Genesis Manazil Company Portfolio

Company Portfolio June 2011

Light Steel Framing Solutions Manazil Steel Framing

Table of ContentsChapter 1 - Manufacturers DataSECTION 1.1 Company Information SECTION 1.2 Proposed scope of work Chapter 2 - Proposed Solution SECTION 2.1 Wall solution SECTION 2.2 Floor solution SECTION 2.3 Roof solution SECTION 2.4 Typical Foundation SECTION 2.5 Design considerations SECTION 2.6 Precast v.s Light Steel Product Comparison SECTION 2.7 Advantages of the Proposed Product SECTION 2.8 Green Benefits Chapter 3 - Technical Information SECTION 3.1 Overview of cold formed steel framing SECTION 3.2 Codes and standards SECTION 3.3 Sample Approved Drawings Chapter 4 - Typical Schedule SECTION 4.1 Typical Construction Schedule Chapter 5 - Specifications SECTION 5.1 Cold Formed Steel (ASTM A653) SECTION 5.2 Cement Board SECTION 5.3 Fiberglass Insulation

Company Information Subsection 1.1 A - Company Collateral Subsection 1.1 B - Sample UAE Projects Subsection 1.1 C - Sample International Projects Subsection 1.1 D - UAE Approvals

SECTION 1.1

Manufacturing Company: Manazil Steel Framing Factory LLC Contracting Company: Gulf Genesis General Contracting LLC Parent Company: Al Fahad Holding Sister Company: Khalifa Al Fahad Contracting

Genesis Worldwide Inc., an industry leader in “green” structural building technologies using light steel in the residential, commercial and institutional construction markets, established in December 2007, the production facility of its licensee, Manazil Steel Framing Factory (“Manazil”) in Abu Dhabi.

Manazil is a subsidiary of Al Fahad Holding of Abu Dhabi, an Emirati construction company established in 1980. The Company previously announced the signing of the License & Services Agreement (the “Agreement”) on July 10, 2007. Under the terms of the Agreement, Manazil is the exclusive provider of Genesis building systems in the United Arab Emirates and Qatar.

The company has a Qatari branch under the name Manazil Co. Qatar, which oversees all company’s operations in the state of Qatar. In addition to building villas, office spaces, government buildings locally, Manazil has recently started to export steel structures to neighbouring countries such as Iran and Afghanistan to build houses and schools in earthquake affected areas.

The Manazil manufacturing plant, located in the industrial zone of ICAD, produces light steel paneled structures using the Genesis turn-key solution, which includes leading-edge software, industrial equipment, hardware, processes and engineering services (“Genesis Solution”).

Genesis light steel structural technology, an energy efficient, environmentally friendly building alternative, is well suited to the hot climates of the UAE. The Genesis Solution utilizes a cavity wall design that incorporates air barriers, vapour barriers and insulation materials in order for its structures to improve energy efficiency, as opposed to the use of a single material, such as concrete, which does not conserve energy as well as buildings with a cavity wall design. By using light steel, less energy is consumed in order to bring the temperature down to a comfortable level.

Manazil is contracted to build large family style villas which can be constructed with speed, cost-effectiveness and efficiency, an improvement on the traditional concrete building methods often used in the UAE.

For additional information about the Company, visit www.genesismanazil.com

Social and Health

No harmful emission, corrosion or mold

Non-combustible and non-organic

Safe for seismic, wind, and heavy rains

Vapor control and thermal performance

Environmental

Environmentally responsible material

Long life cycle

Infinite recyclability

Limited waste (1 to 10 ratio compared to lumber)

Superior energy efficiency

Aligned with government initiatives (LEED)

Business

Faster deliveries

Turnkey integration efficiencies

Reduced delays from weather

No multi-trade/supply coordination

Accelerated deliveries

Safe, clean and accessible jobsites

Better Quality

Controlled workmanship and consistent dimensions

High strength and durable product (protective coating)

Longer spans, increased design flexibility

No shrinking, warping and cracking

Wide range of architectures and finishing options

Cost Effective

Off-site manufacturing accuracy and predictability

Low skill requirement for structure assembly and finish

Reduced after sales service, call backs and repairs

Low maintenance costs and high resale value

Steel commodity readily available and competitive

Waste disposal, clean-up, and removal reduced

Low contractor’s risk insurance costs

Light stress on foundations, cranes, and contractors

Limited material stock for suppliers and contractors

One-stop accountability resulting in on-time and on-budget deliveries

Genesis Manazil Steel Framing has gained unique light-steel Framing (LSF) technical and execution expertise in United Arab Emirates based on the Genesis Technology Platform. Starting from the architectural drawings all the way to inspecting the finished LSF structure, Genesis Manazil delivers complete turnkey solutions to cost-conscious real estate developers and construction companies eager to join the Green Building movement.

Structural Engineering Services: our dedicated team of professional structural engineers, framing designers and technologists bring the experience and the specialized skills required to engage in any type of structural and non-structural projects using LSF products according to local building codes and requirements.

Manufacturing Services: a state-of-the-art and lean industrial operation located in Abu Dhabi with advanced material handling, cold roll forming, automated framing and sheathing assembly equipment produces on-demand accurate and consistent LSF joist, wall, truss and floor systems in a 100% quality controlled environment.

Logistics Services: a live (web-based) and just-in-time management of product inventories on-site and off-site gives instantaneous access to status of any roof, floor, and wall systems pre-fabricated and pre-bundled in sequence for installation of a specific project.

Installation Services: experienced and efficient site crews, supervisors and professional engineers are committed and available to ensure the structure gets erected and inspected on-time and with the highest quality standards.

Project management Services: dedicated resources to each project manage continuously all the services described above to ensure all the customer deliverables are met within the agreed budget at all times. Our professional project managers are the focal points from the onset of any project including the contractual phase so communication is transparent and effective during the complete project.

A Turnkey Approach to Green Building Structures

Light-Steel Structural Systems Benefits

Residential, Institutional, and Commercial Projects of up to 8 Storeys

Effective and Seamless Project Integration

A Proven and Cost Effective Process

REDUCER

EC

YC L E R E U SE

Structural Design and Fabrication Drawings for all Structral Elements

Wall / Floor / Roof Panels Production & Delivery

On-site Installation

Day 5

Final Inspection

Proj

ect M

anag

emen

t 1

2

3

4

A Comprehensive Portfolio of Engineered Structural SystemsThanks to its unique and wide capabilities, Genesis Manazil Steel Framing can engineer, manufacture and deliver a building structure for any residential, commercial and institutional building project and can consequently achieve any design architecture with the desired comfort for the occupants. The innovative and smart Genesis Manazil Green Systems provide a complete realm of solutions for floor, roof and wall applications meeting or exceeding the International specifications for fire, sound and thermal ratings.

Structural & Partition Wall Systems

Curtain Walls Shear Walls Non-Load Bearing Walls Sound Proof Walls Insulated Walls

Structural Floor Systems

Sound Rated Floor PanelsFire Rated Floor PanelsiSPAN Joist System iSPAN Joist System Fire Rated iSPAN Joist System Composite

Complex TrussesScissor TrussesParallel Chord TrussesCommon Truss Jack/Mansard Truss

Structural Roof Systems

MEMBER

Genesis Manazil Green Systems are continuously improved based on a philosophy of on-going innovation, and a clear focus on using the most site-friendly methods of construction. Smart product features are embedded in the systems not only to provide an enhanced assembly experience to all trades but

also to accelerate the erection of any building up to 8-storey high. The accuracy and quality of the products combined with a perfect logistic coordination yield into unbeatable delivery schedules, exceeding any traditional construction expectations.

Unbeatable Delivery Schedule

Starting the Foundation

Installation Commences

Panels Arrive

Assembly Continues

1

3

2

4

Engineering Inspects

Install Insulation Materials

Finished house is ready

Structure complete

Apply External Finishing

5

7

9

6

8

Genesis Manazil Steel F

ra

min

g

READY

Gen

es

is Manazil Steel Fram

ing

Slope Roofs

Substrate/Sheathing

OSB

Plywood

Structural Insulated Panel (SIP)

Metal Deck

Flat Roofs

Substrate/Sheathing

OSB

Plywood

Structural Insulated Panel (SIP)

Metal Deck

EPS/EPDM built-up rubber membrane

Standing Seam

Floors

Substrate/Sheathing

OSB

Plywood

Metal Deck & Concrete

Metal Deck

Walls

Substrate/Sheathing

Rigid

OSB or Plywood

Densglass

Light steel structures provides full flexibility in terms of building envelope giving Manazil Steel Framing’s customers the advantage to get the panelized systems insulated and finished on site. Genesis® Green Systems offer a variety of pre-engineered options for sound, thermal and fire insulation combined with finish fascias so the occupant’s comfort and exterior preference can be met.

Pre-insulated Systems Ready for Finishing

Sheathing Products

Insulation Products

OSB

Densglass™

EPS Insulation

Blueskin

Plywood

Drywall / Concrete Board

XPS Insulation

Fiberglass Insulation

Com

mer

cial

Fra

min

g

Restaurants Shopping Centers Motels, Hotels & Resorts

Schools & Day-Care CentersInst

itutio

nal F

ram

ing

Health Care Facilities Senior Care Facilities

Modular Residential/Pods School Portable Mobile Homes/ Trailers

Port

able

Fra

min

g

Semi-Detached HomesCustom Estate HomesResi

dent

ial F

ram

ing

Single Family Homes

Multi-Family Townhomes Condominiums Apartments

Manazil Steel Framing Can Build a Wide Range of Projects up to 8 Storeys using Genesis® Structural Systems

Sample UAE Projects 500+ Projects were built using the Genesis Light Steel system around the World with over 1.5 million m2 of covered space.

Subsection 1.1 B

ProjectLocationSolution

Villas for Fahad Matooq Al Hossani

Residential - 3 VillasPlot No 67B, Sector No26, Khalifa City A, Abu Dhabi, UAETurnkey


Trinity Villa

Sample VillaICAD 1, Mussaffah, UAETurnkey


Villa for Rukaya Al Muhairy

Residential VillaPlot No 12, Al Baheya, Abu DhabiTurnkey


Villa for Bader Said Al Murekhi

Residential - 2 VillasPlot No 72, Sector NoW52, Al Mushref, Abu Dhabi, UAETurnkey


Villas for Ali Abdullah Al Mansuri

Residential - 2 VillasPlot No 40, Sector No13, Khalifa City A, Abu Dhabi, UAETurnkey


Villas for Nasser Al Reyami

Residential – 3 VillasPlot No 117, Sector Z-5, Mohamed Bin Zayed, Abu Dhabi, UAESteel only


Masdar 1A Ancillary Buildings

Commercial - InstituteMasdar City, Abu Dhabi, UAERoof / Floor Solution


CID (Criminal Investigation Division)

Commercial - OfficeAbu Dhabi Police, 27th - Airport St, Abu Dhabi, UAETurnkey


Majlis for Shafi Al Bajash

Residential - MajlisKhobar, Saudi ArabiaCore and Shell


Service Block for Nasser Al Reyami

Residential - 2 Service BlocksPlot No 117, Sector Z-5, Mohamed Bin Zayed, Abu Dhabi, UAESteel only


Majlis for Faraj Al Mansori

Residential - MajlisPlot NO. 103, Sector 11, Khalifa A, Abu Dhabi, UAE Turnkey


Service Block for Abo Baker Obeid

Residential - Service BlockShamkha City, Shamkha 10, Plot No 35, Abu Dhabi, UAECore and Shell


Al Kahf General Cont. EST.

Residential - MajlisAl Falah, Falah 5, Block number 50, Abu Dhabi, UAECore and Shell


Balcony for Abdullah Al Qubaisy

Extension - BalconyPlot No 42, Sector W46-02, Mushref, Abu Dhabi, UAETurnkey


Roof addition - Farm Villa

Addition – Sloped RoofAl Zayed City, Dubai, UAERoof Solution


AUD Police-Traffic Institute

Commercial - OfficeAl Ain, UAETurnkey


Labour Camp for Onsite Construction

Commercial - Labour CampKabul, Afghanistan Steel Only

Sample International Projects

Subsection 1.1 C

6 Commercial

Forest Manor SchoolProject Category Commercial

Project Type Public School

City Toronto

Province/State Ontario

Country Canada

Storey 2 storey

Qty 1

Square Meter 2,700

Year 2009

Solutions WallsFloorRoof

7 Commercial

Cantebury GardensProject Category Commercial

Project Type Care Facilities

City Peterborough


Country Canada

Storey 4

Qty 1

Square Meter 11,700

Year 2007

Solutions WallsFloorPanel

8 Commecial

Esfahan Primary SchoolProject Category Commercial

Project Type Primary School

City Esfahan

Province/State

Country Iran

Storey 1

Qty 1

Square Meter 560

Year 2007

Solutions Walls, Floors, Roof

9 Commercial

Bold Oaks EstatesProject Category Commercial

Project Type Retail

City Bolton


Country Canada

Storey 1

Qty 7

Square Meter 125

Year 2006

Solutions Roof (Trusses)

10 Commercial

Homewood SuitesProject Category Commercial

Project Type Hotels / Resorts

City Burlington


Country Canada

Storey 6

Qty 1

Square Meter 16,000

Year 2005

Solutions Roof (Panelized)

11 Commercial

Trinity SchoolProject Category Commercial

Project Type Secondary School

City Collingwood


Country Canada

Storey 2

Qty 2

Square Meter 2,300

Year 2004

Solutions WallsFloor (Panelized)Roof (Panelized)

12 Commercial

Eagle’s Nest Golf ClubProject Category Commercial

Project Type Restaurants / Retail

City Vaughan


Country Canada

Storey 2

Qty 1

Square Meter 450

Year 2003

Solutions WallsRoof (Trusses)

13 Residential

Leopard Lane DevelopmentProject Category Residential

Project Type Condominiums

City Vaughan


Country Canada

Storey 3

Qty 1

Square Meter 1,200

Year 2009

Solutions WallsRoof (Panelized)

14 Residential

Dinskaya TownhomesProject Category Residential

Project Type Townhouses

City krasnodar

Province/State krasnodar Region

Country Russia

Storey 4

Qty 8

Square Meter 2,400

Year 2009


15 Residential

Clairlea Gardens - Stacked Town HomesProject Category Residential


City Toronto


Country Canada

Storey 4

Qty 112

Square Meter 11,800

Year 2005


16 Residential

Boardwalk TownhousesProject Category Residential


City Toronto


Country Canada

Storey 4

Qty 8

Square Meter 2,200

Year 2005


17 Residential

Arrowhead TownhomesProject Category Residential


City Collingwood


Country Canada

Storey 4

Qty 38

Square Meter 10,000

Year 2005


18 Residential

Gardens At QueenProject Category Residential


City Toronto


Country Canada

Storey 4

Qty 174

Square Meter 13,500

Year 2004


19 Residential

Jarvis MansionsProject Category Residential

Project Type Condominiums

City Toronto


Country Canada

Storey 3

Qty 1

Square Meter 2,500

Year 2004


UAE Approvals

Subsection 1.1 D

Governmental Approvals

Proposed Scope of Work

SECTION 1.2

SECTION 1.2 PROPOSED SCOPE OF WORK

Genesis Manazil Steel Framing Factory, the world’s leading Genesis® light steel building solutions provider is

pleased to submit its expression of interest to provide the products and service required to construct

a superstructure.

The summary of our products and services are:

• Engineering and design for the cold-formed and hot rolled steel superstructure above Ground Floor.

• Supply and install of cold-formed steel interior and exterior wall panels with sheathing and insulation. For

wall assemblies, please refer to the proposed wall solutions listed in section 2.1.

• Supply and install cold-formed steel floor system with insulation, metal deck sheathing, concrete floor

(reinforced with welded wire mesh), ceiling sheathing. For floor assemblies, please refer to proposed floor

solutions listed in section 2.2.

• Supply and install of cold-formed steel roof system with metal deck sheathing, concrete floor (reinforced

with welded wire mesh), ceiling sheathing. For roof assemblies, please refer to proposed roof solutions

listed in section 2.3.

• Supply and install of cold-formed steel slopped roof system with plywood sheathing. For roof assemblies,

please refer to proposed roof solutions listed in section 2.3.

• Supply and install of hot rolled steel columns and beams as required.

• Site inspection and general review report for cold-formed steel superstructure.

1.2.A General Exclusions

For further clarification, following the items below are excluded from the scope of our proposal. The list of

exclusions is not intended to be a full and comprehensive list of all exclusions but only as a clarification of those

items that may be construed as part of the scope of this proposal.

• All local and federal government permits or charges.

• Traffic diversion / control fees.

• Road access, crane operation area or parking permits.

• Temporary construction facilities such as; water, sanitary, waste removal and/or storage.

• Architectural responsibility pertaining to fire and sound rating, and insulation requirements remains in

architect’s scope of work.

• Design of foundation.

• Design, supply of Mechanical, Electrical and Plumbing works.

• Design, supply or installation of any framing systems or materials other than light steel framing.

• Supply or installation of wooden deck or wooden balcony, privacy screen and post support framing.

• Excavation and/or rehabilitation of construction site.

• Supply and installation of miscellaneous metals such as support shelves, access ladders, railings, bollards

and / or fencing.

• Supply and cast all cast in place concrete other than floor and roof slab.

• Supply and install Cat Ladder.

Joanna

SAMPLE

Wall Solution

SECTION 2.1

SECTION 2.1 Wall Solutions

• Supply and installation of 152mm exterior wall panels, with engineered light-steel framing at 406mm on center, complete with 12.mm Cement Board at exterior with 25mm EPS and 18mm Cement Board at interior side in preparation for wall finishing application as indicated by exterior and interior finish, including but not limited to the engineered window and door openings and pre-punched holes at standard locations. See figure 1 for typical proposed exterior wall panel.

• Supply and installation of 92mm structural interior wall panels, with engineered light-steel framing at 406mm on center, complete with 18mm Cement Board at each side in preparation for wall finishing application as indicated by interior finish. Interior load-bearing wall panels to be positioned at predetermined/pre-approved locations within the structure to satisfy Genesis® engineering requirements. Panels include engineered door openings and pre-punched holes at standard locations. See figure 2 for typical proposed interior wall panel.

Figure 1 (a) Plan view of typical exterior/interior wall Figure 1 (b) 3D view of typical exterior/interior wall

EXTERIOR WALL CONFIGURATION:

• RENDER +PAINT • 12mm CEMENT BOARD • 25mm EPS Thermal Resistance • VAPOR BARRIER R 4 m2.K/W • 152mm METAL STUD @ 406 o/c • 50mm ROCKWOOL Sound Transition Class • 18mm CEMENT BOARD STC ≥ 50 • RENDER + PAINT

INTERIOR WALL CONFIGURATION:

• RENDER +PAINT • 18mm CEMENT BOARD • 92mm METAL STUD @ 406 o/c Sound Transition Class • 50mm ROCKWOOL STC ≥ 50 • 18mm CEMENT BOARD • RENDER + PAINT

Floor Solution

SECTION 2.2

2.2 Floor Solutions

• Supply and installation of 254mm or 305mm structural floor panels, with engineered light-steel floor joists at 406mm on center, complete with site installed galvanized metal deck sheathing with welded wire mesh and concrete, engineered / framed stair openings and pre-punched holes at standard locations. See figure 2 for typical floor panel.

• Floor panels to include integrated engineered transfer elements, web stiffeners and bridging.

Figure 2 (a) Section of typical floor assembly

WITH FALSE CEILING WITHOUT FALSE CEILING

FLOOR CONFIGURATION

• CERAMIC TILE • MORTAR • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 50mm ROCKWOOL • METAL CEILING FRAME • 12.5mm CEMENT BOARD • RENDER + PAINT

FLOOR CONFIGURATION

• CERAMIC TILE • MORTAR • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 50mm ROCKWOOL • 12.5mm CEMENT BOARD • RENDER + PAINT

Figure 2 (b) 3D view of typical Floor

Sound Transition Class

STC 50

Roof Solution

SECTION 2.3

2.3 Roof Solutions

Flat Roof

• Supply and installation of 254mm or 305mm structural roof panels, with engineered light-steel floor joists at 406mm on center, complete with site installed metal deck sheathing with welded wire mesh and concrete. See figure 3 for typical roof panel.

• Roof panels are flat and do not accommodate drainage. Figure 3 (a) Section of typical flat roof assembly WITH FALSE CEILING WITHOUT FALSE CEILING

ROOF CONFIGURATION

• 300x300 TERRAZZO TILE • GROUT WITH WATER PROOF MORTAR • 30mm THICK CEMENT SAND SCREED • 1000 GAUGE POLYTHENE SHEET • WATER PROOF MEMBRANE • 50mm THICK FOAM CONCRETE TO SLOPE • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 100mm ROCKWOOL • VAPOR BARRIER • METAL CEILING FRAME • 12.5mm CEMENT BOARD • RENDER + PAINT

ROOF CONFIGURATION

• 300x300 TERRAZZO TILE • GROUT WITH WATER PROOF MORTAR • 30mm THICK CEMENT SAND SCREED • 1000 GAUGE POLYTHENE SHEET • WATER PROOF MEMBRANE • 50mm THICK FOAM CONCRETE TO SLOPE • 75mm METAL DECK + CONCRETE • 254mm METAL JOIST @ 400 o/c • 100mm ROCKWOOL • VAPOR BARRIER • 12.5mm CEMENT BOARD • RENDER + PAINT

Thermal Resistance R 3.9 m2.K/W

Sound Transition Class STC 50

Figure 3 (b) 3D view of typical flat roof

Sloped Roof

• Supply and installation of cold formed steel structural sloped roof trusses, at 610mm on center, complete with site installed 12.5mm plywood sheathing to receive clay tile finish. See figure 4 for typical roof panel.

• Supply and install all required bracing.

Figure 4 Section of typical sloped roof assembly

SLOPED ROOF ASSEMBLY

• CLAY TILE • 12mm PLYWOOD • STEEL TRUSS @ 610 o/c

Typical Foundation

SECTION 2.4

Design Considetions

SECTION 2.5

SECTION 2.4 Design Considerations

2.4. A Engineering Design Scope

• Genesis Manazil SF to provide supplementary “structural design drawings” (for the Genesis®

structure) conforming with International Building Code (IBC) and Local Building Code, sealed by

Professional Engineer in Ontario, Canada.

• Genesis Manazil SF to provide detailed fabrication drawings for wall, floor and roof panels.

• Genesis Manazil SF to provide wall, floor and roof framing layouts, connection and installation detail

drawings prior to on-site installation.

• Genesis Manazil SF to conduct regular site inspections, and provide engineering general review on

Genesis installed products upon substantial completion of work.

2.4. B Structural Design Considerations

• Structural design of proposed cold formed and hot rolled steel super structure and concrete slab &

foundation shall be performed in accordance to International Building Code (IBC) 2009, British

Standard BS 6399 “Loading for buildings”, British Standard BS 5950 “Structural use of steel work in

building”, British Standard BS 8110 “Structural use of concrete” and applicable local codes.

• All cold formed steel structural materials are confirming with ASTM A-653, structural quality grade 37

(Min. Yield Strength 275 MPa) and feature a galvanized coating of minimum Z-180 (G60).

• Stability of structure under lateral loads (wind & seismic) shall be accommodated by crossed braced

shear walls part of the cold formed steel structure.

• Floor live load deflection shall be limited to L/480 or 20mm, total load deflection shall be limited to

L/250 or 25mm. Horizontal sway of the building shall be limited to H/500, deflection of each storey

shall be limited to h/400.

Self Weight of Each Assembly

Self weight of structural assemblies is as followings:

Exterior / Interior Wall Panels:

Cold formed steel members: 0.10 kPa

Fasteners : 0.05 kPa

Total: 0.15 kPa

Floor Panels:

Concrete with metal deck: 1.5 kPa


Fasteners : 0.05 kPa

Total: 1.9 kPa

Roof Panels:

Concrete with metal deck: 1.5 kPa


Fasteners: 0.05 kPa

Total: 1.9 kPa

Precast v.s Light Steel Product Comparison

SECTION 2.6

SECTION 2.5 Precast vs. Cold Formed Steel Framing Comparison

The main specified option for building material for the project is pre-cast concrete system. In which

walls are sandwich panels and floors are 200mm pre-cast slabs. Our proposed solution is a cold-formed

steel framing system. Walls are pre-manufactured panels finished with cement boards at each side and

floors and roof to be pre-manufactured panels with concrete topping and cement board at ceiling side.

Please refer to the below list for comparison between the two options:

DESCRIPTION PRE-CAST SYSTEM COLD-FORMED STEEL FRAMING

Thermal Performance Sandwich wall panel thermal Wall panel thermal

resistance = R 2.2 m2.K/W resistance = R 4.8 m

2.K/W

Fire Resistance Non-Combustible material. Non-Combustible material.

Acoustical Performance STC 50 STC 50

Manufacturing Manufactured at controlled Manufactured at controlled

environment. environment.

Extended production time. Quick production time.

Curing treatment requires Dry Construction, no additional

for hot climate. treatment requires.

Inconsistent surface and panel Dimensionally stable,

dimensions may occur. all panels have consistent

surface and dimensions.

Transportation Costly transportation Inexpensive transportation

because of heavy material. due to very light material.

Damage may occur Damage very unlikely occur.

during transportation.

Construction Heavy crane is required for handling Light crane would be adequate to

and installation. handle and install panels. Most

panels can be lifted by two workers.

Inconsistent shell walls, specially Consistent quality of

surface. shell walls.

Limited field adaptability, no future Ability to be modified in field

retrofits can be done. and future retrofits are possible .

DESCRIPTION PRE-CAST SYSTEM COLD-FORMED STEEL FRAMING

Construction All mechanical, electrical and Mechanical, electrical and

plumbing runs have to be through plumbing runs can be easily and

outside of wall and floor panels. quickly run in the wall panels.

Structural slab thickness for roof Structural slab thickness for roof

and floor is 200mm. and floor is 330mm.

Expensive treatment may be required No joints between panels.

for joints between panels.

Time of construction faster than Time of construction is faster

in-situ concrete. than pre-cast construction

Architectural Finish According to design. According to design.

Advantages of the Proposed Product

SECTION 2.7

SECTION 2.6 Advantages of the Proposed Product:

Lightweight - Cold-formed steel components weigh approximately 80% to 90% less than pre-cast concrete, which

means easier handling during construction and transportation.

High-strength and stiffness - As a result of the cold-forming process, cold-formed steel possesses one of the

highest strength-to-weight ratios of any building material. This high strength and stiffness advantage means more

design flexibility, wider spans and better material usage.

Fast and easy erection and installation - Building components made of cold-formed steel can be fabricated with

high accuracy in a plant and then assembled on job sites, which greatly increases erection efficiency and ensures

construction quality.

Dimensionally stable material - Cold-formed steel does not expand or contract with moisture content. In addition,

it does not split or warp as time goes by. Therefore, it is dimensionally stable. Cracked gypsum sheathed walls, nail

head popping and other common problems with wood-framed structures can be virtually eliminated in buildings

with cold-formed steel stud walls.

No formwork needed - The use of cold-formed steel decks eliminates the formwork for pouring concrete floor. In

addition, composite action between the steel deck and concrete increases floor strength and stiffness.

Durable material - Cold-formed steel is durable because it is termite-proof and rot-proof. In addition, galvanized

cold-formed steel products can provide long-term resistance to corrosion.

Economy in transportation and handling - Lightweight cold-formed members or panels are easy to handle and to

transport. In addition, they can be nested and bundled, reducing the required shipping and storage space.

Non-combustible material - Steel is a non-combustible material and will not contribute fuel to the spread of a fire.

This can result in better fire resistance and lower insurance premiums.

Recyclable nature - Steel is North America No. 1 recycled construction material, with a minimum 25% recycled

content. Steel products used in construction are infinitely recyclable, with no degradation in structural

properties. It can be recycled and reused. Steel-framed housing dramatically reduces the amount of trees

consumed for residential construction, thus conserving one of nature's most precious resources.

Sagging – Cold formed steel members provide the strength and stiffness to accommodate heavy floor toppings

without long term sagging or creep.

Electrical & Plumbing Services – Steel framing supplied with pre-punched (aligned) holes in the web of floor joists

and wall studs. The installation of electrical and plumbing services is easily and quickly accomplished when the pre-

punched holes used for running these services.

Green Benefits

SECTION 2.8

Assessment of embodied carbon for steel

frame construction

A comparison of Genesis steel frame system versus standard

concrete construction in the Masdar development

Revision Description Date Issued by Reviewed by

V1 1st Draft 15 May 09 Jane Hersey Ben Gill

V2 2nd Draft 26th June 09 Jane Hersey

BioRegional Development Group

BedZED Centre

24 Helios Road

Wallington

Surrey SM6 7BZ

Tel : 020 8404 4880

Fax : 020 8404 4893

Email : [email protected]

Website : www.bioregional.com

Comparison of embodied carbon in construction

of lightweight steel frame versus concrete frame

BioRegional 3 of 12

Contents

Background and Objectives ............................................................................................................. 4

Summary of environmental benefits of Genesis system .................................................................. 4

Our Approach .................................................................................................................................. 4

Raw data for model ..........................................................................................................................5

Results..............................................................................................................................................7

Conclusions ....................................................................................................................................12



4 of 12 BioRegional

Background and Objectives

Genesis Worldwide is a leading provider of structural light steel framing technologies. Light steel

frames are an alternative construction system to the use of structural concrete frames. Genesis

Worldwide has done some initial analysis of their system and state that there are significant

environmental benefits to the use of their steel frame system over and above the alternatives of

concrete frames.

Genesis world wide have been in discussions with Masdar about the use of the Genesis system as an

option for their Masdar City development. This flagship development in the United Arab Emirates will

be the world’s first zero-carbon, zero-waste, car-free city.

The purpose of this study is to assess the environmental benefits in terms of the carbon emissions

associated with the construction systems. A comparison has been done using the Masdar Villas as an

example, comparing the use of the steel frame versus a concrete frame construction.

Summary of environmental benefits of Genesis system

• Reduction in required cement

• Major reduction in required steel compared to other steel systems

• Eliminates waste from framing activities

• Major reduction in shipping energy

• Produced in local factories, with benefits to the local economy

• Steel allows full deconstructability and reuse

Our Approach

In order to analyse the embodied carbon of a construction, we have collected data on the quantities of

steel and concrete used in the two construction systems. Data has been provided by Genesis

Worldwide and Masdar. We collected information on the product specifications, quantity of materials

used in construction and source of material.

To calculate the embodied carbon of the construction system, the data was input into a spreadsheet

to calculate the mass of materials. Conversion factors are used to calculate the embodied carbon of

each material taken from best practice sources; namely data from Bath University (2006/8). In

addition to the carbon embodied in the materials as assessment has been done on the impact of

freight transport.



BioRegional 5 of 12

Raw data for model

Masdar branded villas material quantity comparison

Reinforced Concrete Version CFS + Str. Steel Version

Concrete

(m^3)

Reinforcement

Steel (kg) Steel (kg)

Concrete

(m^3)

Reinforcement

Steel (kg) Steel

Unit

Type

Total

Area

(m^2) Total per

m^2 Total

per

m^2 Total

per

m^2

Total

Self

Weight

(kg/m^2) Total per

m^2 Total

per

m^2 Total

per

m^2

Total

Self

Weight

(kg/m^2)

Total

Concrete

Reduction

(%)

Total

Structural

Framing

Self

Weight

Reduction

(%)

2 Bed 238 96 0.40 7250 30.46 1246 5.24 1003.76 6 0.03 1485 6.24 16657 69.99 136.73 94% 86%

3 Bed 271 102 0.38 8100 29.89 1338 4.94 938.15 7 0.03 1653 6.10 18669 68.89 136.98 93% 85%

4 Bed 382 144 0.38 11400 29.84 2688 7.04 941.59 10 0.03 2414 6.32 28554 74.75 143.90 93% 85%

5 Bed 456 178 0.39 13710 30.07 2938 6.44 973.35 13 0.03 2745 6.02 30853 67.66 142.10 93% 85%

Average 337 130 0.39 10115 30.07 2053 5.91 964.21 9 0.03 2074 6.17 23683 70.32 139.93 93% 85%

Calculation method and assumptions1

1. General

1.1 Podium slab, foundation and level 1 framing remains concrete and the same thickness for both version. Therefore in calculations above considered

only above podium slab

1.2 Density of concrete is 2,400 kg per m3

1 All these assumptions have been provided by Genesis



6 of 12 BioRegional

2. Reinforced Concrete Version

2.1 Concrete volume includes:

a. Load bearing concrete walls and columns

b. All other perimeter walls

c. Floor and roof slab

2.2 Reinforcement steel has been calculated with following assumptions:

a. For concrete walls 70 kg per each m^3 concrete

b. For floor and roof 1 way slabs 90 kg per each m^3 concrete

2.3 Steel quantity includes:

a. Hot rolled steel framing at cantilevered section

b. Interior non load bearing partition walls (assumed as cold formed steel walls)

3. Cold Formed Steel + Structural Steel Version

3.1 Concrete volume includes:

a. Concrete floor over metal deck at level 2 floor

3.2 Reinforcement steel quantity includes:

a. Metal deck and reinforcement mesh at level 2 floor

b. Metal deck at roof level

3.3 Steel quantity includes:

a. Hot rolled and cold formed steel framing for super structure above podium slab including non load bearing partition walls



BioRegional 7 of 12

Results

The embodied carbon emissions of a building are attributed to the manufacture of materials, their

transport and assembly on site, maintenance and replacement, disassembly and decomposition.

Burning fossil fuels is responsible for most CO2 production however some will be due to converting

limestone into cement for example, which also releases fossilised stores of carbon.

The data below details the embodied carbon of the construction of the Masdar villas.

Materials

Key assumptions

The steel used in the main frame was assumed to be general steel with a typical UK recycled content,

resulting in an embodied carbon figure of 1.77kgCO2/kg. It may be possible for higher levels of

recycled steel to be sourced. However, since all steel is recycled anyway it is not considered

appropriate to allocate credit for higher levels of recycled material, as this just reduced the recycled

content, and increases carbon emissions elsewhere.

Table 1: Conversion factors for concrete (Bath, ICE data)

Concrete (RC40) Kg CO2 per kg material

CEM 1 0.169

25% flyash 0.132

50% flyash 0.096

Assessment of materials with 50% flyash concrete mix

The Masdar development is aiming to achieve very high environmental standards, and as a result will

be using concrete with a high flyash content which provides a low embodied carbon content.

However, potential savings have also been assessed against a no flyash content concrete in order to

show the more likely scenario in another development.

Reinforced Concrete Version, 50% flyash

Embodied carbon 204 tonnes CO2

Material

component Quantity

Material

density Mass kgCO2/kg

Embodied

carbon

Concrete 520 m3 2,400 kg/m3 1,248,000 kg 0.096 119,808

Reinforcement steel 40,460 kg 40,460 kg 1.710 69,187

Structural steel 8,210 kg 8,210 kg 1.770 14,532

TOTAL 1,296,670 kg 203,526 kgCO2



8 of 12 BioRegional

Genesis light weight steel version, 50% flyash


Material component Quantity Material


Embodied

carbon

Concrete 36 m3 2,400 kg/m3 86,400 kg 0.096 8,294



TOTAL 189,430 kg 190,160 kgCO2

Assessment of materials with 0% flyash concrete mix

Reinforced Concrete Version, 0% flyash


Material

component Quantity

Material


Embodied

carbon

Concrete 520 m3 2,400 kg/m3 1,248,000 kg 0.169 210,912



TOTAL 1,296,670 kg 294,811 kgCO2

Genesis light weight steel version, 0% flyash


Material component Quantity Material


Embodied

carbon

Concrete 36 m3 2,400 kg/m3 86,400 kg 0.169 14,602



TOTAL 189,430 kg 196,467 kgCO2

50% flyash concrete 0% flyash concrete

Total embodied

carbon

Embodied

carbon by area

(Kg CO2 per m2)

Total embodied

carbon

Embodied

carbon by area

(Kg CO2 per m2)

Reinforced Concrete Version 204 tonnes CO2 151 295 tonnes CO2 219

Genesis light weight steel 190 tonnes CO2 141 196 tonnes CO2 146

Percentage saving 7% 33%



BioRegional 9 of 12

The results show that there are significant embodied carbon savings from the use of the Genesis steel

frame system. The savings for the 50% flyash mix are 7% overall, which is perhaps not as significant as

might be expected. This is because steel has a very high embodied carbon footprint per tonne

compared to concrete and the concrete that is being used in Masdar already has a relative low impact.

When we compare the savings from the steel frame system compared to typical 0% flyash concrete

the embodied carbon is 33% lower than the concrete structure. Both of these examples show that the

steel frame system delivers a significant reduction in embodied carbon emissions in materials.

Water

Water in the UAE is generally produced through desalination meaning that the water has a high

embodied energy. Water made using reverse osmosis is responsible for 1.78kg CO2 per m32 , which is

over six times more embodied carbon than typical European water.

The steel framing system by reducing the quantity of concrete also reduces the quantity of water used.

However, an assessment of the high embodied carbon in the water needed for this development

shows that in this context it has little overall effect on the embodied carbon of the whole construction.

However, there are still environmental benefits from this reduction in water consumption in an area

with water scarcity.

Transport

The table below illustrates the impacts of the transport of the materials and the key assumptions

regarding mode and source. The steel framed system saves 7 tonnes of CO2 from freight based on this

system, or 51%. It should be noted though that the impact of the reinforced concrete version is

heavily dependent on where the aggregate is sourced, and therefore without accurate data on this

there is significant uncertainty in the figure.

Reinforced Concrete Version

STRUCTURAL 14 tonnes CO2

Material

component Mass Source Mode Distance Tonne-km

kgCO2

/tonne

-km

Transport

emissions

kgCO2

Cement

186,667 kg UAE Road 60 km 11,200 0.163

1,829

Aggregate

960,000 kg UAE Road 60 km 57,600 0.163

9,406

Reinforcement

steel 40,460 kg Egypt Shipping 5,499 km 222,473 0.011

2,447

Structural steel 8,210 kg Egypt Shipping 5,499 km 45,143 0.011 497

2 WWF, (2007). Making water Desalination: option or distraction for a thirsty world?



10 of 12 BioRegional

Genesis light weight steel version

STRUCTURAL: 7 tonnes CO2

Material

component Mass Source Mode Distance Tonne-km

kgCO2

/tonne

-km

Transport

emissions

Cement 12,923 kg UAE Road 60 km 775 0.163 127

Aggregate 66,462 kg UAE Road 60 km 3,988 0.163 651

Reinforcement

steel 8,297 kg Egypt Shipping 5,499 km 45,622 0.011 502

Structural steel 94,733 kg Egypt Shipping 5,499 km 520,898 0.011 5,730

Total carbon emissions

The table below shows the embodied carbon savings from the Genesis steel frame system compared

with 50% flyash concrete are 10% overall, when both transport and materials are taken into account.

However, when compared to a standard concrete the savings are 34%. This saving is due to the

reduction in mass of concrete required using the light weight steel frame system.


Embodied carbon

Reinforced

Concrete Version

Genesis light

weight steel

version

Reinforced

Concrete

Version

Genesis light

weight steel

version

Material 204 190 295 196

Transport 14 7 14 7

TOTAL 217.9 197.2 309.0 203.5

Per square metre

(Kg CO2 per m2) 162 146 229 151

Percentage reduction 10% 34%

End of life assessment

Steel is such a high value material that when a building has come to the end of its life and is being

taken down the structural steel would nearly always be recovered and recycled. Reinforcement steel

is also now often recovered from the concrete for recycling. Concrete cannot be recycled in the same

way, and is generally either landfilled or crushed then used as an aggregate replacement. This is a

downcycling of the material which results in a material of lower value and quality.



BioRegional 11 of 12

Using Simapro lifecycle assessment software a basic screening was completed using generic data

from the Ecoinvent library. This is a different dataset than used for the rest of this report, in order to

enable an assessment of the contribution of the waste disposal route of the construction materials to

the carbon footprint. The recycling and downcycling of the construction materials would contribute

another 1% to 3% of the total carbon footprint.

The preferred route for waste disposal is to deconstruct and reuse the structural steel as this provides

an avoidance of burden from the use of primary and secondary steel. An analysis was done assuming

that 50% of the structural steel could be recovered and reused in another project. The results are

shown in the table below.


Embodied carbon

Reinforced

Concrete Version

Genesis light

weight steel

version

Reinforced

Concrete

Version

Genesis light

weight steel

version

Material 204 190 295 196

Transport 14 7 14 7

Reuse discount -7 -84 -7 -84

TOTAL 211 113 302 120

Percentage reduction 46% 60%

The results show that if the steel can be reused in this way the avoided burdens are significant. In the

case of the Masdar development with 50% flyash concrete there is a 46% reduction compared to the

concrete structure.

Gaps in the analysis

There are a number of issues that this study has not been able to address, but which will have impacts

on the embodied carbon in these results. It is felt that the results in this study may be an

underestimate of the savings that could be achieved through the steel framing system. Items that are

not included due to lack of data are:

• The model includes the reduced quantity of concrete required in the steel frame

construction. However, it is possible that the lightweight steel structure may enable an

even higher proportion of fly ash to be used in the concrete mix due to the reduced

strength requirements (leading to a lower impact concrete).

• The Genesis factory in UAE is powered by zero carbon energy. The data available for

embodied carbon in steel is based on typical manufacturing conditions and therefore the

impact of the lightweight steel frame would be lower than is stated here.

• There may be scope to design a lighter-weight ground slab and foundations in the case of

the steel frame construction.



12 of 12 BioRegional

• This analysis does not include any assessment of the in-use energy demand and how this

may be affected by the use of the Genesis steel frame system. The Masdar development

is in an arid climate where night time temperature exceeds a comfortable room

temperature throughout most of the year. This means that thermal mass has a negative

impact on the temperature in housing. The Genesis steel frame system reduces thermal

mass and therefore will enable a reduction in energy demand for cooling in the homes

compared to the proposed construction method.

Conclusions

This assessment shows that at Masdar there would be significant savings of 10% in the carbon

emissions associated with the Genesis construction system using light weight steel frames compared

to concrete frames of 50% flyash content. It can also be seen that these savings are much larger (34%)

when comparing to a standard concrete mix.

An examination of the end of life options for these buildings has shown that reuse of the structural

steel can have an even greater impact on the potential savings from this system. Embodied carbon

savings could be increased to 46% in the case of Masdar if half of the steel is reused. A key

recommendation therefore must be that planning for deconstruction and reuse is one of the most

important factors in reducing the embodied carbon footprint of construction.

However, it is also important to note that this is a fairly limited study, focusing just on a few

components of the system. Also, the available data is based on average UK economy and there may

be significant differences in the UAE. In order to fully examine the potential savings a more detailed

life cycle assessment would be required.

Given more time, and a greater level of data, Simapro could be used to create a more detailed life

cycle assessment of these two construction systems.

Overview of Cold Formed Steel Framing

SECTION 3.1

SECTION 3.1 Overview of Cold Formed Steel Framing

Although "Steel" may conjure up images of a heavy, cumbersome material for construction, steel studs

from coated sheet steel products are just the opposite. Steel studs offer a strong, accurate,

dimensionally stable and durable framing system, and are ideal for residential construction.

Residential steel framing members were originally designed as a substitute for wood framing. However,

they are now being manufactured in systems, which reflect the superior strength and consistency of

steel. The variety of available steel shapes, strengths and sizes has expanded beyond that of standard

lumber, and this versatility offers the advantage of savings in both material cost and time while

delivering a consistently high quality product.

Environmental and economic concerns have prompted the building industry to research alternative

building materials and methods. This, in addition to its construction benefits and excellent recycling

capabilities, is making steel framing a growing choice for residential construction. This follows the long

time use of steel framing in commercial construction where steel has proven quality and performance

records.

Cold-formed steel has been widely used in buildings, automobiles, equipment, home and office

furniture, utility poles, storage racks, grain bins, highway products, drainage facilities, and bridges. Its

popularity can be attributed to ease of mass production and prefabrication, uniform quality, lightweight

designs, economy in transportation and handling, and quick and simple erection or installation.

In building construction, cold-formed steel products can be classified into three categories: members,

panels, and prefabricated assemblies. Typical cold-formed steel members such as studs, track, purlins,

girts and angles are mainly used for carrying loads while panels and decks constitute useful surfaces

such as floors, roofs and walls, in addition to resisting the in-plane and out-of plane surface loads.

Prefabricated cold-formed steel assemblies include roof trusses, panelized walls or floors, and other

prefabricated structural assemblies. Approximately 40% of the total steel used in building construction is

cold-formed steel. Cold-formed steel possesses a significant market share because of its advantages

over other construction materials and the industry-wide support provided by various organizations that

promote cold-formed steel research and products, including codes and standards development that is

spearheaded by the American Iron and Steel Institute (AISI).

Cold-formed steel has become a competitive building material in the last two decades as a result of

industry-wide efforts. The use of cold-formed steel in the structural system of residential construction

has taken hold in some site building markets but potentially offers far more value to the manufactured

home industry.

References: Canadian Sheet Steel Building Institute

Manufactured Housing Research Alliance

Codes and Standards

SECTION 3.2

Section 3.2 Codes & Standards

Cold formed steel framing is fully specified in a wide range of building codes.

3.2.A Applicable Building Codes

• UBC 1997, Uniform Building Code

• IBC 2009, International Building Code (Adopted by Abu Dhabi Municipality starting Jan 1, 2010)

• NBC 2005, National Building Code

• BS, British Standards

• Eurocode

3.2.B Design Standards

• CSA S136-07, AISI S100, North American Specification for the Design of Cold Formed Steel

Structural Members

• BS 5950 – 5, Structural use of steel work in building, Structural use of Cold Formed Steel

Members

3.2.C Manufacturing Standards

• ASTM C645, Standard Specification for Nonstructural Steel Framing Members

• ASTM C955, Standard Specification for Load-Bearing (Transverse and Axial) Steel Studs, Runners

(Tracks), and Bracing or Bridging

3.2.D Material Standards

• ASTM A653 / A653M - 09a Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or

Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process

Or

• ASTM A792 / A792M - 09a Standard Specification for Steel Sheet, 55 % Aluminum-Zinc Alloy-

Coated by the Hot-Dip Process

GENESIS SYSTEM HAS BEEN CERTIFIED BY INTERNATIONAL CODE COUNSIL (ICC) WITH

PRODUCT NUMBER = ESR - 2849

Sample Approved Drawings

SECTION 3.3

Typical Construction Schedule

SECTION 4.1

ID Task Name Duration

1 Engineering 5 days2 Fabrication 14 days?3 Ground Floor Walls 3 days?4 First Floor Panels 3 days?5 First Floor Walls 3 days?6 Roof Panels 3 days?7 Sloped Roof Trusses 2 days?8 Installation 15 days?9 Ground Floor Walls 3 days?

10 First Floor Panels 3 days?11 Ground Floor Sheathing 3 days?12 First Floor Metal Deck + Concrete 3 days?13 First Floor Walls 3 days?14 Roof Panels 3 days?15 First Floor Sheathing 4 days?16 Roof Metal Deck + Concrete 4 days?

S S M T W T F S S M T W T F S S M T W T F S S M T W TW1 W2 W3 W4

TYPICAL WORK SCHEDULE FOR ONE VILLA(WITH FIVE MEN INSTALLATION CREW)

Page 1

Joanna

SAMPLE

PRODUCTION AND INSTALLATION CAPACITY

• Production capacity is up to 200,000 m2 of built up area per year (based on 2 shifts)

• Average speed of site installation is 2500 m2 per week (based on 10 x 6 man crews) this can be increased by adding additional crews to site.

• Company employees (within UAE).

• Number of permanent head office employees. (32) • Number of permanent construction site employees. (16) • Number of temporary contractual construction site employees. (16+)

STAFF STRENGTH • Manazil Steel Framing has 32 white collar staff including 6 dedicated Engineers and Detailers in addition to; staff for Financial Management, Administration, Marketing and Executive Management. • Factory and onsite labour capacity is adjusted according to demand as we have an open contract with Sawa’d Human Resources.

Cold Formed Steel (ASTM A653)

SECTION 5.1

Designation: A 653/A 653M – 06a

Standard Specification forSteel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process1

This standard is issued under the fixed designation A 653/A 653M; the number immediately following the designation indicates the yearof original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.A superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

1. Scope*

1.1 This specification covers steel sheet, zinc-coated (gal-vanized) or zinc-iron alloy-coated (galvannealed) by the hot-dip process in coils and cut lengths.

1.2 The product is produced in various zinc or zinc-ironalloy-coating weights [masses] or coating designations asshown in Table 1.

1.3 Product furnished under this specification shall conformto the applicable requirements of the latest issue of Specifica-tion A 924/A 924M, unless otherwise provided herein.

1.4 The product is available in a number of designations,grades and classes in four general categories that are designedto be compatible with different application requirements.

1.4.1 Steels with mandatory chemical requirements andtypical mechanical properties.

1.4.2 Steels with mandatory chemical requirements andmandatory mechanical properties.

1.4.3 Steels with mandatory chemical requirements andmandatory mechanical properties that are achieved throughsolid-solution or bake hardening.

1.5 This specification is applicable to orders in eitherinch-pound units (as A 653) or SI units (as A 653M). Values ininch-pound and SI units are not necessarily equivalent. Withinthe text, SI units are shown in brackets. Each system shall beused independently of the other.

1.6 Unless the order specifies the “M” designation (SIunits), the product shall be furnished to inch-pound units.

1.7 The text of this specification references notes andfootnotes that provide explanatory material. These notes andfootnotes, excluding those in tables and figures, shall not beconsidered as requirements of this specification.

1.8 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-

priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.

2. Referenced Documents

2.1 ASTM Standards: 2

A 90/A 90M Test Method for Weight [Mass] of Coating onIron and Steel Articles with Zinc or Zinc-Alloy Coatings

A 370 Test Methods and Definitions for Mechanical Testingof Steel Products

A 568/A 568M Specification for Steel, Sheet, Carbon,Structural, and High-Strength, Low-Alloy, Hot-Rolled andCold-Rolled, General Requirements for

A 902 Terminology Relating to Metallic Coated Steel Prod-ucts

A 924/A 924M Specification for General Requirements forSteel Sheet, Metallic-Coated by the Hot-Dip Process

D 2092 Guide for Preparation of Zinc-Coated (Galvanized)Steel Surfaces for Painting

E 517 Test Method for Plastic Strain Ratio r for Sheet MetalE 646 Test Method for Tensile Strain-Hardening Exponents

(n -Values) of Metallic Sheet Materials2.2 ISO Standard:ISO 3575 Continuous Hot-Dip Zinc-Coated Carbon Steel of

Commercial and Drawing Qualities3

ISO 4998 Continuous Hot-Dip Zinc-Coated Carbon Steel ofStructural Quality3

3. Terminology

3.1 Definitions—See Terminology A 902 for definitions ofgeneral terminology relating to metallic-coated hot-dip prod-ucts.

3.2 Definitions of Terms Specific to This Standard:3.2.1 bake hardenable steel, n—steel sheet in which a

significant increase in yield strength is realized when moderate

1 This specification is under the jurisdiction of ASTM Committee A05 onMetallic-Coated Iron and Steel Products and is the direct responsibility ofSubcommittee A05.11 on Sheet Specifications.

Current edition approved Nov. 15, 2006. Published January 2007. Originallyapproved in 1994. Last previous edition approved in 2006 as A 653/A 653M - 06.

2 For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at [email protected]. For Annual Book of ASTMStandards volume information, refer to the standard’s Document Summary page onthe ASTM website.

3 Available from American National Standards Institute (ANSI), 25 W. 43rd St.,4th Floor, New York, NY 10036.

1

*A Summary of Changes section appears at the end of this standard.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

heat treatment, such as that used for paint baking, followsstraining or cold working.

3.2.2 differentially coated, n—galvanized steel sheet havinga specified “coating designation” on one surface and a signifi-cantly lighter specified “coating designation” on the othersurface.

3.2.2.1 Discussion—The single side relationship of eitherspecified “coating designation” is the same as shown in thenote of Table 1 regarding uniformity of coating.

3.2.3 high strength low alloy steel, n—a specific group ofsheet steels whose strength is achieved through the use ofmicroalloying elements such as columbium (niobium), vana-dium, titanium, and molybdenum resulting in improved form-

ability and weldability than is obtained from conventionalcarbon-manganese steels.

3.2.3.1 Discussion—Producers use one or a combination ofmicroalloying elements to achieve the desired properties. Theproduct is available in two designations, HSLAS andHSLAS-F. Both products are strengthened with microalloys,but HSLAS-F is further treated to achieve inclusion control.

3.2.4 minimized spangle, n—the finish produced on hot-dipzinc-coated steel sheet in which the grain pattern is visible tothe unaided eye, and is typically smaller and less distinct thanthe pattern visible on regular spangle.

3.2.4.1 Discussion—This finish is produced by one of twomethods: either (1) the zinc crystal growth has been started but

TABLE 1 Weight [Mass] of Coating RequirementsA,B,C

NOTE 1— Use the information provided in 8.1.2 to obtain the approximate coating thickness from the coating weight [mass].

Minimum RequirementD

Triple-Spot Test Single-Spot Test

Inch-Pound Units

Type Coating Designation Total Both Sides, oz/ft2 One Side Total Both Sides, oz/ft2

Zinc G360 3.60 1.28 3.20G300 3.00 1.04 2.60G235 2.35 0.80 2.00G210 2.10 0.72 1.80G185 1.85 0.64 1.60G165 1.65 0.56 1.40G140 1.40 0.48 1.20G115 1.15 0.40 1.00G100 1.00 0.36 0.90G90 0.90 0.32 0.80G60 0.60 0.20 0.50G40 0.40 0.12 0.30G30 0.30 0.10 0.25G01 no minimum no minimum no minimum

Zinc-iron alloy A60 0.60 0.20 0.50A40 0.40 0.12 0.30A25 0.25 0.08 0.20A01 no minimum no minimum no minimum

SI Units

Type Coating Designation Total Both Sides, g/m2 One Side Total Both Sides, g/m2

Zinc Z1100 1100 390 975Z900 900 316 790Z700 700 238 595Z600 600 204 510Z550 550 190 475Z500 500 170 425Z450 450 154 385Z350 350 120 300Z305 305 110 275Z275 275 94 235Z180 180 60 150Z120 120 36 90Z90 90 30 75

Z001 no minimum no minimum no minimumZinc-iron alloy ZF180 180 60 150

ZF120 120 36 90ZF75 75 24 60ZF001 no minimum no minimum no minimum

AThe coating designation number is the term by which this product is specified. Because of the many variables and changing conditions that are characteristic ofcontinuous hot-dip coating lines, the zinc or zinc-iron alloy coating is not always evenly divided between the two surfaces of a coated sheet; nor is it always evenlydistributed from edge to edge. However, the minimum triple-spot average coating weight (mass) on any one side shall not be less than 40 % of the single-spot requirement.

BAs it is an established fact that the atmospheric corrosion resistance of zinc or zinc-iron alloy-coated sheet products is a direct function of coating thickness (weight(mass)), the selection of thinner (lighter) coating designations will result in almost linearly reduced corrosion performance of the coating. For example, heavier galvanizedcoatings perform adequately in bold atmospheric exposure whereas the lighter coatings are often further coated with paint or a similar barrier coating for increasedcorrosion resistance. Because of this relationship, products carrying the statement “meets ASTM A 653/A 653M requirements” should also specify the particular coatingdesignation.

CInternational Standard, ISO 3575, continuous hot-dip zinc-coated carbon steel sheet contains Z100 and Z200 designations and does not specify a ZF75 coating.DNo minimum means that there are no established minimum requirements for triple- and single-spot tests.

A 653/A 653M – 06a

2

arrested by special production practices during solidification ofthe zinc, or (2) the zinc crystal growth is inhibited by acombination of coating-bath chemistry plus cooling duringsolidification of the zinc. Minimized spangle is normallyproduced in coating designations G90 [Z275] and lighter.

3.2.5 regular spangle, n—the finish produced on hot-dipzinc-coated steel sheet in which there is a visible multifacetedzinc crystal structure.

3.2.5.1 Discussion—Solidification of the zinc coating istypically uncontrolled, which produces the variable grain sizeassociated with this finish.

3.2.6 spangle-free, n—the uniform finish produced on hot-dip zinc-coated steel sheet in which the visual spangle pattern,especially the surface irregularities created by spangle forma-tion, is not visible to the unaided eye.

3.2.6.1 Discussion—This finish is produced when the zinccrystal growth is inhibited by a combination of coating-bathchemistry, or cooling, or both during solidification of the zinc.

3.2.7 solid-solution hardened steel or solution hardenedsteel, n—steel sheet strengthened through additions of substi-tutional alloying elements such as Mn, P, or Si.

3.2.7.1 Discussion—Substitutional alloying elements suchas Mn, P, and Si can occupy the same sites as iron atoms withinthe crystalline structure of steels. Strengthening arises as aresult of the mismatch between the atomic sizes of theseelements and that of iron.

3.2.8 zinc-iron alloy, n—a dull grey coating with no spanglepattern that is produced on hot-dip zinc-coated steel sheet.

3.2.8.1 Discussion—Zinc-iron alloy coating is composedentirely of inter-metallic alloys. It is typically produced bysubjecting the hot-dip zinc-coated steel sheet to a thermaltreatment after it emerges from the molten zinc bath. This typeof coating is suitable for immediate painting without furthertreatment except normal cleaning (refer to Guide D 2092). Thelack of ductility of the alloy coating presents a potential forpowdering, etc.

4. Classification

4.1 The material is available in several designations asfollows:

4.1.1 Commercial steel (CS Types A, B, and C),4.1.2 Forming steel (FS Types A and B),4.1.3 Deep drawing steel (DDS Types A and C),4.1.4 Extra deep drawing steel (EDDS),4.1.5 Structural steel (SS),4.1.6 High strength low alloy steel (HSLAS),4.1.7 High strength low alloy steel with improved formabil-

ity (HSLAS-F),4.1.8 Solution hardened steel (SHS), and4.1.9 Bake hardenable steel (BHS).4.2 Structural steel, high strength low alloy steel, solution

hardened steel, and bake hardenable steel are available inseveral grades based on mechanical properties. Structural SteelGrade 50 [340] is available in four classes based on tensilestrength. Structural Steel Grade 80 [550] is available in twoclasses, based on chemistry.

4.3 The material is available as either zinc-coated or zinc-iron alloy-coated in several coating weights [masses] orcoating designations as shown in Table 1, and

4.3.1 The material is available with the same or differentcoating designations on each surface.

5. Ordering Information

5.1 Zinc-coated or zinc-iron alloy-coated sheet in coils andcut lengths is produced to thickness requirements expressed to0.001 in. [0.01 mm]. The thickness of the sheet includes boththe base metal and the coating.

5.2 Orders for product to this specification shall include thefollowing information, as necessary, to adequately describe thedesired product:

5.2.1 Name of product (steel sheet, zinc-coated (galvanized)or zinc-iron alloy-coated (galvannealed)),

5.2.2 Designation of sheet [CS (Types A, B, and C), FS(Types A and B), DDS (Types A and C), EDDS, SS, HSLAS,HSLAS-F, SHS, or BHS].

5.2.2.1 When a CS type is not specified, CS Type B will befurnished. When a FS type is not specified, FS Type B will befurnished. When a DDS type is not specified, DDS Type A willbe furnished.

5.2.3 When a SS, HSLAS, HSLAS-F, SHS, or BHS desig-nation is specified, state the grade, or class, or combinationthereof.

5.2.4 ASTM designation number and year of issue, as A 653for inch-pound units or A 653M for SI units.

5.2.5 Coating designation,5.2.6 Chemically treated or not chemically treated,5.2.7 Oiled or not oiled,5.2.8 Minimized spangle (if required),5.2.9 Extra smooth (if required),5.2.10 Phosphatized (if required),5.2.11 Dimensions (show thickness, minimum or nominal,

width, flatness requirements, and length, if cut lengths). Thepurchaser shall specify the appropriate table of thicknesstolerances in Specification A 924/A 924M that applies to theorder, that is, the table of thickness tolerances for 3⁄8-in.[10-mm] edge distance, or the table of thickness tolerances for1-in. [25-mm] edge distance.

5.2.12 Coil size requirements (specify maximum outsidediameter (OD), acceptable inside diameter (ID), and maximumweight [mass]),

5.2.13 Packaging,5.2.14 Certification, if required, heat analysis and mechani-

cal property report,5.2.15 Application (part identification and description), and5.2.16 Special requirements (if any).5.2.16.1 If required, the product may be ordered to a

specified base metal thickness (see Supplementary Require-ment S1.)

NOTE 1—Typical ordering descriptions are as follows: steel sheet,zinc-coated, commercial steel Type A, ASTM A 653, Coating DesignationG 115, chemically treated, oiled, minimum 0.040 by 34 by 117 in., forstock tanks, or steel sheet, zinc-coated, high strength low alloy steel Grade340, ASTM A 653M, Coating Designation Z275, minimized spangle, notchemically treated, oiled, minimum 1.00 by 920 mm by coil, 1520-mmmaximum OD, 600-mm ID, 10 000-kg maximum, for tractor inner fender.

A 653/A 653M – 06a

3

NOTE 2—The purchaser should be aware that there are variations inmanufacturing practices among the producers and therefore is advised toestablish the producer’s standard (or default) procedures for thicknesstolerances.

6. Chemical Composition

6.1 Base Metal:6.1.1 The heat analysis of the base metal shall conform to

the requirements shown in Table 2 for CS (Types A, B, and C),FS (Types A and B), DDS (Types A and C), and EDDS, andTable 3 for SS, HSLAS, HSLAS-F, SHS, and BHS.

6.1.2 Each of the elements listed in Tables 2 and 3 shall beincluded in the report of heat analysis. When the amount ofcopper, nickel, chromium, or molybdenum is less than 0.02 %,report the analysis as either <0.02 % or the actual determinedvalue. When the amount of vanadium, titanium, or columbiumis less than 0.008 %, report the analysis as either <0.008 % orthe actual determined value. When the amount of boron is lessthan 0.0005 %, report as <0.0005 % or the actual determinedvalue.

6.1.3 See Specification A 924/A 924M for chemical analy-sis procedures and product analysis tolerances.

6.2 Zinc Bath Analysis—The bath metal used in continuoushot-dip galvanizing shall contain not less than 99 % zinc.

NOTE 3—To control alloy formation and promote adhesion of the zinccoating with the steel base metal, the molten coating metal compositionnormally contains a percentage of aluminum usually in the range from0.05 to 0.25. This aluminum is purposely supplied to the molten coatingbath, either as a specified ingredient in the zinc spelter or by the additionof a master alloy containing aluminum.

7. Mechanical Properties

7.1 Structural steel, high-strength low-alloy steel, highstrength low alloy steel with improved formability, solutionhardened steel, and bake hardenable steel shall conform to themechanical property requirements in Table 4 for the grade, orclass, or both.

7.1.1 Bake hardenable steel shall conform to bake harden-ing index requirements included in Table 4 for the gradespecified. The method for measuring the bake hardening indexis described in the Annex. Bake hardenable steel shall exhibita minimum increase in yield strength of 4 ksi [25 MPa] asbased on the upper yield point or of 3 ksi [20 MPa] as based onthe lower yield stress, after a prestrained specimen has beenexposed to a standard bake cycle (340°F [170°C] for 20minutes).

TABLE 2 Chemical RequirementsA

Composition, %—Heat Analysis Element, max (unless otherwise shown)

Designation Carbon Manganese Phosphorus Sulfur Aluminum,min

Cu Ni Cr Mo V Cb TiB N B

CS Type AC,D,E 0.10 0.60 0.030 0.035 . . . 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . . . . .CS Type BF,C 0.02 to

0.150.60 0.030 0.035 . . . 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . . . . .

CS Type CC,D,E 0.08 0.60 0.100 0.035 . . . 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . . . . .FS Type AC,G 0.10 0.50 0.020 0.035 . . . 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . . . . .FS Type BF,C 0.02 to

0.100.50 0.020 0.030 . . . 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . . . . .

DDS Type AD,E 0.06 0.50 0.020 0.025 0.01 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . . . . .DDS Type CH 0.02 0.50 0.020 to

0.1000.025 0.01 0.25 0.20 0.15 0.06 0.10 0.10 0.15 . . . . . .

EDDSH 0.02 0.40 0.020 0.020 0.01 0.25 0.20 0.15 0.06 0.10 0.10 0.15 . . . . . .

AWhere an ellipsis (. . .) appears in this table, there is no requirement, but the analysis shall be reported.BFor steels containing more than 0.02 % carbon, titanium is permitted at the producer’s option, to the lesser of 3.4N + 1.5S or 0.025 % for the purpose of stabilization.CWhen a deoxidized steel is required for the application, the purchaser has the option to order CS and FS to a minimum of 0.01 % total aluminum.DSteel is permitted to be furnished as a vacuum degassed or chemically stabilized steel, or both, at the producer’s option.EFor carbon levels less than or equal to 0.02 %, vanadium, columbium, or titanium, or combinations thereof are permitted to be used as stabilizing elements at the

producer’s option. In such cases, the applicable limit for vanadium and columbium shall be 0.10 % max and the limit for titanium shall be 0.15 % max.FFor CS and FS, specify Type B to avoid carbon levels below 0.02 %.GShall not be furnished as a stabilized steel.HShall be furnished as a stabilized steel.

TABLE 3 Chemical RequirementsA

Designation

Composition, %—Heat Analysis Element, max(unless otherwise shown)

Carbon Manganese Phosphorus Sulfur Si Al, min Cu Ni Cr Mo VB CbB TiB,C,D N

SS33 [230] 0.20 1.35 0.04 0.04 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . .37 [255] 0.20 1.35 0.10 0.04 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . .40 [275] 0.25 1.35 0.10 0.04 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . .50 [340] Class 1, 2, and 4 0.25 1.35 0.20 0.04 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . .50 [340] Class 3 0.25 1.35 0.04 0.04 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . .55 [380] 0.25 1.35 0.04 0.04 0.25 0.20 0.15 0.06 0.008 0.008 0.025 . . .80 [550] Class 1 0.20 1.35 0.04 0.04 0.25 0.20 0.15 0.06 0.008 0.015 0.025 . . .80 [550] Class 2E 0.02 1.35 0.05 0.02 0.25 0.20 0.15 0.06 0.10 0.10 0.15 . . .

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TABLE 3 Continued

Designation

Composition, %—Heat Analysis Element, max(unless otherwise shown)

Carbon Manganese Phosphorus Sulfur Si Al, min Cu Ni Cr Mo VB CbB TiB,C,D N

HSLASF

40 [275] 0.20 1.20 . . . 0.035 . . . 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

50 [340] 0.20 1.20 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

55 [380] Class 1 0.25 1.35 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

55 [380] Class 2 0.15 1.20 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

60 [410] 0.20 1.35 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

70 [480] 0.20 1.65 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

80 [550] 0.20 1.65 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

HSLAS-FF,G

40 [275] 0.15 1.20 . . . 0.035 . . . 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

50 [340] 0.15 1.20 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

55 [380] Class 1 0.20 1.35 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

55 [380] Class 2 0.15 1.20 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

60 [410] 0.15 1.20 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

70 [480] 0.15 1.65 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

80 [550] 0.15 1.65 . . . 0.035 0.20 0.20 0.15 0.16 0.01 min 0.005min

0.01min

. . .

SHSD 0.12 1.50 0.12 0.030 . . . . . . 0.20 0.20 0.15 0.06 0.008 0.008 0.025 . . .BHSD 0.12 1.50 0.12 0.030 . . . . . . 0.20 0.20 0.15 0.06 0.008 0.008 0.025 . . .

AWhere an ellipsis (. . .) appears in this table there is no requirement, but the analysis shall be reported.BFor carbon levels less than or equal to 0.02 %, vanadium, columbium, or titanium, or combinations thereof, are permitted to be used as stabilizing elements at the

producer’s option. In such cases, the applicable limit for vanadium and columbium shall be 0.10% max., and the limit for titanium shall be 0.15 % max.CTitanium is permitted for SS steels at the producer’s option, to the lesser of 3.4N +1.5S or 0.025 % for the purpose of stabilization.DFor steels containing more than 0.02 % carbon, titanium is permitted to the lesser of 3.4N + 1.5S or 0.025 %.EShall be furnished as a stabilized steel.FHSLAS and HSLAS-F steels commonly contain the strengthening elements columbium, vanadium, and titanium added singly or in combination. The minimum

requirements only apply to the microalloy elements selected for strengthening of the steel.GHSLAS-F steel shall be treated to achieve inclusion control.

TABLE 4 Mechanical Requirements, Base Metal (Longitudinal)

Inch-Pound Units

Designation GradeYield

Strength,min, ksi

TensileStrength,min, ksiA

Elongation in2 in., min,

%A

Bake Hardening Index, min, ksiUpper Yield/Lower YieldA

SS 33 33 45 20 . . .37 37 52 18 . . .40 40 55 16 . . .

50 Class 1 50 65 12 . . .50 Class 2 50 . . . 12 . . .50 Class 3 50 70 12 . . .50 Class 4 50 60 12 . . .

55 55 70 11 . . .80 Class 1B 80C 82 . . . . . .80 Class 2B,D 80C 82 . . . . . .

HSLAS 40 40 50E 22 . . .50 50 60E 20 . . .

55 Class 1 55 70E 16 . . .55 Class 2 55 65E 18 . . .

60 60 70E 16 . . .70 70 80E 12 . . .80 80 90E 10 . . .

HSLAS-F 40 40 50E 24 . . .50 50 60E 22 . . .

55 Class 1 55 70E 18 . . .55 Class 2 55 65E 20 . . .

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TABLE 4 Continued

Inch-Pound Units


Strength,min, ksi

TensileStrength,min, ksiA

Elongation in2 in., min,

%A

Bake Hardening Index, min, ksiUpper Yield/Lower YieldA

60 60 70E 18 . . .70 70 80E 14 . . .80 80 90E 12 . . .

SHS 26 26 43 32 . . .31 31 46 30 . . .35 35 50 26 . . .41 41 53 24 . . .44 44 57 22 . . .

BHS 26 26 43 30 4 / 331 31 46 28 4 / 335 35 50 24 4 / 341 41 53 22 4 / 344 44 57 20 4 / 3

SI Units


Strength,min, MPa

TensileStrength,

min, MPaA

Elongationin 50 mm,min, %A

Bake Hardening Index, min, MPaUpper Yield/Lower YieldA

SS 230 230 310 20 . . .255 255 360 18 . . .275 275 380 16 . . .

340 Class 1 340 450 12 . . .340 Class 2 340 . . . 12 . . .340 Class 3 340 480 12 . . .340 Class 4 340 410 12 . . .

380 380 480 11 . . .550 Class 1B 550C 570 . . . . . .550 Class 2B,D 550C 570 . . . . . .

HSLAS 275 275 340E 22 . . .340 340 410E 20 . . .

380 Class 1 380 480E 16 . . .380 Class 2 380 450E 18 . . .

410 410 480E 16 . . .480 480 550E 12 . . .550 550 620E 10 . . .

HSLAS-F 275 275 340E 24 . . .340 340 410E 22 . . .

380 Class 1 380 480E 18 . . .380 Class 2 380 450E 20 . . .

410 410 480E 18 . . .480 480 550E 14 . . .550 550 620E 12 . . .

SHS 180 180 300 32 . . .210 210 320 30 . . .240 240 340 26 . . .280 280 370 24 . . .300 300 390 22 . . .

BHS 180 180 300 30 25 / 20210 210 320 28 25 / 20240 240 340 24 25 / 20280 280 370 22 25 / 20300 300 390 20 25 / 20

AWhere an ellipsis (. . .) appears in this table there is no requirement.BFor sheet thickness of 0.028 in. [0.71 mm] or thinner, no tension test is required if the hardness result in Rockwell B 85 or higher.CAs there is no discontinuous yield curve, the yield strength should be taken as the stress at 0.5 % elongation under load or 0.2 % offset.DSS Grade 80 [550] Class 2 may exhibit different forming characteristics than Class 1, due to difference in chemistry.EIf a higher tensile strength is required, the user should consult the producer.

7.2 The typical mechanical properties for CS (Types A, B,and C), FS (Types A and B), DDS (Types A and C), and EDDSsheet designations are listed in Table 5. These mechanicalproperty values are nonmandatory. They are intended solely toprovide the purchaser with as much information as possible tomake an informed decision on the steel to be specified. Valuesoutside of these ranges are to be expected.

7.3 When base metal mechanical properties are required, alltests shall be conducted in accordance with the methodsspecified in Specification A 924/A 924M.

7.4 Bending Properties Minimum Cold Bending Radii—Structural steel and high-strength low-alloy steel are com-monly fabricated by cold bending. There are many interrelatedfactors that affect the ability of a steel to cold form over a given

A 653/A 653M – 06a

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radius under shop conditions. These factors include thickness,strength level, degree of restraint, relationship to rollingdirection, chemistry, and base metal microstructure. The tablein Appendix X1 lists the suggested minimum inside radius for90° cold bending for structural steel and high-strength low-alloy steel. They presuppose “hard way” bending (bend axisparallel to rolling direction) and reasonably good shop formingpractices. Where possible, the use of larger radii or “easy way”bends are recommended for improved performance.

8. Coating Properties

8.1 Coating Weight [Mass]:8.1.1 Coating weight [mass] shall conform to the require-

ments as shown in Table 1 for the specific coating designation.8.1.2 Use the following relationships to estimate the coating

thickness from the coating weight [mass]:8.1.2.1 1 oz/ft2 coating weight = 1.7 mils coating thickness,

and8.1.2.2 7.14 g/m2 coating mass = 1 µm coating thickness.8.2 Coating Weight [Mass] Tests:8.2.1 Coating weight [mass] tests shall be performed in

accordance with the requirements of Specification A 924/A 924M.

8.2.2 The referee method to be used shall be Test MethodA 90/A 90M.

8.3 Coating Bend Test:8.3.1 The bend test specimens of coated sheet designated by

prefix “G” [“Z”] shall be capable of being bent through 180° inany direction without flaking of the coating on the outside of

the bend only. The coating bend test inside diameter shall havea relation to the thickness of the specimen as shown in Table 6.Flaking of the coating within 0.25 in. [6 mm] of the edge of thebend specimen shall not be cause for rejection.

8.3.2 Because of the characteristics of zinc-iron alloy coat-ings designated by prefix “A” [“ZF”] as explained in 3.2.3,coating bend tests are not applicable.

9. Retests and Disposition of Non-Conforming Material

9.1 Retests, conducted in accordance with the requirementsof the section on Retests and Disposition of Non-ConformingMaterial of Specification A 924/A 924M, are permitted whenan unsatisfactory test result is suspected to be the consequenceof the test method procedure.

9.2 Disposition of non-conforming material shall be subjectto the requirements of 9.2 of Specification A 924/A 924M.

10. Dimensions and Permissible Variations

10.1 All dimensions and permissible variations shall com-ply with the requirements of Specification A 924/A 924M,except for flatness of SS, HSLAS, and HSLAS-F, which isspecified in Table 7 for SS and Table 8 for HSLAS andHSLAS-F.

11. Keywords

11.1 alloyed coating; bake hardenable steel; high strengthlow alloy; minimized spangle coating; sheet steel; solutionhardened steel; spangle; steel; steel sheet; structural steel; zinc;zinc coated (galvanized); zinc iron-alloy; zinc iron-alloy coated

TABLE 5 Typical Ranges of Mechanical PropertiesA,B (Nonmandatory)

Designation

(Longitudinal Direction)

rmValueC

nValueDYield Strength Elongation

in 2 in. [50mm], %ksi [MPa]

CS Type A 25/55 [170/380] $20 E E

CS Type B 30/55 [205/380] $20 E E

CS Type C 25/60 [170/410] $15 E E

FS Types Aand B

25/45 [170/310] $26 1.0/1.4 0.17/0.21

DDS Type A 20/35 [140/240] $32 1.4/1.8 0.19/0.24DDS Type C 25/40 [170/280] $32 1.2/1.8 0.17/0.24EDDSF 15/25 [105/170] $40 1.6/2.1 0.22/0.27

AThe typical mechanical property values presented here are nonmandatory. They are intended solely to provide the purchaser with as much information as possible tomake an informed decision on the steel to be specified. Values outside of these ranges are to be expected. The purchaser may negotiate with the supplier if a specificrange or a more restrictive range is required for the application.

BThese typical mechanical properties apply to the full range of steel sheet thicknesses. The yield strength tends to increase and some of the formability values tend todecrease as the sheet thickness decreases.

Crm Value—Average plastic strain ratio as determined by Test Method E 517.Dn Value—Strain-hardening exponent as determined by Test Method E 646.ENo typical mechanical properties have been established.FEDDS Sheet will be free from changes in mechanical properties over time, that is, nonaging.

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TABLE 6 Coating Bend Test Requirements

Inch-Pound Units

Ratio of the Inside Bend Diameter to Thickness of the Specimen (Any Direction)CS, FS, DDS, EDDS, SHS, BHS SS, GradeA

Coating DesignationBSheet Thickness

33 37 40Through 0.039 in. Over 0.039 through 0.079 in. Over 0.079 in.

G235 2 3 3 3 3 3G210 2 2 2 2 2 21⁄2G185 2 2 2 2 2 21⁄2G165 2 2 2 2 2 21⁄2G140 1 1 2 2 2 21⁄2G115 0 0 1 11⁄2 2 21⁄2G100 0 0 1 11⁄2 2 21⁄2G90 0 0 1 11⁄2 2 21⁄2G60 0 0 0 11⁄2 2 21⁄2G40 0 0 0 11⁄2 2 21⁄2G30 0 0 0 11⁄2 2 21⁄2G01 0 0 0 11⁄2 2 21⁄2

HSLASA HSLAS-F

40 50 60 40 50 60 70 80

G115 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2G100 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2G90 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2G60 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2G40 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2G30 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2G01 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2

SI Units

Ratio of the Inside Bend Diameter to Thickness of the Specimen (Any Direction)CS, FS, DDS, EDDS, SHS, BHS SS, GradeC

Coating DesignationB

Sheet Thickness230 255 275

Through 1.0 mm Over 1.0 mm through 2.0 m Over 2.0 mm

Z700 2 3 3 3 3 3Z600 2 2 2 2 2 21⁄2Z550 2 2 2 2 2 21⁄2Z500 2 2 2 2 2 21⁄2Z450 1 1 2 2 2 21⁄2Z350 0 0 1 11⁄2 2 21⁄2Z305 0 0 1 11⁄2 2 21⁄2Z275 0 0 1 11⁄2 2 21⁄2Z180 0 0 0 11⁄2 2 21⁄2Z120 0 0 0 11⁄2 2 21⁄2Z90 0 0 0 11⁄2 2 21⁄2Z001 0 0 0 11⁄2 2 21⁄2

HSLASC HSLAS-F

275 340 410 275 340 410 480 550

Z350 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2Z305 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2Z275 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2Z180 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2Z120 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2Z90 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2Z001 11⁄2 11⁄2 3 1 1 1 11⁄2 11⁄2

ASS Grades 50 and 80, HSLAS, and HSLAS-F Grades 70 and 80 are not subject to bend test requirements.BIf other coatings are required, the user should consult the producer for availability and suitable bend test requirements.CSS Grades 340 and 550, HSLAS, and HSLAS-F Grades 480 and 550 are not subject to bend test requirements.

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TABLE 7 Structural Steel—Flatness Tolerances(Cut Lengths Only)

NOTE 1—This table also applies to sheets cut to length from coils by theconsumer when adequate flattening measures are performed.

NOTE 2—For Grade 50 [340] (Classes 1, 2, 3, and 4) use 11⁄2 times thevalues given in this table.

NOTE 3—For Grade 80 [550], there are no defined flatness standards.

Specified Thickness,in. [mm]

SpecifiedWidth, in. [mm]

Flatness Tolerance(Maximum Devia-tion from a Hori-zontal Flat Sur-face), in. [mm]

Over 0.060[1.5]

to 60 [1500], inclusive 1⁄2 [12]

over 60 [1500] to 72 [1800],inclusive

3⁄4 [20]

0.060 [1.5]and thinner

to 36 [900], inclusive 1⁄2 [12]

over 36 [900] to 60 [1500], inclusive 3⁄4 [20]over 60 [1500] to 72 [1800], inclusive 1 [25]

TABLE 8 High-Strength Low-Alloy Steel and High-Strength Low-Alloy Steel with Improved Formability—Flatness Tolerances (Cut

Lengths Only)

NOTE 1—This table also applies to sheets cut to length from coils by theconsumer when adequate flattening measures are performed.

Inch-Pound Units

Specified Thick-ness, in.

SpecifiedWidth, in.

Flatness Tolerances (Maximum Deviationfrom a Horizontal Flat Surface), in.

Grade

40 50

55(Classes1 and 2)

60

70 80

Over 0.060 to 60, inclusive 5⁄8 3⁄4 7⁄8 1 11⁄8over 60 1 11⁄8 11⁄4 13⁄8 11⁄2

0.060 andthinner

to 36, inclusive 5⁄8 3⁄4 7⁄8 1 11⁄8

over 36 to 60,inclusive

1 11⁄8 11⁄4 13⁄8 11⁄2

over 60 13⁄8 11⁄2 15⁄8 13⁄4 17⁄8SI Units

SpecifiedThickness, mm

SpecifiedWidth, mm

Flatness Tolerances (Maximum Deviationfrom a Horizontal Flat Surface), mm

Grade

275 340

380(Classes1 and 2)

410

480 550

Over 1.5 to 1500, inclu-sive

15 20 22 25 30

over 1500 25 30 32 35 381.5 and thinner to 900, inclu-

sive15 20 22 25 30

over 900 to1500,

inclusive

25 30 32 35 33

over 1500 35 38 40 45 48

A 653/A 653M – 06a

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SUPPLEMENTARY REQUIREMENTS

The following standardized supplementary requirements are for use when desired by the purchaser.These additional requirements shall apply only when specified on the order.

S1. Base Metal Thickness

S1.1 The specified minimum thickness shall apply to thebase metal only.

S1.2 The coating designation shown on the order indicatesthe coating to be applied to the specified minimum base metalthickness.

S1.3 The applicable tolerances for base metal thickness areshown in Tables 16 and Tables 17, Thickness Tolerance ofCold-Rolled Sheet (Carbon and High-Strength, Low-AlloySteel), of Specification A 568/A 568M.

ANNEX

(Mandatory Information)

A1. BAKE HARDENABLE STEELS

A1.1 Determination of Bake Hardening Index

A1.1.1 The bake hardening index (BHI) is determined by atwo-step procedure using a standard longitudinal (rollingdirection) tensile-test specimen, prepared in accordance withTest Methods A 370. The test specimen is first strained intension. The magnitude of this tensile “pre-strain” shall be 2 %

(extension under load). The test specimen is then removedfrom the test machine and baked at a temperature of 340°F[170°C] for a period of 20 minutes. Referring to Fig. A1.1, thebake hardening index (BHI) of the material is calculated asfollows:

BHI 5 B 2 A (A1.1)

FIG. A1.1 Representation of Bake Hardening Index

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10

where:A = flow stress at 2 % extension under loadB = yield strength [upper yield strength (BU) or lower yield

stress (BL)] after baking at 340°F [170°C] for 20minutes.

A1.1.2 The original test specimen cross section (width andthickness) is used in the calculation of all engineering strengthsin this test.

A1.1.3 The pre-straining of 2 % in tension is intended tosimulate a modest degree of forming strain, while the subse-quent baking is intended to simulate a paint-curing or similartreatment. In the production of actual parts, forming strains andbaking treatments can differ from those employed here and, asa result, final properties can differ from the values obtainedunder these controlled conditions.

APPENDIXES

(Nonmandatory Information)

X1. BENDING PROPERTIES

X1.1 Table X1.1 lists suggested minimum inside radii forcold bending.

TABLE X1.1 Suggested Minimum Inside Radii for Cold BendingA

NOTE 1— (t) equals a radius equivalent to the steel thickness.NOTE 2—The suggested radii should be used as minimums for 90° bends in actual shop practice.

Designation Grade Minimum Inside Radius for Cold BendingB

SS 33 [230] 11⁄2 t37 [255] 2t40 [275] 2t

50 [340] Class 1 not applicable50 [340] Class 2 not applicable50 [340] Class 3 not applicable50 [340] Class 4 not applicable

55 [380] not applicable80 [550] Class 1 not applicable80 [550] Class 2 not applicable

HSLAS 40 [275] 2t50 [340] 21⁄2 t

55 [380] Class 1 3t55 [380] Class 2 3t

60 [410] 3t70 [480] 4t80 [550] 41⁄2 t

HSLAS-F 40 [275] 11⁄2 t50 [340] 2t

55 [380] Class 1 2t55 [380] Class 2 2t

60 [410] 2t70 [480] 3t80 [550] 3t

SHS 26 [180] 1⁄2 t31 [210] 1t35 [240] 11⁄2 t41 [280] 2t44 [300] 2t

BHS 26 [180] 1⁄2 t31 [210] 1t35 [240] 11⁄2 t41 [280] 2t44 [300] 2t

AMaterial that does not perform satisfactorily, when fabricated in accordance with the requirements in Table X1.1, may be subject to rejection pending negotiation withthe steel supplier.

BBending capability may be limited by coating designation.

A 653/A 653M – 06a

11

X2. RATIONALE FOR CHANGES IN PRODUCT DESIGNATIONS

X2.1 Subcommittee A05.11 has revised the designationsused to classify the various products available in each hot-dipcoated specification. The previous “quality” designations havebeen replaced with designations and descriptions more closelyrelated with product characteristics. Many of the former“quality” specifications described the steel only in terms oflimited chemical composition, which in some cases wasidentical for two or more qualities. The former designationsalso did not reflect the availability of new steels which are theresult of the use of new technologies such as vacuum degassingand steel ladle treatments.

X2.2 The former “quality” designators, defined in verybroad qualitative terms, did not provide the user with all theinformation needed to select the appropriate steel for anapplication. The new designations are defined with technicalinformation such as specific chemical composition limits andtypical nonmandatory mechanical properties. These steel char-acteristics are important to users concerned with the weldabil-ity and formability of the coated steel products. The typicalmechanical properties included in the new designation systemare those indicated by the tension test. These properties aremore predictive of steel formability than other tests such as thehardness test which may not compensate adequately forproduct variables such as substrate thickness and coatingweight.

X2.3 The new designations also provide the user with theflexibility to restrict the steels applied on any order. Forexample, a user can restrict the application of ultra low carbonsteels on an application through the selection of an appropriate“type” designator.

X2.4 There is a limited relationship between the former andcurrent systems of designation. Some of the reasons for thislimited relationship are: addition of steels not previouslydescribed in ASTM specifications, restrictions placed onranges of chemical composition, the addition of typical me-chanical properties, and the enhanced capability of steelproducers to combine chemical composition and processingmethods to achieve properties tailored to specific applications.

X2.5 The changes in designation are significant which maycreate transition issues that will have to be resolved. Continueddialogue between users and producers will have to be main-tained to assist with the transition to the new system ofdesignations. A user with concerns about the appropriatecoated steel to order for a specific application should consultwith a steel supplier or producer.

X3. RELATIONSHIP BETWEEN SPECIFICATIONS THAT DESCRIBE REQUIREMENTS FOR A COMMON PRODUCT

X3.1 ISO 3575 and ISO 4998 may be reviewed for com-parison with this standard. The relationship between thestandards may only be approximate; therefore, the respective

documents should be consulted for actual requirements. Thosewho use these documents must determine which specificationsaddress their needs.

X4. COATING MASS SELECTION BASED ON ATMOSPHERIC CORROSION RATES4 FOR ZINC-COATED STEEL SHEET

X4.1 The proper selection of coating mass to meet a user’sneeds for zinc-coated steel sheet requires some knowledgeabout the relative corrosiveness of the environment in whichthe product will be used. The corrosion rate of the zinc coatingvaries widely depending upon many factors of the environ-ment. For example, the time of wetness is an important issuethat affects the corrosion rate. The presence of impurities suchas chlorides, nitrates, and sulfates can also dramatically affectthe rate of corrosion. Other issues such as the presence orabsence of oxygen and the temperature of the environment areimportant determinants for predicting the “life of the product.”

X4.2 The final performance requirements can also impactthe minimum coating mass needed for a given application. Forexample, is the application an aesthetic one that requires no redrust. In this case, the time to failure is thus defined as the time

for the onset of red rust (the time for the zinc coating to beconsumed in a large enough area for rusting of the steel to beobserved). Or, is the application one in which the time tofailure is defined as the time when perforation of the steel sheetis observed? In this case, the thickness of the steel sheet as wellas the thickness of the zinc coating impact the time to failure.

X4.3 No matter how one defines the “product life,” thereare data in the published literature to assist users once theenvironment and desired product life are determined.

X4.4 Although the corrosion rate can vary considerablydepending on the environmental factors, it is well known that,in most instances, the life of the zinc coating is a linearfunction of coating mass for any specific environment. Thatmeans, to achieve twice the life for any specific application, theuser should order twice the coating mass.

X4.4.1 Examples:4 Atmospheric corrosion rates do not apply to zinc-iron alloy coatings.

A 653/A 653M – 06a

12

X4.4.1.1 A G60 coating mass will exhibit approximatelytwice the life of a G30 coating mass.

X4.4.1.2 A G90 coating mass will exhibit about 50 %longer life than a G60 coating mass.

X4.5 The following two reference books are excellentsources for additional and more detailed information on the

corrosion behavior of zinc-coated steel sheet products:

X4.5.1 Corrosion and Electrochemistry of Zinc, X. GregoryZhang, published by Plenum Press, 1996.

X4.5.2 Corrosion Resistance of Zinc and Zinc Alloys, FrankC. Porter, Published by Marcel Dekker, Inc., 1994

SUMMARY OF CHANGES

Committee A05 has identified the location of selected changes to this standard since the last issue(A 653/A 653M - 06) that may impact the use of this standard. (November 15, 2006)

(1) Added new Section 9.(2) Added boron reporting requirement to Table 2.

(3) Defined boron reporting precision in 6.1.2.

Committee A05 has identified the location of selected changes to this standard since the last issue,A 653/A 653M - 05a, that may impact the use of this standard. (May 1, 2006)

(1) Added Grade 55 [380] to designation SS in Table 3, andTable X1.1.(2) Added Grade 55 [380] Classes 1 and 2 to designationsHSLAS and HSLAS-F in the applicable tables.(3) Revised Footnote B in Table 2.

(4) Revised Footnote C in Table 3.

(5) Revised Cu limit in Table 2 for CS, FS, DDS, and EDDSgrades.

(6) Revised Cu limit in Table 3 for SS grades.

Committee A05 has identified the location of selected changes to this standard since the last issue,A 653/A 653M - 05, that may impact the use of this standard. (October 1, 2005)

(1) Revised Table 1 and Table 6 with the addition of G100 andZ305 coating designations.

ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentionedin this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the riskof infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years andif not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standardsand should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of theresponsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you shouldmake your views known to the ASTM Committee on Standards, at the address shown below.

This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959,United States. Individual reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the aboveaddress or at 610-832-9585 (phone), 610-832-9555 (fax), or [email protected] (e-mail); or through the ASTM website(www.astm.org).

A 653/A 653M – 06a

13

Cement Board NOTE: Brand indicated is for illustration purposes only, other brands may be used with matching material specifications.

SECTION 5.2

SA932 09305

DUROCK® Brand

systemscement board

TomCat

Information Only

DUROCK� Brand DUROCK® Brand Cement Board offers architects, builders and tile contractors a strong, water-durable tile base for Cement Board tub and shower areas. Also an ideal underlayment for tile on floors and countertops in new construction and

remodeling. Board is readily applied over wood or steel framing spaced 16� o.c. with corrosion-resistant wood orsteel screws or hot-dipped galvanized roofing nails. After joints are treated, ceramic wall or floor tile is appliedusing latex fortified mortar or Type I organic adhesive.

DUROCK Brand Cement Board is preferred by many applicators as a base for finishes used in building exteriors.See publication SA700 for complete information on the applications of this product. The 1/2� thick DUROCK BrandCement Boards are Listed by Underwriters Laboratories Inc. for use with UL-Listed solid-fuel room heaters and fire-place stoves. Used as a wall shield, board reduces by two thirds the manufacturer-specified clearance (minimum12�) between room heater or stove and combustible wall surface. Board may also be used as a floor protector inplace of one layer of 3/8� thick millboard. For hearth extensions, see Specification 3.6B.

DUROCK® Brand In addition to standard 1/2� DUROCK Brand Cement Board, DUROCK® Brand Underlayment is available for floors and Underlayment countertops. Its nominal 5/16� thickness helps eliminate transition trim when abutting carpet or wood flooring, and

helps minimize level variations with other finish materials. Its 4� x 4� size is easy to handle and helps cut down onwaste. Applies directly over old substrate on countertops to save time.

DUROCK™ Brand Corrosion-resistant; 8-gauge; wafer heads with countersinking ribs to prevent stripout; self-drilling points. DUROCK

Screws Brand Wood Screws come in three lengths: 1-1/4�, 1-5/8� and 2-1/4�. DUROCK Brand Steel Screws can be usedwith steel framing where steel thickness is from 14 to 20-gauge; they come in two lengths: 1-1/4� and 1-5/8�.Both wood and steel screws have heads a minimum of 0.40� in diameter; their driving recess is a No. 2 “Phillips”design.

DUROCK™ Brand Akali-resistant glass-fiber tape reinforces joints to provide a strong, continuous surface. Each roll 2� x 50�,Joint Tape 2� x 250�or 4� x 150�.

Features and High Strength – High flexural strength resists bending to prevent finish cracking.Benefits of – High compressive strength to resist impact damage.DUROCK® BrandCement Board

Dual Surface – Smooth side for mastic applications; increases adhesive coverage.– Textured surface enhances bonding, reduces tile slip with mortar applications.

Dimensional – Low thermal and hygrometric expansion helps prevent cracking.Stability – Will not swell, soften, decay, delaminate, or disintegrate in water.

Fire-Resistance – Noncombustible panel.– Assemblies with 1/2� DUROCK Brand Cement Board have achieved 1 and 2 hr. fire-resistance ratings.

Light Weight – At approximately 3 psf, the 1/2� thick board is one fourth the weight of a conventional 1� thick metal lath and portland cement plaster system.

Easy Installation – Easy to cut and fasten.– Dry panel application eliminates cement mixing and drying time, shortening job schedules and lowering

in-place cost.

Convenient sizes – May be ordered in sizes to meet job requirements (see table of sizes and packaging).

Versatility – Provides a smooth, sound base for glass and ceramic mosaics; ceramic and quarry tile; lugged tile; thin stone tile; and thin brick.

– Adaptable for fences, fireplace fronts, mobile home skirting, agricultural buildings, UL-listed wall shield/floorprotectors, garage wainscoting and exterior finishes.

DUROCK® BrandCement Board Systems


United States Gypsum Company SA932 3

Limitations 1 Do not use drywall screws or drywall nails.2 Systems using DUROCK Brand Cement Board are designed for positive or negative uniform loads up to 50 psf.

(See publication SA700 for complete information on wind load capacity.)3 Maximum stud spacing: 16� o.c. (24� o.c. for cavity shaft wall assembly); maximum allowable deflection, based on

stud properties only, L/360. Maximum fastener spacing: 8� o.c. for wood and steel framing on floors and walls; 6� o.c. for ceiling applications.

4 Maximum dead load for ceiling system is 7.5 psf.5 Steel framing must be 20 gauge or heavier.6 Not recommended for vinyl flooring.7 5/16� thickness should not be used for walls or ceilings.

Product Data Material Formed in a continuous process of aggregated portland cement slurry with polymer-coated, glass-fiber mesh completely encompassing edges and back and front surfaces.Edges Formed smooth—Patent No. 4,916,004.Ends Square cut.

Sizes and Packaging Type Size (Thickness xWidth x Length)(1) Units (pcs)(2)

Cement Board 1/2� x 32� x 5� 50

1/2� x 36� x 5� 50

1/2� x 32� x 8� 30

1/2� x 36� x 8� 30

1/2� x 48� x 8� 30

5/8� x 36� x 5� 30

5/8� x 32� x 8� 30

5/8� x 48� x 8� 24

Underlayment 5/16� x 48� x 4� 40

5/16� x 36� x 5� 40

(1) Other lengths available. Contact your USG Representative. (2) Stretch-wrapped and shipped in packaging units as shown.

Typical Physical Properties ASTM test Cement UnderlaymentProperty reference board value (1/2�) value (5/16�)Flexural strength-psi C947-81 750 1250

Indentation strength—psi 1� dia. disc @ 0.02� indent. D2394 2300 2300

Uniform load—psf studs 12� o.c. — 50 max. —

Water absorption-% by wt. 24 hrs. C473-84 10 10

Nail pull resistance—lb. 0.4� head diameter (wet or dry) C473-84 125 —

Weight—psf C473-84 3 2

Freeze/thaw resistance—Procedure B number of cycles C666-84 100 100

with no deterioration

Surface burning characteristics—flame/smoke E84 5/0 5/0

Thermal �R�/k value C177 0.26/1.92 —

Standard method for evaluating ceramic floor tile C627 Residential Residential

installation systems

Min. bending radius1—ft. — 8 —

(1) Requires special framing. Details available on request.

Building Refer to current National Evaluation Service Report Nos. 259 and 396 for allowable values and/or conditions of Code Data use concerning material presented in this document.

Standards DUROCK Brand Cement Board exceeds the ANSI Standards for cementitious backer units (CBU). See ANSI A118.9-1992 for Test Methods and Specifications for CBU and ANSI 108.11-1992 for Interior Installation of CBU. AllDUROCK Brand Cement Board products meet ASTM Standard E136 for noncombustibility.

LU®

Listed 34L2For floor protectors and wall shields

09305/UNIBuyLine 3900

DUROCK® Brand Cement Board Systems


��

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tile

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3⁄4" min. plywood DUROCK Brand cementboard or underlayment

DUROCK Brand interior tape

liquid or sheet membraneType I organic adhesive or latex-fortified mortar

��

padding

wood or steel joists

carpet

��

3⁄4" min. plywood or OSB subfloor

Note: For bonding cement backer board to plywood subfloor, use Type 1 organic adhesive orlatex-fortified mortar that is suitable for this kind of application. For application of various types oftiles to cement backer board on floors or countertops, contact the tile manufacturer for the appropriate type of tile-setting mortar.

tile

DUROCK Brand cement board or underlayment Type I organic adhesive or

latex-fortified mortar

Counter tops Floors, interior-wood or steel joists

��

hanger

20 ga. min. metal furring channel

DUROCK Brandfastener 6" o.c.

control jointDUROCK Brand cement panel ceramic tile

wire tie

20 ga. min. metal furring channel

hangerwire tie

11/2" channel

23/4"

DUROCK Brand screw 6" o.c.

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� �� wood blocking16" o.c.


1/2" DUROCK Brand cement panel

2"x4" wood stud 16" o.c.

ceramic tile

1/2" SHEETROCK

Brand gypsum panel

DUROCK Brand wood screws 6" o.c.

Type I organic adhesive or latex-fortified mortar



DUROCK Brand cement panel must be primed before application of joint compound or use it on one side only and set the tile side with mastic.

see note above*

*

Wood soffit framingSuspended ceiling detail

Tub and shower - single layer board

��

��DUROCK Brand

cement panel

tile

wood or metal studs

��

�


1' to 13⁄4" reinforced mortar bed

shower pan or membrane

sloped fill weep holes

crushed tile or stone

��

��

��

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DUROCK Brand cement panel

caulk

tub rim

leveling guide


��

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tilecaulk

horizontal supportat DUROCK Brand panel edge

��

precast concrete shower base

��

��

DUROCK Brand steel or wood screw 8" o.c.

tile




setting material

wood or steel studs 16" o.c. max.

membrane (if required)

Walls, interior, and exterior - wood or steel studs



DUROCK Brand tape

4" DUROCK Brand tape embedded in exterior basecoat

water barrier

DUROCK Brand screws at 8" o.c.

exterior finish

in tile areas treat DUROCK Brand joints by embedding 2" DUROCK Brand tape in tile setting material

wood or metalstuds at 16" o.c.

DUROCK Brand panel

2" DUROCK Brand tape


exteriorbasecoat

DUROCK Brand panel

tile settingmortar tile base

pool

��

2 x 4 woodstuds 16" o.c.

wood plate

tub


ceramic tile

1/4" space

DUROCK Brandtape

1/2" DUROCK Brand cement panel 32" x 5'-0"

1/2" DUROCK Brand cement panel 32" x 5'-0"

DUROCK Brand screws 8" o.c.

DUROCK Brand tape

1/2" SHEETROCK Brand gypsum panel

support framing for attachment of fixtures

Use SHEETROCK Brand joint treatment system and sealer for finishing DUROCK to gypsum board joints (Refer to 3.7B) in painted areas

��

��

�� in tiled areas

treat DUROCK Brand board joints by embedding DUROCK Brand tape in tile setting material

1/2" SHEETROCK

Brand gypsum panel


Typical bathtub installation

Typical swimming pool installation (tile or exterior finish) DUROCK Brand alkali-resistant tape

DUROCK Brand wood screws

DUROCK Brand steel screws

/8" TYPE S-12an head screw

teel runner

steel framingmember–gauge and size as required

3/8" TYPE S-12pan head screw

steel framingmembers–misc.gauge and depth

Fixture attachment - steel framing

Hot-dipped galvanized roofing nails


Good Design 1 System Performance Systems covered herein have been tested and evaluated for use as described. For other system applications,Practices consult your local representative.

All details, specifications, and data contained in this literature are intended as a general guide for using DUROCK Brand Cement Board Systems. These products must not be used in a design or construction of any given structure without complete and detailed evaluation by a qualified structural engineer or architect to verify suitability of a particular product for use in the structure.

Information in this publication should be used only for DUROCK Brand Cement Board Systems, as physical proper-ties of competitive products may vary. United States Gypsum Company assumes no liability for failure resulting fromthe use of alternative materials or improper application or installation of DUROCK Brand Cement Board Systems asspecified herein.

United States Gypsum Company will provide building officials and design professionals upon written request withtest certification for published fire, sound, and structural data covering systems constructed with Company productsand assembled to meet performance requirements of established test procedures specified by various agencies.

2 Expansion and Contraction Wall surfaces should be isolated with surface control joints (sometimes referred to by the industry as expansion joints) or other means where: (a) a wall abuts a structural element or dissimilar wall or ceiling; (b) constructionchanges within the plane of the wall; (c) tile and thin brick surfaces exceed 16�. Surface control joint width shouldcomply with architectural practices.

Location of building control joints is the responsibility of the design professional/architect. Steel framing atbuilding control joints that extend through the wall (with top and bottom runner tracks broken) should have 1-1/2�cold-rolled channel alignment stabilizers spaced a maximum of 5�0� o.c. vertically. Channels should be placedthrough holes in the stud web of the first two adjacent studs on both sides of the joint and securely attached to the first adjacent stud on either side of the joint.

Cement board should be separated at all surface and building control joints. Where vertical and horizontal jointsintersect, the vertical joint should be continuous and the horizontal joint should abut it. Splices, terminals, and inter-sections should be caulked with a sealant complying with architectural practices and sealant manufacturer recom-mendations. Do not apply tile or finishes over caulked sealed expansion joints. (See SA700 for additional information).

3 Water Barrier DUROCK Brand Cement Board is vapor permeable and does not deteriorate in the presence of water. For interior applications, if a vapor retarder or waterproof construction is specified, a separate barrier must be applied over or behind the DUROCK Brand Board. For exterior applications of DUROCK Brand Cement Board, see SA700Exterior Substrate Systems.

4 Swimming Pool Enclosures DUROCK Brand Cement Board Systems may be used for the walls and ceilings around indoor swimming pools.Consideration shall be given to adequate ventilation in plenums and corrosion protection of metal hangers andframing members.

5 Soffits and Ceilings DUROCK Brand Cement Board Systems finished with ceramic tile, thin brick, and textured finish may be used onproperly vented soffits and ceilings with DUROCK Brand Screws spaced 6� o.c. max. A qualified structural engineershould evaluate design including uplift bracing.

6 Steam Rooms and Saunas For steam rooms and saunas where temperatures exceed 120 °F for extended periods, use latex-fortified portlandcement mortar; do not use organic adhesive.

7 Abuse Resistant Partitions IMPERIAL� Brand Finish Plaster and DIAMOND� Interior Finish Plaster can be applied over DUROCK Brand Cement Boardto provide a high-impact resistant wall. See United States Gypsum Company publication SA920 for specifications.

8 Window and Door Openings All window and door openings must be properly flashed and caulked.

9 Smooth Side/ DUROCK Brand Cement Board has a smooth side and a rough side. Use the smooth side for mastic applicationsRough Side and the rough side for mortar applications.



10 Shadowing and Spotting When the outside temperature differs considerably from the building�s interior temperature, airborne dirt can accumulate on the colder regions of walls, causing “shadowing” or “spotting,” particularly over fasteners and framing. This is a natural phenomenon which occurs through no fault in the products.

Where temperature, humidity, and soiling conditions are expected to cause objectionable blemishes, provide a thermal separation between the interior and exterior faces.

11 Leaching and Latex leaching and efflorescence are natural phenomena which occur with the use of latex modified mortars andEfflorescence grouts through no fault in the products. To help protect against their occurrence, follow current industry

guidelines and recommendations.

12 Vapor Retarders Humidity and temperature conditions may require a vapor retarder. Its location should be determined by a qualified mechanical engineer or architect to prevent moisture condensation within the wall.

13 Corrosion Protection All architectural components, such as anodized-aluminum window frames, trims, flashings and casings, shall be protected from alkaline building materials such as cement board, portland cement basecoats, mortars and grouts.

Specifications 1.1 Specify to meet project requirements.Part 1: Scope

General1.2 All materials, unless otherwise indicated, shall be manufactured by United States Gypsum Company and shallQualifications be installed in accordance with its current printed directions.

1.3 All materials shall be delivered in their original unopened packages and stored in an enclosed shelter providing Delivery and protection from damage and exposure to the elements. Damaged or deteriorated materials shall be removed Storage of Materials

from the premises. WARNING: Store all DUROCK Brand Cement Board panels flat. Panels are heavy and can fall over,causing serious injury or death. Do not move unless authorized.

1.4 In cold weather and during DUROCK Brand Cement Panel and tile installation, temperatures within the building shall Environmental Conditions be maintained within the range of 40 to 100 °F. Adequate ventilation shall be provided to carry off excess moisture.

Interior Applications Wood framing shall approximate the moisture content it will reach in service by allowing the enclosed building to stand as long as possible prior to the application of the cement board. Do not install board when the board is wet.Exterior Applications Finishes, leveling/skim coats and basecoats shall not be applied to DUROCK Brand Cement Panelthat is wet or frozen or that contains frost. After application, and for at least 24 hours, finishes, leveling/skim coatsand basecoats shall be effectively protected from rain and excessive moisture.

In cold weather and during finish applications, DUROCK Brand Cement Panel, skim or basecoat, mortar, finishmaterial and air temperature must be at least 40 °F, and must remain at this temperature or higher for at least 24hours after application. Hot and dry weather may affect working time of leveling/skim or basecoat and finish mate-rials. Under rapid drying conditions, dampening or light fogging of board, leveling/skim or basecoat surface maybe required to improve workability.

1.5 Steel or wood wall framing to receive DUROCK Brand Cement Panels shall be structurally sound, free from bow, andFraming in general compliance with local building code requirements. Damaged and excessively bowed studs shall be

replaced before installation of DUROCK Brand Cement Panels. Framing shall be designed (based on stud propertiesalone) not to exceed L/360 deflection for tile and thin brick, L/240 for Direct-Applied Exterior Finish Systems. Steelframing must be 20 gauge or heavier with corrosion-resistant metal coating equivalent to G60 hot-dipped galva-nized. Exterior steel framing should be laterally braced.

1.6 DUROCK Brand Panel should be cut to size with carbide-tipped knife and straight edge. Power saw should be used Installation Practices only if equipped with a dust-collection device and a NIOSH/MSHA-approved respirator is worn.

Contractors installing tile and tile-setting materials should always follow current ANSI specifications and TCAguidelines.




Part 2: 2.1 A Cement BoardProducts Materials —DUROCK Brand Cement Board, 1/2� or 5/8� thickness, 32�, 36�, or 48� width x lengths of 4� to 10�; exceeds

ANSI A118.9-1992 for cementitious backer units.—DUROCK Brand Underlayment, 5/16� thickness, 48� width x 4� length, other sizes available.

B Joint Reinforcement—DUROCK Brand Joint Tape (alkali-resistant), 2� x 50�, 2” x 250’, or 4” x 150’.C Fasteners

—DUROCK Brand Steel Screws (No. 8), 1-1/4� and 1-5/8� for 14 to 20 gauge steel framing; DUROCK Brand WoodScrews (No. 8), 1-1/4�, 1-5/8�, and 2-1/4� for wood framing.

—Nails (1-1/2� hot-dipped galvanized roofing nails).D Subfloor—(5/8�) (3/4�) plywood or oriented strand board (OSB), 4� x 8� sheets, exterior grade or better, exterior

glue conforming with PS-1-66, T&G or back block long edges.E Adhesives/Mortars

Products compatible with alkaline or portland cement-based DUROCK Brand Cement Board:—Meeting ASTM C557-73: multipurpose adhesive (for subfloor to framing attachment).—Meeting ANSI A136.1 Type I.—Meeting ANSI A118.1: dry-set mortar mixed with acrylic latex additive.—Meeting ANSI A118.4: latex portland cement mortar.

F GroutProducts compatible with high pH-based DUROCK Brand Cement Board:—Meeting ANSI A118.6: specify type.

G Tile—Tile shall meet ANSI A137.1.H Membrane—#15-lb. felt or 4-mil polyethylene membrane, if required, in accordance with local building codes.

Part 3: 3.1 A Subfloor—Apply 3/8� bead of multipurpose adhesive to center of top flange of joists. Place 5/8� min. exterior Execution Floors grade plywood or OSB sheets with long dimension across or parallel to wood or steel joists spaced max. 16� o.c.

Fasten plywood to steel joists with 1-15/16� pilot point self-drilling screws spaced 16� o.c. Fasten plywood to wood joists with adhesive and suitable nails or screws spaced max. 12� o.c.

B Panel Application—Laminate 5/16� DUROCK Brand Underlayment to subfloor using Type 1 organic adhesive, latex- fortified mortar or dry-set mortar mixed with acrylic latex additive that is suitable for bonding cement backer boardto plywood subfloor, with 1/4� square-notched trowel for mortar, 5/32� V-notched trowel for adhesive. Place under-layment with joints staggered from subfloor joints. Fit ends and edges closely but not forced together, leaving a 1/8�gap. Fasten to subfloor with 1-1/4� DUROCK Brand Wood Screws or 1-1/2� hot-dipped galvanized roofing nailsspaced 8� o.c. in both directions with perimeter fasteners at least 3/8� and less than 5/8� from ends and edges.

1/2� and 5/8� DUROCK Brand Cement Board—Same procedure as DUROCK Brand Underlayment.

3.2 A Framing—Space wood and steel framing a maximum of 16� o.c. (24� o.c. for UL Design U459 or U415). The studs of Walls freestanding furred walls must be secured to the exterior wall with wall furring brackets or laterally braced with horizontal

studs or runners spaced 4� o.c. max. Laterally brace all steel-framed walls prior to the application of joint treatment.B Panel Application—After tub, shower pan or receptor is installed, place temporary 1/4� spacer strips around

lip of fixture. Pre-cut board to required sizes and make necessary cut-outs. Fit ends and edges closely but not forced together, leaving a 1/8� gap. Install board abutting top of spacer strip. Stagger end joints in successivecourses. Fasten boards to wood studs spaced max. 16� o.c. and bottom plates with 1-1/4� DUROCK Brand WoodScrews or 1-1/2� hot-dipped galvanized roofing nails spaced 8� o.c. Fasten DUROCK Brand Cement Board to steelstuds spaced max. 16� o.c. and bottom runners with 1-1/4� DUROCK Brand Steel Screws spaced 8� o.c. withperimeter fasteners at least 3/8� and less than 5/8� from ends and edges. In double-layer walls where cementboards are installed over base-layer gypsum boards, apply a vapor-permeable water barrier over gypsum boards.

C Shaft Wall—Attach DUROCK Brand Cement Board over base layer of gypsum panels with 1-5/8� DUROCK Brand Steel Screws at 8� o.c. to studs. Since studs are at 24� o.c., laminate cement board to base layer of gypsum panelswith a 4� wide strip of construction adhesive between studs. Apply adhesive with a 1/4� square-notched trowel.

D Exterior Walls—Attach DUROCK Brand Cement Board with corrosion-resistant screws spaced a maximum of 8� o.c. over framing spaced a maximum of 16� o.c. Apply a weather resistive barrier and flashing behind thepanels as required. Follow the exterior finish manufacturer’s recommendations for application over DUROCK

Brand Cement Board.



3.3 A Base—Install minimum 3/4� exterior-grade plywood base across wood cabinet supports spaced maximum Countertops 16� o.c. Position ends and edges over supports.

B Membrane—Staple-attach 15-lb. felt or 4-mil polyethylene film using 1/4� galvanized stapes over plywood base.C Panel Application—Secure 5/16� DUROCK Brand Underlayment to plywood. Fasten to plywood with 1-1/4� DUROCK

Brand Wood Screws or 1-1/2� hot-dipped galvanized roofing nails spaced 8� in both directions and around edges;fit ends and edges closely but not forced together, leaving a 1/8� gap.

Application of 1/2� or 5/8� DUROCK Brand Cement Board—Use same procedure as for DUROCK BrandUnderlayment.

D Joint Finishing—Prefill joints with latex-fortified mortar or Type 1 organic adhesive; completely embed DUROCK

BRAND Interior Tape; and level all joints and outside corners.

3.4 A Framing—Ceiling joists, furring channels or strips must be spaced max. 16� o.c. Framing must be capable ofCeilings supporting the total ceiling system dead load, including insulation, ceramic tile, bonding materials and cement

board, with deflection not exceeding L/360 of the span. When steel framing is used, min. 20 ga. is required.B Panel Application—Apply 1/2� DUROCK Brand Cement Board to framing with long dimension across framing. Center

end or edge joints on framing and stagger joints in adjacent rows. Fit ends and edges closely, but not forcedtogether, leaving a 1/8� gap. Fasten boards to steel framing with 1-1/4� DUROCK Brand Steel Screws spaced 6� o.c.and to wood framing with 1-5/8� DUROCK Brand Wood Screws spaced 6� o.c. with perimeter fasteners at least 3/8�and less than 5/8� from ends and edges. If necessary, provide additional blocking to permit proper attachment.Edges or ends parallel to framing shall be continuously supported.

3.5 A Furring—Cut 1/2� DUROCK Brand Cement Board to panel and furring strip sizes with a scoring tool or circular saw Wall Shield with a carbide-tipped blade. Attach a double layer of furring strips to wall framing with 2-1/4� DUROCK Brand Wood

Screws or 2-1/4� galvanized roofing nails with 3/4� minimum framing penetration.B Panel Application—Attach 1/2� DUROCK Brand Cement Board wall shield through furring to wall framing with 2-3/4�

galvanized roofing nails with 3/4� minimum framing penetration.

3.6 A Panel Application—Apply 1/8� to 1/4� thick latex-fortified portland cement to solid surface—never on top of Floor Protector carpeting or padding. Attach 1/2� DUROCK Brand Cement Board with 1-1/4� DUROCK Brand Wood Screws or 1-1/2�

galvanized roofing nails at 8� o.c. both directions and with 3/4� minimum flooring penetration.B Hearth Extension—To substitute DUROCK Cement Board in hearth extension designs, use the guidelines

specified by local building code and the fireplace manufacturer, and the following formula:k-value DUROCK Brand x Hearth extension = Thickness of DUROCK Brand k-value specified thickness Cement Panels (not less

(specified) than hearth extension thickness specified)

Example: If the fireplace manufacturer or code requires one layer of 3/4� millboard with a k-value of .84, use the formula as follows to determine the required layers of DUROCK Brand Cement Panels:

1.92.84

x .75� = 1.71� or four layers.

Installation of panels for hearth extension is same as 3.6.A.

3.7 A For Tile and Thin Brick—Prefill all DUROCK Brand Cement Board joints, and joints where DUROCK Brand Cement Joint Treatment Boards abut other panels or surfaces such as gypsum board, with tile-setting mortar or adhesive, and thenApplication

immediately embed tape and level the joints.B For Dry Untiled Areas—For small areas where the DUROCK Brand Cement Board will not be tiled, such as a board

extending beyond the tiled area and abutting another surface, treat joints as follows. Seal DUROCK Brand Board with DUROCK Brand or Type I Ceramic Tile Adhesive. (Mix four parts adhesive with one part water.) EmbedSHEETROCK� Brand Joint Tape over joints and treat fasteners with SHEETROCK� Brand Setting-Type Joint Compound(DURABOND� 45 or 90) applied in conventional manner. Flat trowel SHEETROCK Brand Setting-Type Joint Compound over board to cover fasteners and fill voids to a smooth surface. Finish joints with at least two coatsSHEETROCK� Brand Ready-Mixed Joint Compound. Do not apply ready-mixed or setting-type joint compound over unsealed board.




Fiberglass Insulation NOTE: Brand indicated is for illustration purposes only, other brands may

be used with matching material specifications.

SECTION 5.3

KALINING KKL 36

■ The 21st century wall.

■ The best thermal and acoustical insulation for walls.

■ The best product to insulate your old house and other building; thus reducing your electricty bill.

■ The best product to set up partitions in existing house or building.

NEW OR RETROFIT

PRIVATE OR COMMERCIAL

INSULATE AND SAVE ENERGY

INSULATION SYSTEM FOR WALLS

KKL 36 is a thermal-acoustical insulation system for walls of residential houses and commercial buildings. The system consists of a “rolled” glasswool panel and metal accessories. The metal accessories are forming a framework to support the finishing elements (plasterboard).

WORKING METHOD KKL 36 FOR WALLSA rail is fixed on the floor and on the ceiling.Metal furring channels are fixed horizontal on the wall.The rolled panel KKL 36 is installed between the furring channels.

THE ROLLED PANELKKL 36 is a semi rigid glasswool panel to be rolled off, on one side faced with a kraft vapor barrier. Packed as a roll, KKL 36 becomes a real panel when it is rolled off. In this way a “rolled” panel is combining the advantage of rolls in storage and the advantages of panels with it’s rapid installation.

DIMENSIONS OF KKL 36

THE ADVANTAGES OF KKL 36

1. The best thermal results: the metal framework disconnects the outside wall from the inside plasterboard. This suppresses the thermal bridges.

2. The best acoustical results: the principle mass-spring-mass increases the accoustical insulation with 10 to 24 dB.

3. A simple and flexible system: (1) with the same elements you can insulate both common and complicated situations, (2) the system has no problems with an irregular surface, (3) electrical cables can pass without problems between the insulation and the plasterboard finishing.

4. You can adjust the metal frame work in order to achieve a flat surface.

INSTALLATION

Depending on the type of construction site, 2 to 6 m2 per hour.

Thicknessmm85

7550

Lengthm5,48,110

Widthm1.21.21.2

Application

Walls

Insulation is cut as per distance between floor and ceilling increased by 1 cm.

Plasterboard length will be as per distance between floor and ceilling minus 1 cm.

THERMAL RESISTANCE (m2. K/w) for thefollowing Thicknesses of KKL 36

Mean Temperature

oC

ThermalConductivity

(W/m.k)0

10255075

0.0290.0300.0320.0360.039

50 mm1.7241.6671.5631.3891.282

75 mm2.5862.5002.3442.0831.923

85 mm2.9312.8332.6562.3612.179

THERMAL RESISTANCE (ft2h.F/Btu) for thefollowing Thicknesses of KKL 36

Mean Temperature

oF

ThermalConductivity(Btu.in/ft2h.F)

325077

122167

0.200.210.220.250.27

2 inch10.009.5249.098.007.407

3 inch15.0

14.28613.63612.00011.111

3.5 inch17.50016.66715.90914.00012.963

These are typical values subject to normal manufacturing and testing variances

PRODUCT Absorption coefficients at the octave frequencies HZ

Type 125 250 500 1000 2000 4000 NRC

KKL 365085

0.260.53

0.581.05

0.921.08

1.001.00

1.001.01

0.961.10

0.901.05

Thickness(mm)

PERFORMANCES

PERMANENCE:Dimensionally stable under varying conditions of temperature and humidity, rot proof, odourless, non-hygroscopic and will not sustain vermin or fungus.

No sagging nor settling so longer life.

THERMAL PERFORMANCES:

FIRE SAFETY:

Base fibre are Non-combustible when tested in accordance with BS 476 (Part4), ASTM E 84, 136.

MOISTURE ABSORPTION:Less than 1% by volume when tested in accordance with BS 2972 or 6676, ASTM C 553. KIMMCO Kalining does not absorb moisture from the ambient air nor water by capillary attraction. Only water under pressure can enter the insulation products, but that will quickly dry out owing to the material’s open cell structure.NON TOXIC:KIMMCO KALINING 36 IS NOT HAZARDOUS TO HEALTH (See KIMMCO MSDS)

ACOUSTICS:ASTM C 423 - Mounting A as per ASTM E 795

CONFORMITY TO STANDARDSKIMMCO Kalining complies with the following Standards:

AMERICAN STANDARDSASTM C 168, 177, 423, 1104/1104M, 1335; E 84, 96, 795UL 723NFPA 255NAIMA Standards

BRITISH STANDARDSBS 476 (part 4), 874, 2972, 3533, 5234, 6676 (part 1)

GERMAN STANDARDSDIN 18165, 52612

ISO354, 8301, 8302, 9229, 9291

This document has been published for the purpose of providing information of a general nature only. Further, no guarantee, warranty, or any other form of assurance is given as to the accuracy, currency or completeness of the information provided. Accordingly, any reliance on, or use, by you of any information contained within this document for any purpose whatsoever shall be entirely at your own risk, and any liability to you is expressly disclaimed to the maximum extent permitted by law.

All Logos are trademarks of Genesis Manazil Steel Framing

Copyright® 2010 Genesis Manazil Steel Framing. Reproduction of any part of this document is prohibited, except with the prior written consent of Genesis Manazil Steel Framing.

Contact Us

Genesis Manazil Steel Framing provides world leading structural solutions, technologies and expertise. Starting from the architectural drawings all the way to inspecting the finished LSF structure, Genesis Manazil Steel Framing delivers complete turnkey solutions to cost-conscious real estate developers and construction companies eager to join the green building revolution.

For more information, please contact us at:

www.genesismanazil.comEmail: [email protected] Phone: 02-550 2265 Fax: 02-550 2265

P.O. Box 29396 ICAD, Musaffah, Abu Dhabi, United Arab Emirates

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