallic coating

Base substrate


Pre-treatment

High performance backing coat

Figure 1. Colorcoat HPS200 Ultra® layers illustration

Robust painttechnology

Colorcoat HPS200 Ultra® Durability

Figure 2. Scintilla® emboss

Figure 3.Leathergrain emboss


Nominal depth of 70 microns.Blue denotes depth of emboss.

Nominal depth of only 50 microns.Blue denotes depth of emboss.

Colorcoat HPS200 Ultra® is the result of 50years of sustained research, developmentand investment. We apply our technicalexpertise and market knowledge to ensurethat our pre-finished steel is innovative andenhanced to meet the demands of anevolving industry.

In the 1960s we were the first company inEurope to develop and manufacture a 200micron plastisol.

Since then, our team of researchers hascontinued to lead the way with newdevelopments to improve our products andservices. These include long-lasting,guaranteed protection from corrosionthrough the use of our unique Galvalloy®metallic coating and a step change in topcoatperformance through the utilisation of acustomised polymer.

Evolution of performanceThe development of Colorcoat HPS200 Ultra®has been driven and guided by many factors.These include legislative changes, aesthetictrends, technological advances and increasingdemands for robust, long-lasting buildingswith low life cycle costs.

Today’s super durable Colorcoat HPS200Ultra® comes with comprehensive guaranteesand offers a sustainable solution for thebuilding envelope where longevity anddurability are imperative.

Evolution of colourOver time, we have utilised topcoat andpigment technology for the continuousimprovement of both colour performance andchoice. Tests show that Colorcoat HPS200Ultra® exceeds the highest Europeanstandards for both colour and gloss retention.

The extensive colour range providesexceptional choice - offering scope for bothbold and subtle design statements. ColorcoatHPS200 Ultra® is available in 40 standardcolours and to make the colour selectionprocess easier the palette is grouped bySignature, Classic and further extended Mattcolours

To view the full standard colour range or toorder samples visit www.colorcoat-online.com/samples or call the Colorcoat Connection® helpline on+44 (0) 1244 892434 to order a colour card.

Product of sustainedevolution

Colorcoat HPS200 Ultra® Evolution


1960s

1970s

1980s

1990s

2000s

2010s

19990s

2010s

2000s

19800s

19700s

19660s


Today’s super durable Colorcoat HPS200 Ultra® is the result ofcontinuous development and improvement over 50 years

Figure 4. Evolutionary development

Colorcoat HPS200 Ultra® Evolution

1960sColorcoat® launchesin 12 colours – first inEurope with 200micron plastisol.

1970sColorcoat® furtherdeveloped forimproved colour andgloss retention.

1980sColorcoat HP200®brings more colourchoice withperformance levelincreased to 20 years.

1990sConfidex® Guarantee,Galvalloy® metalliccoating and Scintilla®emboss introduced.Improved colour andgloss with extended28 shade colourpalette.

2000sColorcoat HPS200Ultra® with advancedtopcoat technologyand phthalate freeformulation.Guarantee extendedup to 40 years. Newcolour palette andlaunch of Repertoire®for bespoke colours.

2010sSuper durability andsustainability are keybenefits as ColorcoatHPS200 Ultra® istested beyond thelimits. Now an idealproduct fordemanding internalenvironments too.

With a world class reputation in steel, TataSteel products and services are widely usedin the construction market. The steelsubstrate for Colorcoat HPS200 Ultra® ismanufactured by Tata Steel.

Strong, versatile and truly recyclable, steel isa compelling choice for the buildingenvelope.

Steel has one of the highest strength-to-weight ratios of any building material –producing strong, lightweight structuresenabling fast build programs that are costeffective without any compromise on quality.

Steel provides:• Functionality, versatility,

strength and flexibility.

• Ability to work well with other materials.

• Excellent environmental performance –offering high recyclability and re-usepotential.

• Ability to be pre-fabricated off-site andconstructed quickly and accurately on-site.

• Excellent durability and performance in use.

Designing with steelThe gauge of the steel plays a vital role in thephysical properties and performance of theroof or wall cladding that is manufacturedfrom it. Incorrect specification may, in theworst cases, have safety implications such asroof fragility.

The European standard EN 10143:2006 definesthe tolerances for different grade, width andgauge material for normal and specialtolerance categories. In the case of ColorcoatHPS200 Ultra®, the gauge is measured as thesteel substrate plus the Galvalloy® metalliccoating.

Tata Steel supplies pre-finished steel tonormal and special tolerances according to EN 10143:2006 to ensure that the claddingperforms as designed.

Incorrectly specifying gauge or gauge tolerances can affect:1. Structural performance, including

in service load capacity and purlin spacingsas well as safety implications duringconstruction and maintenance.

2. Building visual appearance, lighter gaugematerial is more prone to damage duringinstallation, and distortion of the profilearound fasteners due to slightmisalignment of the primary/secondarystructure.

Steel substrate

Colorcoat HPS200 Ultra® Steel substrate


Double sided Colorcoat HPS200 Ultra®

Colorcoat HPS200 Ultra® Double sided product

Colorcoat HPS200 Ultra® is available doublesided. This option is ideal for complex ordemanding applications where an increasedlevel of protection is required on both sidesof the steel substrate.

For double sided Colorcoat HPS200 Ultra®, thesame unique topcoat formulation topcoat andcorrosion-resistant primer is applied to thereverse side of the product. This provides arobust barrier on the reverse side of the steelsubstrate for buildings with demandinginternal environments. These include leisurefacilities with high levels of humidity andmanufacturing plants where chemical agentsare used.

The application of our unique Galvalloy®metallic coating and corrosion resistant primeron both sides of the steel substrate ensures asuperior cut edge performance for doublesided products.

Both the topcoat and the reverse coat areavailable in any colour from the ColorcoatHPS200 Ultra® colour range and are a nominal200 microns. For the 200 micron reverse side,this is embossed with the unique Scintilla®emboss. A further option of 100 micronsmooth reverse side is also available.

Table 1. Product options

Topcoat Reverse Reverse Reverse(DFT) (DFT) Emboss Colour200 200 Scintilla Any

200 100 Smooth Any

Key

Top coat with unique Scintilla® emboss


Pre-treatment


Base substrate


Pre-treatment


Backing coat with unique Scintilla® emboss or smooth 100 micron

Figure 5. Double sided Colorcoat HPS200 Ultra® by Tata Steel


Colorcoat HPS200 Ultra® uses our uniqueGalvalloy® metallic coating, a special mix ofZinc and Aluminium that provides unrivalledcorrosion protection, even at cut edges.

How does Galvalloy® work?The metallic coating is essential to theperformance of the pre-finished steel.Traditionally, pre-finished steel products haveused a Zinc metallic coating which is oftenreferred to as Hot-Dipped Galvanised Steel(HDG). This HDG coating does provideimproved corrosion protection, in comparisonwith uncoated steel, but often leaves cutedges vulnerable to increased rates ofcorrosion and will ultimately lead to peelingand/or premature paint delamination.

To address this problem, Colorcoat HPS200Ultra® uses the unique and proven Galvalloy®metallic coating. Galvalloy® is made with aspecial mix of 95% Zinc (Zn) and 5%Aluminium (Al) that conforms to EN10346:2015.

The carefully developed proportions of Zincand Aluminium (Zn-Al) in Galvalloy® offer acombination of increased barrier andsacrificial protection when compared withconventional HDG coatings.

The sacrificial protection results frompreferential corrosion of the Zinc over thesteel, and the barrier protection results fromthe presence of a stable Aluminium oxidelayer on the surface of the Galvalloy® coating,both of which inhibit and slow the rate ofanodic undercutting compared toconventional HDG metallic coatings.

The Aluminium in the metallic coating ofGalvalloy® and the manufacturing parametersare optimised to give a very fine two-phasemicrostructure compared with the uniformmicrostructure of HDG.

A typical microstructure of Galvalloy® is shownin figure 7 where the primary Zinc dendritesmake up approximately 20% of the bulkmicrostructure and the Zinc/Aluminiumeutectic the remaining 80%.

Unrivalled Galvalloy®corrosion protection

Colorcoat HPS200 Ultra® Galvalloy®

Colorcoat HPS200 Ultra® with Galvalloy® roof after 7 years.

Leathergrain alternative on hot dip galvanised steelsubstrate roof after 7 years.

Figure 7. Typical Galvalloy® microstructure

Figure 6. Galvalloy® and Hot Dip Galvanised comparison

Primary Zinc Zn-Al eutecticdendrites


For a product using conventional HDG, thecorrosive attack will dissolve all of the metalliccoating at the same rate – leading to obviouspeeling of the paint system as the paint hasnothing to adhere to.

For the same time period, the optimisedGalvalloy® microstructure has a majoradvantage in that the corrosion will occur intwo stages.

Initially, the Zinc phase will be corrodedpreferentially to the Zinc/Aluminium eutectic.As the paint adheres to the eutectic structure,no edge peel is observed.

Over time, the eutectic structure will corrode –but at a greatly reduced rate when comparedwith HDG coatings and thus results in longerdurability.

In addition to exhaustive artificial testing,Galvalloy® has been subjected to prolongedand independent natural weather testingsince its introduction in 1998. Its proven,superior performance means that Galvalloy®lasts for a longer time period than HDG andremains the preferred metallic coating for ourlatest generation of super durable pre-finishedsteel, Colorcoat HPS200 Ultra®.

The micro cross-section of Galvalloy®illustrates the before, figure 8, and after, figure9, corrosion process. It clearly shows the Zincdendrites corroding at a faster rate than theZinc and Aluminium eutectic composition.The protective Zinc and Aluminium phase isleft behind and remains adhered to theorganic coating providing improved corrosionprotection.

Colorcoat HPS200 Ultra® Galvalloy®

Figure 8. Galvalloy® microstructure before corrosion

Figures 8 and 9 illustrate how, as the lightercoloured Zinc dendrites ultimately corrode, theunique microstructure of the Galvalloy® layerensures that the surface coating remains adhered tothe eutectic surface.

Figure 9. Galvalloy® microstructure after corrosion


Exposure to the elements, pollutants andabrasives will affect the performance anddurability of the building envelope.Colorcoat HPS200 Ultra® is protected andhas been tested and proven in a wide rangeof demanding environments.

Colorcoat HPS200 Ultra® isprotected:• Unique Galvalloy® metallic coating for

unrivalled corrosion resistance even at cutedges.

• Corrosion-resistant pre-treatment andprimer to deliver optimum durability.

• Unique topcoat formulation - providingaesthetics together with another barrierand resistance to corrosion, UV light andabrasion.

• Subtle and unique Scintilla® emboss.

Colorcoat HPS200 Ultra® is tested:• Natural weather testing in a range of

climates around the world.

• Testing at UKAS accredited laboratories toEuropean standards.

• Extended accelerated testing way beyondthe industry norm.

• Comprehensive regimes to testperformance against corrosion, effects ofsunlight, chemical attack and abrasion.

Colorcoat HPS200 Ultra® is proven:• Test results show that it meets and excels

highest European standards. See pages 13 –25 of this brochure for details.

• Real life building applications of ColorcoatHPS200 Ultra® in operation around theworld underline its exceptionalperformance.

Product performance

Colorcoat HPS200 Ultra® Performance

Table 2. Typical properties

Colorcoat Test HPS200 Ultra® standard

Nominal organiccoating thickness (µm)* 200 EN 13523-1

Specular gloss (60°):Non-matt colours % 20-40 EN 13523-2Matt colours % 5000 EN 13523-12

Abrasion resistance(Taber, 250 rev, 1 kg) (mg)

The super durability of Colorcoat HPS200Ultra® derives from its Galvalloy® metalliccoating, high performance primer and thick,durable barrier topcoat which providesexcellent scratch and abrasion resistance.Testing of products is carried out in UKASaccredited laboratories to EuropeanStandards.

Testing has shown that Colorcoat HPS200Ultra® benefits from high levels of scratch andabrasion resistance, the advantages are:

• Less susceptible to damage during storage,handling and construction.

• Longer life of the completed buildingenvelope due to superior resistance towind-blown material and site damage.

• Robustness of the top coat reducing therequirement for filming before profiling.

Scratch testsThe scratch test method is a technique thatapplies critical loads to a sample to test atwhat point failure appears – testing thecohesive and/or adhesive properties of pre-finished steel. Colorcoat HPS200 Ultra®has been tested alongside a typical PVDF anda polyester product. During the test, samplesof Colorcoat HPS200 Ultra® were scratchedwith a needle which was drawn at a constantspeed under a progressive load. The test wasconcluded when sufficient weight was addedto cut through the Colorcoat HPS200 Ultra®sample revealing the metallic coating. Themore weight recorded the greater theresistance of the topcoat.

The unique topcoat formula meant thatconsiderably more weight was required toexpose the metallic coating on ColorcoatHPS200 Ultra® when compared to othercoating types as shown in figure 10.

Falling sand testAbrasion resistance is commonly tested by the‘falling sand’ test to ASTM D968:2001. This testmeasures the stream of falling sand requiredto erode a paint system - to determine thetopcoat’s resistance.

Colorcoat HPS200 Ultra® was tested against atypical PVDF product. Results showed thatmore than twice as much sand was requiredto expose the metallic coating of ColorcoatHPS200 Ultra® compared to alternativeproducts tested.

Abrasion resistance


Figure 10.Scratch resistance of pre-finished steels (EN 13523-12)

Weight (g)

5500

5000

4500

4000

3500

3000

2500

2000

Colorcoat HPS200 Ultra® PVDF Polyester

Figure 11.Abrasion resistance comparison (ASTM D968:2001)

Sand(litres)

550

500

450

400

350

300

250

200

150

100

50

0

Colorcoat HPS200 Ultra® PVDF


Natural weather testing is an essential partof testing the corrosion resistance of a pre-finished steel product. Colorcoat HPS200Ultra® has undergone a comprehensiveprogram of testing in key weatheringclimates around the world – achieving thehighest classification possible.

Exposure sites for Colorcoat HPS200 Ultra®were chosen to provide the full spectrum ofweathering zones - from equatorial andtropical climates to urban, rural, industrial andcoastal locations.

Samples of Colorcoat HPS200 Ultra® havebeen tested and remain exposed atweathering sites in USA (Florida, Arizona,Ohio), Australia, China, India, Dubai, Sweden(Bohus Malmon), France (Brest) and sitesacross the UK. This has enabled us to build upa comprehensive assessment of the corrosionresistance of Colorcoat HPS200 Ultra® in awide-range of extreme climates.

Figure 12. RC5 Certificate for Colorcoat HPS200 Ultra®

Highest corrosion classificationColorcoat HPS200 Ultra® has undergoneextensive corrosion testing in accordance withthe European Standard EN 10169:2010‘Continuously organic coated (coil coated) steelflat products’. Samples of Colorcoat HPS200Ultra® were exposed to the extreme coastalenvironment of Brest on the west coast ofFrance to assess corrosion resistance.

The European Standard requires the samplesto have more than two years exposure at thesite. During this time they must be able toresist blistering, coating damage and edgepeel (containing any edge peel to less than2mm) in order to achieve the highestcorrosion resistance classification of RC5.

After independent assessment, The FrenchCorrosion Institute concluded that ColorcoatHPS200 Ultra® achieves RC5 corrosion rating inaccordance with EN 10169:2010. An example ofone of the Colorcoat HPS200 Ultra® test panelsis shown in figure 13. This shows no edge peeland no surface damage or blisters after morethan two years exposure at Brest, France.

Colorcoat HPS200 Ultra® utilises the optimisedGalvalloy® metallic coating, which is anessential element of it’s super durableproperties. We have gone beyond the twoyear testing period required for Europeanstandards to examine products dating back tothe 1990’s when the unique Galvalloy®metallic coating was first introduced to themarket, to assess its superior performancequalities over Hot-Dipped Galvanised Steelmetallic coating.

Figure 13. A Colorcoat HPS200 Ultra® test panelafter more than 2 years exposure at Brest

Figure 14. Tata Steel weathering site, Brest C5marine site

Corrosion resistance


Technopôle de Brest Iroise 220, Rue Pierre Rivoalon – 29220 Brest, France. Tel : +33 (0)298 051 552 - Fax : +33 (0)298 050 894

TATA Steel UK Research, Development & Technology Swinden Technology Centre Moorgate, Rotherham S60 3AR UK

Classification of Natural Weathering [Type of Panels 2 – EN 13523-19]

Panel Identification No & Description

Start of Exposure

Date of Inspection

Accumulative Time of Exposure (months)

Exposure Site & Corrosivity Category (EN ISO 12944-2)

Orientation of Exposed Panel

9KR097 – ZA255 / Colorcoat HPS200

Ultra (Goosewing grey)

05/10/2009 05/10/2011 24 months

Sainte Anne BREST (France)

Carbon Steel – C5 (Very High)Zinc – C3 (medium)

90° North

Average Edge Delamination (mm) Damage on Bend BlisteringConforms to RC5 requirements Conforms to RC5 requirements Conforms to RC5 requirements

Corrosion Resistance Category (as defined by EN 10169)

The coil coated material ref 9KR097 (ZA255 /Colorcoat HPS200 Ultra (Goosewing grey)) may be classified RC5 according to standard EN10169

Brest, October 5th , 2011 Written by Jean-Michel Hamoignon Approved by Nathalie Le Bozec Stamp


In 1998 Galvalloy® metallic coating was usedwith an earlier generation of the product –Colorcoat HPS200®. Samples of this productwere exposed at Bohus Malmon (figure 15)and Rye (figures 16 and 17) to evaluate theperformance of the Galvalloy® metallic coatingand corrosion resistance primer.

Bohus Malmon is a C4/C5 classified site (high /very high corrosivity) as per EN 10169:2010 on

the West coast of Sweden, Rye is situated inthe UK within 50 metres of the sea in thesouth of England and would typically be a C3site (moderate corrosivity).

After more than 13 years of exposure at Ryeand 10 years at Bohus Malmon there isvirtually no edge delamination (measured asless than 2mm), blistering or any other surfacedegradation of Colorcoat HPS200®.

This long-term exposure demonstrates theexcellent performance of the Galvalloy®metallic coating combined with the optimisedcorrosion-resistant primer.

The performance of the corrosion resistanceprimer is further demonstrated by theevaluation of Colorcoat HP200® that wasproduced in 1993, that has been exposed formore than 18 years at Rye.

Long-term weathering



Figure 15. Colorcoat HPS200® with Galvalloy® metallic coating – 10 yearsexposure at Bohus Malmon, Sweden.

Figure 17. Colorcoat HPS200® with Galvalloy® metallic coating – 13 yearsexposure at coastal weathering site at Rye, England.

Figure 16. Colorcoat HPS200® with Galvalloy® metallic coating – 6 yearsexposure at coastal weathering site at Rye, England.

Figure 18. Colorcoat HP200® 18 years exposure at coastal weathering site atRye, England.

Natural weathering testing of corrosionresistance can be greatly acceleratedthrough the use of specially designedweathering chambers. The super durableproperties of Colorcoat HPS200 Ultra® havebeen proven through extensive andaggressive accelerated corrosion tests.

Accelerated corrosion testsSamples of a representative selection of theColorcoat HPS200 Ultra® colour range wereput through a series of rigorous tests designedto predict the corrosion resistance of theproduct in different environments – coastal(salt spray), humidity, prohesion (cyclic wetand dry), water soak and Kesternich (acid rain).The tests are symbolic and often are far moreaggressive than would be seen in real worldsituations.

Samples of Colorcoat HPS200 Ultra® - with oneedge exposed and a cross scribed into thecoating to simulate site damage, were placedin UKAS accredited test chambers for therequired test duration. The results of theseaccelerated corrosion tests are given in table 3.

Representative photographs of ColorcoatHPS200 Ultra® in Goosewing Grey after 1000hours testing in this suite of accelerated testsare shown in figures 19-22.

Both saltspray (continuous fog of sodiumchloride) and prohesion (cyclic phases ofsodium and ammonium chloride fog followedby a drying cycle) are extremely aggressiveaccelerated corrosion tests. Despite this, theUKAS tests showed that the extent of paintdelamination at both the cut edge and scribeis minimal.

The Kesternich test (moist/humid sulphurdioxide test) is designed to simulate thedamaging effects of harsh environments,particularly sulphur dioxide contaminants andacid rain.

Colorcoat HPS200 Ultra® showed minimal (lessthan 3mm) edge and scribe delaminationfollowing repeated cycles of testing.

Following 1,000 hours of humidity and watersoak tests, no blistering or significant paintdelamination was observed on the ColorcoatHPS200 Ultra® panels. This demonstrates

excellent paint adhesion between theGalvalloy® metallic coating and the organiclayers of Colorcoat HPS200 Ultra®. In figures21, 22 and table 4 the topcoat has beenremoved to clearly show absolutely no creepat the scribe, or cut edge.

Corrosion resistanceaccelerated testing


Figure 19. Test panel after saltspray 1000 hours Figure 20. Test panel after prohesion 1000 hours

Figure 21. Test panel after humidity 1000 hours Figure 22. Test panel after Watersoak 1000 hours

Table 3. Accelerated corrosion tests showed minimal delamination and surface degradation

Corrosion Test Test Maximum Maximum Test paneltest duration standard average edge average scribe surface delamination delamination (mm) (mm)Salt Spray 1000 hours EN 13523-8

Table 4. Colorcoat HPS200 Ultra® comparisons

5000 hours humidity as per EN 13523-25Test panel Test panel all taped

Colorcoat HPS200 Ultra® Colorcoat HPS200 Ultra®

PVDF PVDF

25 micron polyester 25 micron polyester

Extended accelerated testsAgain we have tested Colorcoat HPS200 Ultra®beyond the industry standards subjecting thesamples to 5000 total hours acceleratedcorrosion testing with salt spray, water soakand humidity tests. Colorcoat HPS200 Ultra®samples were compared to generic PVDF and25 micron polyester pre-finished steel. Twotypes of test panel were used:

• Standard WA6 corrosion panels with oneedge exposed and a cut scribe.

• WA6 corrosion panels with all sides tapedand no cut scribe.

The panel configurations were chosen todemonstrate both:

• The superior corrosion resistance ofColorcoat HPS200 Ultra® provided by theGalvalloy® metallic coating, pre-treatment,corrosion-resistant primer and the topcoatpaint system.

• The barrier properties of the ColorcoatHPS200 Ultra® topcoat compared to genericpre-finished steel products.

The results of testing Colorcoat HPS200 Ultra®versus generic PVDF and 25 micron polyesterfollowing 5000 total hours in the humidity testas per EN13523-25 using both test panelconfigurations are shown in table 4. Even after5000 hours testing, the test results clearlyshow no evidence of blistering, surfacedegradation or creep at both the edge orscribe for the Colorcoat HPS200 Ultra® sample.Both the generic PVDF and 25 micronpolyester pre-finished steels exhibit extensiveblistering in the samples with all 4 sides taped.The exposed edge and scribe also exhibitsignificant creep and blistering whencompared to Colorcoat HPS200 Ultra®.



In the internal environment of a building,corrosion factors can be increased by thecreation of a microclimate. ColorcoatHPS200 Ultra® has been tested and provento provide the highest level of corrosionprotection for internal environments.

Increased corrosion factorsIn normal external atmospheres the rate ofcorrosion is accelerated by the following factors:an increase in relative humidity; frequency ofcondensation (time of wetness); the amount ofpollution and rising temperatures.

In the internal environment (ambience) of abuilding these corrosion factors can be greatlyenhanced by the creation of an internalmicroclimate as a result of activities carriedout inside the building such as manufacturing,waste processing or swimming pools.

A building’s internal environment can beclassified according to its corrosivity. Theprincipal factors that determine the corrosivityof internal environments are the risk ofcondensation (time of wetness) and theaggressiveness of any chemicals present andcleaning operation. Table 5 provides guidanceon different levels of aggressiveness for eachof these factors.

These factors are considered in theEN10169:2010 classification of internalambience types. The five categories rangefrom ‘non-aggressive’ to ‘very aggressive’.Very aggressive environments include thosewith high chemical aggressivity levels wherecleaning agents with a pH of 5–9 are useddaily and environments with a high andpermanent risk of condensation.

Internal certificationCoil coating standard EN10169:2010 classifiesthe suitability of organic coatings for use ininterior environments. Excellent test resultsmean that Colorcoat HPS200 Ultra® is classifiedas a CPI5 product. This is the highest classifiedlevel of corrosion protection for interiors andmeans that Colorcoat HPS200 Ultra® is suitableto be used in the most demanding internalenvironments such as swimming pools andsewage treatment plants.

Interior performance -corrosion resistance


Table 5. Definitions and criteria

Corrosive criteria

Non aggressive No chemical aggressivity. Neutral cleaning less than once a month.

Low aggressive No chemical aggressivity. Neutral cleaning less than once a week.

Medium aggressive Low chemical aggressivity. Cleaning pH 5-9 less than once a week.

Aggressive Chemical aggressivity or risk of mould. Cleaning pH 5-9 less than once a day.

Very aggressive High chemical aggressivity or high risk of mould. Cleaning pH 5-9 once a day.

Cleaning criteria

Routine upkeep Periodical cleaning with neutral products. No pressure washing.

Non-intensive cleaning Periodical cleaning with neutral products at less than 30°C. Low pressure spraying.

Intensive cleaning Cleaning with products pH 5-9 at less than 40°C and at pressure.

Humidity criteria

Low hygrometry W/n ≤ 2.5g/m3

Medium hygrometry 2.5g/m3 < W/n < 5.0g/m3

High hygrometry 5.0g/m3 < W/n < 7.5g/m3

Humid High hygrometry and risk of condensation.

Very humid Very high hygrometry and frequent risk of condensation.*

W – Quantity of vapour produced inside the building in g/m3/h.n – Hourly air renewal rate.* – Condensation is considered frequent if it can be detected daily on interior surfaces but the duration of humidity is generally

short, < 2 hours.


For added reassurance of long-term internalperformance, Colorcoat HPS200 Ultra® hasbeen tested to 5,000 hours humidity - far inexcess of the 1,500 hours stipulated inEN10169:2010. Test results showed that evenin this extended test the product still achievedthe CPI5 performance requirements.

The classification of Colorcoat HPS200 Ultra®as a category CPI5 product means it has beenproven suitable to provide corrosionprotection in ‘very aggressive’ internalenvironments as well as having provenchemical resistance properties.

Colorcoat HPS200 Ultra® either single ordouble sided is the most suited andrecommended pre-finished steel product fordemanding and corrosive internalenvironments. Depending on the specificbuilding details, internal warranties can beprovided for Colorcoat HPS200 Ultra® whenused as the internal product on a case by casebasis. For case studies of where ColorcoatHPS200 Ultra® has been used internally go towww.colorcoat-online.com/projects

Table 6 below provides examples of buildingtypes with increasing aggressive/corrosiveinternal environments (A1 to A5) and therecommendations as to which Colorcoat® pre-finished steel product is best suited forthe internal application.

If the building has a requirement for afoodsafe product (indirect contact only) then apre-finished steel product from the Advantica®range by Tata Steel is recommended.


Table 6. Internal environments table.

Defining atmospheric criteria Typical building use Colorcoat® PE 15 Colorcoat® ColorcoatCorrosiveness Cleaning Humidity & Colorcoat® PE 25 PVDF HPS200 Ultra®

A1 Non aggressive Routine upkeep Low Offices, Schools and Residential buildings � � �hygrometry (excluding kitchens and bathrooms)

A2 Low aggressive Routine upkeep Medium Sports Halls and Supermarkets � � �hygrometry

A3 Medium aggressive Non-intensive High Industrial buildings and Factories �cleaning hygrometry using dry processes

Non-intensiveHumid –

Factories using wet processesA4 Aggressivecleaning

Low risk ofand Swimming Pools �

condensation

Very humid – Papermills, Seafood processing,A5 Very aggressive Intensive cleaning High risk of Mushroom cultivation, �

condensation Cheese factories


CPI5 RatingPre‐finished steels for use in building interiorscan be classified into corrosion protectioncategories CPI in accordance with EN10169:2010. The classifications are from thelowest category CPI1 to the highest categoryCPI5. To obtain CPI5 samples should be testedfor a minimum of 1500 hours humidity inaccordance with EN 13523‐26 with blisteringless than category 2 (S2) of EN ISO 4628‐2.

Test panel shows:

• Blistering less than category 2 (S2) of EN ISO 4628‐2.

• No edge creep or other surfacedegradation.

• Topcoat removed at both scribe and cutedge to clearly show no corrosion.

These results confirm that Colorcoat HPS200Ultra® meets the requirements of CPI5 as perEN 10169:2010.

CPI5 RatingPre‐finished steels for use in buildinginteriors can be classified into corrosionprotection categories CPI in accordancewith EN 10169:2010. The classifications arefrom the lowest category CPI1 to thehighest category CPI5. To obtain CPI5samples should be tested for a minimum of1500 hours humidity in accordance with EN 13523‐26 with blistering less thancategory 2 (S2) of EN ISO 4628‐2.

The test panel shows:• Blistering less than category 2 (S2) of

EN ISO 4628‐2.

• No edge creep or other surfacedegradation.

N.B. Topcoat removed at both scribe andcut edge to clearly show no corrosion.

These results confirm that Colorcoat HPS200Ultra® meets the requirements of CPI5 as perEN 10169:2010.

The thick topcoat of Colorcoat HPS200 Ultra®provides an extra barrier between theatmosphere and the steel substrate –considerably delaying the onset ofcorrosion. Permeability tests prove thesuperior performance of the product.

Atmospheric corrosion is an electrochemicalprocess that takes place in a thin film of wateron the steel surface. Both water and oxygenare required to instigate corrosion.

Pre-finished steels, apart from the aestheticbenefits, provide a barrier that blocks thepassage of water and oxygen reaching themetal surface and hence slows the corrosionrisk. Top coats on pre-finished steel aregenerally semi permeable to water andoxygen transmission and the greater theirability to restrict transmission - the moredurable the pre-finished steel overall.

Colorcoat HPS200 Ultra® has been developedto ensure an effective and long-lasting barrierbetween the internal atmosphere and thesteel substrate – deferring the onset ofcorrosion. The robust topcoat plays a vital rolealongside the Galvalloy® metallic coating andprimer in preventing corrosion.

Recent test results show low levels of waterand oxygen permeability of Colorcoat HPS200Ultra® when compared to other generic paintsystems.

Water permeabilitySamples of Colorcoat HPS200 Ultra® weresubjected to water vapour transmission/vapour permeance tests undertaken by thePaint Research Agency. The tests were carriedout in accordance with ASTM D1653 using testmethod B – wet cup method, condition A.Within this test method, samples of thefreepaint film are sealed over a vesselcontaining water which are placed in a testchamber with a controlled atmosphere.Regular weighings of the vessel are made todetermine the rate of water movementthrough the paint film. The purpose of thistest was to obtain values for water vapourtransfer through the different coating typesand provide a relative rating of the coatingswhen they are tested under the same closelycontrolled conditions.

The results presented in the table belowclearly show that the thicker barrier topcoat ofColorcoat HPS200 Ultra® was considerably lesspermeable to water vapour than other genericpre-finished steel.

Oxygen permeabilityAll paints and polymers are oxygen-permeable but tests conducted by SmithersRapra confirmed that the thick barrier topcoatof Colorcoat HPS200 Ultra® was significantlyless permeable to oxygen than other generic pre-finished steel products. All paint filmswere tested using the constant volumemethod as detailed in BS ISO 2782:2006. Thetemperature of the test was maintained to23°C and conducted using oxygen at 1 Bar.

Interior performancebarrier properties


Table 7. Permeability to Water vapour and Oxygen

Colorcoat HPS200 Ultra® PVDF PolyesterNominal Topcoat

200 25 25coating thickness

Water Vapour Transmission 10.17 23.17 124.72(g/m2/24 hours)

Oxygen permeability 2.609 E-17 1.345 E-16 1.578 E-16(m2/sec/Pa)

N.B: Results obtained using freepaint films prepared in the laboratory by paint suppliers.


Due to its tough, less permeable topcoatColorcoat HPS200 Ultra® also providesexcellent chemical resistance. Along with ahigh level of resistance to humidity, thismakes the product the ideal choice foraggressive internal environments.

When Colorcoat HPS200 Ultra® is used forinteriors including double sided applications,its super durable topcoat provides excellentchemical resistance – when in direct contactwith the chemical and also when exposed tochemical vapour.

Chemicals and pollutants accelerate corrosionby attacking the chemical bonds that make upthe topcoat polymers. In aggressive internalenvironments, where chemicals are present,this can result in discolouring and degradationof the topcoat. The information providedbelow relates to the effects of chemicals onColorcoat HPS200 Ultra®. Any exposed steelsuch as cut edges must be protected with asuitable lacquer or protective coating system.

Independent testing under strict laboratoryconditions has proven the impressivechemical resistance levels of ColorcoatHPS200 Ultra® in the vast majority of tests.

Chemical resistance performance is rated on ared, amber, green scale. Green is acceptable,amber requires further advice from Tata Steeland red means it is unsuitable for use with thischemical.

Independent tests show that:• Dilute acids at room temperature do not

normally attack the top coat of ColorcoatHPS200 Ultra®; only concentrated acidsattack the topcoat – normally after aprolonged period of exposure.

• Aqueous solutions of alkalis such asammonia and caustic soda do not attackColorcoat HPS200 Ultra® except in highconcentrations at elevated temperatures.

Chemical resistance


Table 8. Chemical resistance levels of Colorcoat HPS200 Ultra®

Chemical Exposure Continuous contact Vapour duration Visual Adhesion Visual Adhesion

30% Sodium Hydroxide 15 minutes 24 hours

30% Ammonium Solution 15 minutes 24 hours

10% Ammonium Sulphate 15 minutes 24 hours

10% Ammonium Nitrate 15 minutes 24 hours

30% Hydrogen Peroxide 15 minutes 24 hours

10% Hydrochloric Acid 15 minutes 24 hours

37% Hydrochloric Acid 15 minutes 24 hours

10% Nitric Acid 15 minutes 24 hours

30% Nitric Acid 15 minutes 24 hours

10% Sulphuric Acid 15 minutes 24 hours

30% Sulphuric Acid 15 minutes 24 hours

Sunflower oil 15 minutes 24 hours

Engine oil 15 minutes 24 hours

Diesel 15 minutes 24 hours

Petrol 15 minutes 24 hours

Methanol 15 minutes 24 hours

Ethanol 15 minutes 24 hours

Isopropyl Alcohol (IPA) 15 minutes 24 hours

Ethyl Acetate 15 minutes 24 hours

Fuel Oil Gel 15 minutes 24 hours

10% Acetic Acid 15 minutes 24 hours

Notes:Colorcoat HPS200 Ultra® resists oils but the surface can swell and soften slowly over a period of many years.Colorcoat HPS200 Ultra® is unsuitable for direct contact with organic solvents such as aliphatic hydrocarbons, chlorinatedhydrocarbons, ketones and esters.Mastics and sealants cured by acetic acid should not be used with Colorcoat HPS200 Ultra® as the acid will attack the metalliccoating and steel base.% shown are concentration levels.


A pre-finished steel must resist thedamaging affects of the suns emissionsincluding Ultra-Violet and Infra-Redradiation. Exposure to solar radiation cancause a deterioration of colour and glossretention, both of which are precursors ofpaint cracking and delamination. ColorcoatHPS200 Ultra® is classed as RUV4 - thehighest classification of UV resistance. Thisproven and superior UV resistance meansoutstanding colour and gloss retention,resulting in a superior product that lastslonger.

Sun and pre-finished steelThe sun emits a spectrum of light energy(figure 23) including invisible ultraviolet (UV),visible light and infrared radiation (IR). Theshorter wavelengths of UV radiation - whichinclude UVB and UVA radiation - are the mostdestructive on polymer materials. The UV lightis absorbed directly by the polymer andpigment at the molecular level, ultimatelyleading to the breaking of chemical bonds.This results in loss of colour and gloss,chalking, brittleness and, eventually, loss oftopcoat adhesion. The length of time that thistakes depends on the durability of the pre-finished steel, as depicted in figure 24.

Figure 24. Light degradation over time

Colorcoat HPS200 Ultra® has been developedto offer outstanding UV resistance throughincorporation of the latest polymertechnology in its durable topcoat. This 200micron topcoat contains specially developedheat and UV stabilisers which mitigate anydegradation caused by the absorption of UVradiation together with advanced plasticisersthat increase the durability of ColorcoatHPS200 Ultra® compared to alternative pre-finished steel products.

The IR radiation is also absorbed at themolecular level (solar absorption) whichresults in the topcoat heating up. Such solarabsorption can cause thermal degradation ofthe polymer chemical bonds. The extent ofthis IR absorption is dependant on acombination of the colour pigments used and

other constituents within the paint that canreflect certain proportions of this radiation.The incorporation of an advanced package ofheat stabilisers in combination with the latestpigment technology within the topcoat ofColorcoat HPS200 Ultra® reduce the affect ofIR radiation damage resulting in a productthat maintains it colour and gloss for longer.

The UV resistance of Colorcoat HPS200 Ultra®has been extensively tested andindependently verified with a suite of naturaland accelerated tests that range in theirseverity. Samples have been exposed andremain exposed at weathering sites that coverthe full spectrum of weathering zones such asFlorida, Arizona, Prescott Arizona, Dubai,China, India, Australia and sites within the UK.

UV resistance



1. Gloss Loss 2. Colour Change 3. Cracking and delamination

StandardLeathergrain

Steel Substrate

Years

1. Gloss Loss 2. Colour Change 3. Cracking and delamination

ColorcoatHPS200 Ultra®

Steel Substrate

Years

Figure 23. Solar radiation spectrum

UV radiation Visible light IR radiation

0 400 780 3000Wavelength cm-1

RUV4 requirements

RUV4 requirements

UVA testingTo meet the requirements of RUV4, samplesare exposed to artificial UVA radiation for atotal of 2,000 hours as well as two years at anaccredited weathering site with a cumulativeUV radiation in excess of 4,500 MJ/m2 peryear. Colorcoat HPS200 Ultra® has beensubjected to both of these testing conditions.

EN 10169:2010 stipulates that, for RUV4classification:

• The percentage gloss retention (% GR) mustbe greater than 80% after each test and theextent of colour change (ΔE) must be lessthan 2ΔE for artificial UV testing and lessthan 3ΔE following natural weatheringexposure.

In both tests, Colorcoat HPS200 Ultra® easilymeets these requirements in terms of thestipulated colour and gloss retention whichprovides clients with even greater reassurancethat their buildings will retain their true colourfor longer.

The superior UV resistance of ColorcoatHPS200 Ultra® has been independentlyverified by ATLAS following exposure at theFlorida weathering facilities. Figure 25 is theRUV4 certificate for Colorcoat HPS200 Ultra®.

Extended testingIn addition to the standard tests for RUV4classification, samples of Colorcoat HPS200Ultra® have completed more than 6,000 hoursof exposure to artificial UVA radiation – threetimes the required length of testing. Evenafter this extended testing period, ColorcoatHPS200 Ultra® still met the requirements ofRUV4. The tests showed that Signature colourshad a ΔE of less than 1.0 and the Classic andMatt colours had a ΔE of less than 1.5.

Extended testing: All colours had a percentagegloss retention greater than 80% even afterthis accelerated test. The Matt colours had agloss retention greater than 100% and as suchare not represented in the graph.

Figure 25. RUV4 Certificate


Figure 26. ΔE for Colorcoat HPS200 Ultra® in UVA

ΔE3.0

2.5

2.0

1.5

1.0

0.5

0

2000 4000 6000 Total hours in UVAKey

Signature Colours Classic Colours Matt Colours

Figure 27. % Gloss Retention for Colorcoat HPS200 Ultra® in UVA

%GR100

80

60

40

20

0

2000 4000 6000 Total hours in UVAKey

Signature Colours Classic Colours


Continuing with testing the product beyondindustry standards. Colorcoat HPS200 Ultra®has been subjected to extended UV testingand long term natural weathering.

UVB testingDue to the short wavelengths of radiation inUVB testing it is more damaging to polymersthat UVA artificial testing. Samples ofColorcoat HPS200 Ultra® have also beenexposed to artificial UVB radiations for 6000total hours. Even after this extended exposurein this harsh testing environment, ColorcoatHPS200 Ultra® Signature colours have a ΔE ofless than 1.5 and a percentage gloss retentiongreater than 50 per cent, with nodelamination between the topcoat andsubstrate. When Colorcoat HPS200 Ultra® iscompared to standard leathergrain pre-finished steel exposed for 2000 total hoursin the UVB test, performance in terms ofcolour and gloss retention are superior.

Figure 28: Standard leathergrain productshows significant colour and gloss losscompared to Colorcoat HPS200 Ultra®.

Figure 29: Standard leathergrain productshows not only colour and gloss loss but thetopcoat has delaminated exposing themetallic substrate. Colorcoat HPS200 Ultra® isstill exhibiting excellent adhesion.

Extended UV testing


Figure 28. Anthracite standard leathergrain and Colorcoat HPS200 Ultra® after 2000 total hours in UVBtest

Figure 29. Heritage Green standard leathergrain and Colorcoat HPS200 Ultra® after 2000 total hours inUVB test


Xenon testingIn addition to UVA and UVB artificial testing,Colorcoat HPS200 Ultra® has undergone Xenontesting – a whole-spectrum test designed tosimulate natural sunlight. Xenon testingclosely follows the full sun spectrum fromtypically 300 to 3000nm wavelength andtherefore covers all UV, visible and IR radiation.

The average colour and % GR results forColorcoat HPS200 Ultra® Signature and Classiccolours tested after 2000 light hours (2400total hours) is a ΔE of 1.7 and a % GR > 80 percent with no delamination.

Table 9. Xenon test results

ΔE % GR1000 1.5 95.62000 1.7 81.2

Figure 30. Suite of natural weathering andaccelerated UV tests.

Natural weatheringIn addition to the accelerated weatheringprogramme, Colorcoat HPS200 Ultra® hasbeen exposed to full scale testing at ournatural weathering facilities, which confirmsthe proven performance and super durableproperties of the product.

By the end of 2011, initial production samplesof Colorcoat HPS200 Ultra® had beensubjected to more than three years ofexposure at the ATLAS weathering facilities inFlorida.

The UV resistance demonstrated by ColorcoatHPS200 Ultra® under these natural weatheringconditions provides further proof of itsdurability and excellent colour and glossretention. After three years exposure in Floridathe colour change was approximately 1.0ΔEwith a % GR approximately 80 per cent.

Figure 31. Colorcoat HPS200® after 8 yearsexposure in Florida

A year’s exposure to sunlight in Florida canequate to four to seven years of exposure inNorthern Europe. Based on the test results todate, Colorcoat HPS200 Ultra® has had UVexposure equivalent to up to 21 yearsexposure in Northern Europe with excellentgloss and colour retention.

A whole suite of natural weathering andaccelerated tests are used to assess the UVperformance of Colorcoat HPS200 Ultra®. Asindicated in figure 30 this suite of tests rangein both exposure time and aggressivity of thetest environment. The collated test dataprovides an understanding and reassuranceon the performance of Colorcoat HPS200Ultra® in different world wide climates. Thissuper durable UV performance quality hasenabled Colorcoat HPS200 Ultra® to be usedon prestigious projects throughout the worldwith Tata Steel backed warranties issued on acase by case basis.

Long term naturalweathering



Hours

% Glossretention

MonthsTime in test

Years

HT-UVB UV-B UV-A Xenon EMMAQUA NaturalWeathering

Exposed Unexposed

Understanding reflectivity and emissivity ofpre-finished steel is important, to evaluatetheir affect on thermal loading and theurban heat island effect.

The sun’s infrared (IR) light is absorbed bymaterials, causing an increase in surfacetemperature that can be greater than thesurrounding air temperature. The ability of apre-finished steel system to reflect IR light canhave a significant effect on the building’stemperature, decreasing the need for highenergy consumption in air conditioning, andthe amount of thermal expansion of thecladding profile. Colour has a significant effecton the Total Solar Absorption (TSA) of IRradiation with a black roof reaching a fargreater surface temperature than a white roofunder the same climatic conditions.

Figure 32. Solar reflectivity

All colours in the Colorcoat HPS200 Ultra®range have been tested to determine theirreflectivity performance. The heat absorptionand emittance values for each colour havealso been measured, along with the maximumsurface temperature for the various coloursunder standard conditions. The total solarreflectance (TSR) was measured according toASTM E903-96 and emissivity according toASTM C1371-04a.

Several Signature colours have exceptionalreflective properties (table 10) in that virtuallyall of the sun’s radiation is reflected - resultingin a coating that does not heat up comparedto other pre-finished coatings. This reductionin thermal load minimises heat gain indoorsand in turn energy consumption required tocool the building, and reduces the urban heatisland affect by lowering outdoortemperatures. The total solar reflectance (TSR)and emittance values quoted in the tablebelow are beneficial when undertaking wholebuilding assessments such as LEED which giveadditional credits for solar reflective products.

Table 10. High reflectivity

Colour TSR TSA EmittanceWhite 0.88 0.12 0.88Ice Blue 0.75 0.25 0.88Marlstone 0.78 0.22 0.89Honesty 0.75 0.25 0.89Hamlet 0.74 0.26 0.89

The wide colour range of Colorcoat HPS200Ultra® gives the maximum surface temperaturefor each colour following testing to E1980standard at a test temperature of 310 degreesKelvin (37°C) with a medium wind speed.

Table 11. Maximum surface temperatures

Maximum surfaceTopcoat temperatureBlackIvyJuniper GreenAnthracite ≥ 80°CAnthracite MattOxidised MattVan Dyke BrownArdenneOlive GreenOcean BlueHeritage GreenMerlin GreyMole BrownAlaska Grey ≥ 70°C < 80°CAlaska Grey MattPure GreyWedgewood BlueSvelte GreyRavenSargassoBuranoSolent BlueChiliGreen Grey MattMoorland GreenGoosewing GreyJade Green ≥ 60°C < 70°CBarn RedTerracottaPetraTerracotta MattMushroomStrawAlbatrossMeadowland

≥ 50°C < 60°C

HamletHonestyIce Blue < 50°CMarlstoneWhite

Solar reflectivity



Total incoming solarradiation expressed asa percentage (e.g. 100%)or decimal (e.g. 1.0)

Total solar reection(TSR) expressed as a

percentage (e.g. 65%)or decimal (e.g. 0.65)

Total solar absorption(TSA) expressed as apercentage (e.g. 35%)or decimal (e.g. 0.35)

ColorcoatHPS200 Ultra®

Steel

Tata Steel has long been at the forefront ofresponsible sourcing. Colorcoat HPS200Ultra® is fully compliant with REACHregulations regarding the use of chemicalsubstances including pigments.

REACH (Registration, Evaluation andAuthorisation of Chemicals) is a EuropeanRegulation. It addresses the production anduse of chemical substances and their potentialimpacts on both human health and theenvironment. It requires manufacturers andimporters to gather information on theproperties of their chemical substances and toregister the information in a central databaserun by the European Chemicals Agency(ECHA) in Helsinki.

At Tata Steel we do not utilise lead chromatebased pigments in the Colorcoat HPS200Ultra® colour range.

Tata Steel is the first pre-finished steelproducer to achieve BES 6001 (very goodrating) in recognition of responsible sourcing.

With almost every business in Europe having aresponsibility under REACH legislation,specifying Colorcoat HPS200 Ultra® providesclients with the confidence that they aremeeting their corporate social responsibility(CSR) obligations and using a product that isfully compliant.

Colorcoat HPS200 Ultra® is fully compliantwith all current REACH legislation. To assistcustomers, updates on REACH obligations,together with product health and safety datasheets, are available.

Compliance withREACH



Fire performance is a fundamentalrequirement when considering theperformance of a building in a potential firesituation for Building Regulations andinsurance requirements.

UK Building RegulationsFollowing a decision to harmonise standardsin the construction sector across Europe, newEuropean standards have been introducedinto the regulations. At present in the UK,there is a period of co-existence of standardsand either EN Standards or BS 476 can be usedto demonstrate compliance.

Wall applicationsBritish Standard tests

1. Surface spread of flame productsBS 476 Part 7 ‘Method for classification ofsurface spread of flame of products’, specifiesa test method for measuring the lateral spreadof flame along the surface of the sample. Theclassification system is based on the rate andextent of the spread of flames (results areclassified from 1 the best, to 4 the worst).

Colorcoat HPS200 Ultra® has a class 1 surfacespread of flame when tested in accordancewith BS 476 part 7.

2. Fire propagationBS 476 Part 6. ‘Method of test for firepropagation of products’ - The test specifiesthe procedure for measuring the firepropagation indices of the product.

When tested in accordance with BS 476 part 6,Colorcoat HPS200 Ultra® has fire propagationindices, I

Roof applicationsBritish Standard tests

External fire performance for roof coveringproductsThe ability of roof systems to resist firespreading to the roof of a building, from a fireoutside the building itself, is assessed bytesting samples of the roof in accordance withBS 476 Part 3.

The test assesses the resistance of the roofstructure to fire penetration with results ratedfrom A (best) to D (worst), and the spread offlame across the roof again with results ratedfrom A (best) to D (worst).

Colorcoat HPS200 Ultra® has a notionaldesignation of AA (National classification)within approved document B of the BuildingRegulations (England and Wales).

European Standard tests

Euroclassification - External fire performancefor roofs/roof coveringsEN 1187 defines a number of different testmethods for assessing the performance ofroofs/roof coverings. Performance is ratedfrom BROOF (best) to FROOF (worst). EN 1187test method 4 is based on BS 476 part 3 and isthe only method accepted in the UK.

EN 1187 test methods 1, 2 and 3 are usuallyspecified in Europe, dependant upon thelocation.EN 1187 test method 1 German test.EN 1187 test method 2 Nordic test.EN 1187 test method 3 French test.

External fire performance for roof coveringproductsColorcoat HPS200 Ultra®, when used as part of a roof cladding system can be classified as BROOF(t1), BROOF(t2), BROOF(t3), without furthertesting, in accordance with CommissionDecision 2005/403/EC for all material greaterthan or equal to 0.4mm gauge and for allcolours in the product range.

Colorcoat HPS200 Ultra® has a notionaldesignation BROOF(t4) within ApprovedDocument B of the Building Regulations(England and Wales).

Insurance requirementsInsurance companies often specifyadditional fire performance criteria and/ortests which building components mustmeet. Cladding systems that meet therequirements of these tests are seen aspresenting a lower level of fire risk.

The Association of British Insurers (ABI) whichuses the Loss Prevention Certification Board(LPCB) assessment, and FM Global who havetheir own FM Approvals, are the two mainbodies that undertake testing.

ABI and Loss Prevention Certificate Board(LPCB) The LPCB specifies two separatestandards:

• LPS 1181 Fire growth tests.• LPS 1208 Fire resistance.

FM Global and FM ApprovalsFM Approvals is the testing and certificationbody for FM Global. It applies to two separatestandards for assessment of wall systems andpanel roofs:

• 4881 Approved Standard for Class 1 ExteriorWall Systems.

• 4471 Approved Standard for Class 1 PanelRoofs.

The standards cover a number of keyperformance criteria including fire, wind,traffic, hail and water-tightness.

Colorcoat HPS200 Ultra® can be used in roofand wall cladding systems which can meet therequirements of the LPCB and FM approvalsassessments.

Colorcoat HPS200 Ultra® Fire performance


Peace of mindOnce your building project is completed youneed peace of mind that if anything does gowrong with your pre-finished steel you canget things fixed.

Confidex® is the product performanceguarantee for the weatherside of ColorcoatHPS200 Ultra®, when used in an externalconventional building envelope application,namely roof and wall cladding using singleskin, built-up or composite panel constructionin industrial and commercial buildings.

Confidex® offers the longest and mostcomprehensive guarantee for pre-finishedsteel available in Europe with ColorcoatHPS200 Ultra® being guaranteed for up to 40years. Dramatic and unrivalled improvementsin colour stability and gloss retention aretranslated into a durable product with greatlongevity. We are so confident in our productthat we cover the cut edges for the entirety ofthe guarantee. With no mandatory inspectionsor maintenance, we remove the need to go onto the roof to maintain the validity of theguarantee – Confidex® is the only pre-finishedsteel guarantee on the market that offers this.

We also include cover for Colorcoat HPS200Ultra® that is situated under a photovoltaic(PV) frame module. Providing the buildingowner with the confidence that installing a PVarray will not have a detrimental effect on theperformance of the pre-finished steel. PVmodules can be installed at any pointthroughout the Confidex® Guarantee Period,providing it was registered, and will becovered for the remainder of the guaranteeperiod.

The Confidex® Guarantee is project specificand upon registration online - provides acontractual relationship between Tata Steeland the building owner meaning that in the

case of a claim the contact with Tata Steel isdirect rather than having to go through thesupply chain, saving time and money.

The Confidex® Guarantee is transferable, soshould the building owner change it is simplya case of filling in the form on the back of theguarantee certificate and posting back to TataSteel.

Who registers?Usually the building owner, claddingcontractor or the cladding systemmanufacturer, but anyone in the supply chaincan apply online at: www.colorcoat-online.com/registration

If you want to check your building has beenregistered, contact the Colorcoat Connection®helpline on +44 (0) 1244 892434.

Other warrantiesWhilst Confidex® has always been restricted tothe weathering performance of the externalcladding, we have recognised the growingemergence of demanding internalenvironment projects, such as energy fromwaste plants, and may offer a non-Confidex®warranty on a case by case basis for ColorcoatHPS200 Ultra® used internally.

Application specific warranties are alsoavailable for non-standard claddingapplications; i.e residential roofs, flashings andsectional roller shutter doors. Please contactthe Colorcoat Connection® helpline forguarantees associated with such applications.

Northern Europe – Zone 1 Southern Europe – Zone 2

For areas outside of Confidex® zones please contact TataSteel for more information.

40years 30

years 30years

40years

40years 30years 30years 25years

Roofs

Walls

Inland

Coastal

30years 25

years 20years

30years

30years 20

years 20years 15

years

Roofs

Walls

Inland

Coastal

Signature Colours Classics & Matts

Confidex® Guarantee

Colorcoat HPS200 Ultra® Guarantees

Notes1. Figures under the Coastal heading are for buildings within

1km of any coast.2. Full terms and conditions of the Confidex® Guarantee are

on the online application form, available atwww.colorcoat-online.com/registration

3. Confidex® must be registered within 3 months of thebuilding completion date for the guarantee to be valid.

4. The Confidex® Guarantee periods on the diagram aboveare applicable to Zone 1 and Zone 2. For moreinformation visit www.colorcoat online.com/confidexmap

5. Anthracite Matt is available with a Confidex® Guaranteeof up to 40 years in Zone 1 and up to 30 years in Zone 2.

Figure 33. Diagram of Confidex® Guarantee periodsfor Zone 1 and 2.

Zone 1

Zone 2


Table 12. Comparison of guarantees

Area

Headline guarantee and cut edges

Rectification costs

Inspection and maintenance free

Non standard colours

Guarantee transfer

In the event of a coating failure

Roof pitches

Processing of pre-finished steel

Application process

Coastal environments

Confidex® Guarantee

Headline guarantee statement of up to 40 years

including cut edges.

Full remedial action so all rectification costs covered.

Confidex® does not specify mandatory inspections or

maintenance to maintain the validity of the guarantee

except when Colorcoat HPS200 Ultra® is used on a roof

that has a photovoltaic (PV) installation.

Solid colours specified through Repertoire® are covered

by the Confidex® Guarantee.

Can easily be transferred should building ownership

change.

Building owner contacts Tata Steel directly to address

claim.

Covers roof pitches down to 1°.

Tata Steel requires the product to have been used within

18 months of manufacture, and the Confidex® Guarantee

registered within 3 months of building completion.

Simple, short online form.

0-1km.

Other guarantees

Cut edges may only be covered for 10 years.

Some limit the claim to the invoice value of the Steel,

which may offer the full value at the beginning but can

reduce over the duration of the guarantee.

Some claim to be maintenance free but require regular

inspection logs to be kept.

Do not generally provide any guarantee for non standard

colours.

Some suggest transferring ownership is possible but at

the discretion of the supplier i.e. the transfer is not

assured.

Some require the building owner to contact the supply

chain with the cladding manufacturer ultimately making

contact with the steel supplier to pursue claim.

Higher roof pitches drain more easily so not all

guarantees cover pitches below 6°.

Some guarantees require the product to have been used

within 4 weeks of manufacture.

Lengthy paper based questionnaire to complete.

0-3km.

Colorcoat HPS200 Ultra® Guarantees

The British Board of Agrément Certificate

Don’t just take our word for it, ColorcoatHPS200 Ultra® has been assessed by theBritish Board of Agrément (BBA) which is theUK’s major authority offering approval ofconstruction products, systems andinstallers.

The BBA awards Agrément Certificates to aproduct only after it has successfully passed

a comprehensive assessment involvinglaboratory testing, on-site evaluations andinspections of production.

Colorcoat HPS200 Ultra® has been awardedAgrément Certificate 91/2717 by the BBA forindustrial, commercial, retail and leisure useand for residential and non-residentialdwellings.

The BBA states: “Colorcoat HPS200 Ultra®coating and metal treatment will protect thesteel substrate against corrosion for a period inexcess of 40 years in normal industrial, urban, suburban and rural environments.”


Reducing embodied energyTata Steel has an ongoing commitment toreduce CO2 emissions associated with pre-finished steel manufacture and we workwith leading experts to ensure that both theColorcoat® products and the roof and wallcladding systems that it is part of, contributeto sustainable building envelope solutions -now and in the future.

Colorcoat HPS200 Ultra® is manufactured atTata Steel’s Shotton site in North Wales. AtShotton we have already delivered significantreduction in CO2 emissions and material wastethrough strategies such as a move from roadto 100% rail transport for all feedstock comingfrom Tata Steel in South Wales; installation ofvariable speed drives and energy-efficientlighting; reclaim and recycle of 95% of our Zincpot waste; and reuse of solvents used forwashdowns.

Responsible SourcingResponsible sourcing provides an approach tomanaging a product from the point at which amaterial is mined or harvested in its raw statethrough manufacture and processing, use,re-use and recycling.

Tata Steel is leading the way as the first pre-finished steel manufacturer to secure BES 6001 certification for its Colorcoat®products manufactured at Shotton includingColorcoat HPS200 Ultra®, and have achieved a‘Very Good’ rating.

Colorcoat HPS200 Ultra® is exclusively fromTata Steel and, as such, is fully traceable. Ourmanufacturing site has an environmentalmanagement system which has been certifiedto ISO 14001.

For a copy of our latest certification contactthe Colorcoat Connection® helpline on +44 (0) 1244 892434

Sustainable design and useA key part of sustainable design is specifyingproducts that offer long-term performance.The super durable properties of ColorcoatHPS200 Ultra® are unsurpassed in the industryand are backed by the Confidex® Guaranteefor up to 40 years.

However, the life of Colorcoat HPS200 Ultra®can be extended almost indefinitely over andabove the Confidex® Guarantee period byusing appropriate maintenance and remedialaction such as over-painting.

End of life and recyclingIf corrective action is not an option there is awell established and very efficientinfrastructure which ensures that all steelcollected at end of life goes back intosteel manufacture without any loss of quality.This means that the investment in steel-makingis never wasted, making steel the mostsustainable construction material.

Life cycle assessmentTo demonstrate environmental impacts and toallow you to make detailed comparisons andinformed decisions when purchasingconstruction products, Tata Steel has carriedout comprehensive life cycle assessments on awide range of cladding systems using Colorcoat HPS200 Ultra®.

For more information visit www.colorcoat-online.com/epd

Sustainability

Colorcoat HPS200 Ultra® Sustainability


Operational efficiencyWe have worked closely with one of theleading architectural schools at Oxford BrookesUniversity to study the operational impacts of abuilding and identify the contribution that pre-finished steel cladding can make to itsefficient running.

Optimising the building envelope efficiencythrough insulation, high air-tightness levels andthe minimisation of linear thermal bridging canreduce the operational impacts.

We have provided best practice advice andguidance on detailing in our Colorcoat®technical papers so that cladding systemsmanufactured using Colorcoat HPS200 Ultra®can reduce the associated heat losses from thebuilding envelope.

All Tata Steel supply chain partner roof and wallcladding systems in the UK have details thathave been designed and modelled to improvethe thermal performance of the building.

For more information visit www.colorcoat-online.com/technical

System environmental assessmentIn the UK all roof and wall systems using pre-finished steel achieve a Green Guide A+rating. Manufacture and processing ofColorcoat HPS200 Ultra® into buildingenvelope products, through our approvedsupply chain, can maximise credits assessedthrough BREEAM.

PhotovoltaicsTo demonstrate Tata Steel's commitment tothe environment and renewable energyofferings, Colorcoat HPS200 Ultra® includescover through the comprehensive Confidex®Guarantee for the pre-finished steel that isunder the photovoltaic (PV) frame modules ona roof.

This provides the building owner with theconfidence that installing a PV array will nothave a detrimental effect on the performanceof the pre-finished steel, and that the product isguaranteed to perform for the same duration ofthe guarantee up to 40 years.

For advice and guidance on PVs and theConfidex® Guarantee contact the ColorcoatConnection® helpline on +44 (0) 1244 892434.

Investing in sustainable buildingenvelopes Tata Steel, together with partners such as theLow Carbon Research Institute, WelshAssembly Government, and SwanseaUniversity has invested in the creation of theSustainable Building Envelope Centre (SBEC)and the Sustainable Product EngineeringCentre for Innovative Functional IndustrialCoatings (SPECIFIC).

The aim of the research at these two centres isto develop a portfolio of products that willturn buildings into power stations to generateover one third of the UK’s requirement forrenewable energy by 2020.

Colorcoat HPS200 Ultra® Sustainability


When sourcing material for your buildingenvelope, consideration should be given tocolour availability, consistency and matchingcomponents. Colorcoat HPS200 Ultra®provides the widest colour

Colorcoat HPS200 Ultra Technical - Euroclad...EN 10143:2006 to ensure that the cladding performs as...

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