CSSBI B17-2002

1

PREFACEThis publication is an educational tool

intended to give guidance to anyone

specifying paint systems for sheet steel

building products. This particular

publication deals with Barrier Series

pre�nish system intended for more

aggressive environments.

The material presented in this publication

has been prepared for the general

information of the reader. While the

material is believed to be technically correct

and in accordance with recognized good

practice at the time of publication, it should

not be used without �rst securing

competent advice with respect to its

suitability for any speci�c application.

Neither the Canadian Sheet Steel Building

Institute nor its Members warrant or assume

liability for the suitability of the material for

any general or particular use.

Copyright © July 2002All rights reserved. This publication, or any part thereof, maynot be reproduced in any form without the writtenpermission of the publisher.

B17-2002ISBN 1-895535-25-5

Barrier Series Pre�nished Sheet Steel

ProductPerformance & Applications

TABLE OF CONTENTS

DESCRIPTION OF BARRIER SERIES

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CASE HISTORIES:HEAVY INDUSTRIAL

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CASE HISTORIES:ARCHITECTURAL, RESIDENTIAL,COMMERCIAL & AGRICULTURAL

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APPLICATION NOTES

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FIELD PERFORMANCE

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SUMMARY

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APPENDIX

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Barrier Series Prefinished Sheet Steel

ProductPerformance

& Applications

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BARRIER SERIES PREFINISHEDSHEET STEEL: PRODUCT PERFORMANCE ANDAPPLICATIONS

The challenge for today's cladding specifieris to choose a system capable of providinglong-term performance whether theenvironment is localized as a result of on-site processing or nearby industry, orwidespread due to geographic region.Amid the multitude of building materialsavailable, Barrier Series stands out as theleader in durable, economic protection in awide variety of industrial and architecturalapplications.

In 1969, the need was recognized for aprefinished steel product suitable for moreaggressive industrial applications. Thin-film systems were not developed for theharsh, corrosive environments of manyindustrial applications. Other claddingmaterials have proven inadequate inwithstanding a wide variety of harshenvironments or inappropriate for theextremes of the Canadian climate. Afterseveral years of development and testing,followed by field testing, Barrier Series wasintroduced to the market.

Today, Barrier Series on galvanized Z275(G90) substrate is one of the most durablesteel cladding materials available, with atrack record of over twenty years provenperformance in hundreds of installationsand a variety of demanding applicationsacross Canada and the United States. Theproduct has been used extensively inchemically aggressive environments oftenfound in heavy industrial applications,consistently demonstrating its superiorityin areas where the elements incombination with salts, acids, alkalis,oxidizing agents and industrial andautomotive fumes are quickly deterioratinga variety of other building materials.Specifiers also are discovering itsadvantages under less harsh conditions forarchitectural applications where corrosion

concerns are greater than normal. Forexample, buildings near salted roadways ormarine environments, residential roofs,designs that feature sheltered overhangs,and even corrosive interior environmentssuch as indoor swimming pools and highhumidity areas.

Today many installations have madeBarrier Series part of their plantspecification and order it routinely for newconstruction and as replacement claddingfor other materials. They have come torely on the consistent quality andperformance of Barrier Series to meet theirneeds.

This publication documents fieldapplications, provides some of theinformation necessary when selectingBarrier Series cladding and decking for aparticular application and describes someof its key attributes. Laboratory test resultsare included for comparative informationpurposes. This data can be used forpreliminary comparison of theperformance of various systems, the firststep in the selection process. Thesignificance of laboratory evaluationbecomes increasingly apparent as each testresult is backed by proven excellence infield performance.

DESCRIPTION OF BARRIER SERIES

Barrier Series is comprised of acontinuously hot dipped galvanized sheetsteel substrate with a factory appliedprimer and polyvinyl chloride (PVC)topcoat and meets the requirements ofASTM A 755/755M. The zinc coated steelsubstrate conforms to ASTM A653/653M,coating designation Z275 (G90). The zinccoated steel substrate is normally availablein thicknesses from 0.38 mm to 1.30 mm(0.015 in. to 0.051 in.) and in widths up to1219 mm (48 in.). Barrier Series isavailable in the coating thicknesses shownin Table 1. The topside surface (normally

the intended exposed surface) is texturedwith an embossment for uniform gloss andappearance.

Before coating with the Barrier Seriessystem, the substrate is cleaned, and achemical pretreatment is applied toenhance paint adhesion and corrosionprotection. The Barrier Series primer isspecially formulated to provide exceptionaladhesion between the pretreated substrateand the PVC coating throughout the life ofthe cladding. The primer containscorrosion inhibitors to further improveadhesion and corrosion resistance. Theprimer layer is 7.5 µm (0.3 mils) under100, 200 or 300 µm coatings. The reverseside, or Washcoat, can be applied eitherwith the special Barrier Series primer ordirect to substrate.

Unlike other plastisols, Barrier Seriescontains no solvent thinners, soconsequently virtually none of the appliedvolume evaporates during curing. Thisapproach, made possible by the unique

formulation, reduces porosity, enhancesfilm integrity and long-term flexibility.The photochemical stability, film integrity,and long-term flexibility combine toprovide lasting cracking resistance and theassurance of colourfastness for everyBarrier Series colour offered.

The PVC coating is applied as a liquidplastisol and heat cured in a coil coatingoperation producing a homogeneous,cohesive, solid film. Barrier Series plastisolis unique in coil coating because 100 percent of the applied wet film becomes asolid coating. This permits the lay-downof thick (100 to 300 µm) coatings withhigh film integrity in a single pass on apaint line. The Barrier Series thick coatingoffers a remarkably effective, lasting barrieragainst harsh industrial environments andtoday's increasingly aggressive urbanenvironments.

The Barrier Series coating was specificallyformulated for metal cladding. Thisformulation provides coating film integrity

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Barrier Series Prefinished Sheet Steel

ProductPerformance & Applications

(1) Thickness tolerance for the Barrier Series coating exclusive of zinc coated steel substrate is ±10%.(2) 1 mil = 0.001 in. = 0.025 mm = 25 µm(3) Washcoat is a thin film, approximately 5 µm (0.2 mils) thick, applied to the backside, intended only

as a protection for the coated sheet while in coil form.(4) Barrier Series for the reverse side is typically specified the same colour as the topside.(5) 100 µm (4 mils) Barrier Series is intended only for residential and other applications away from

heavy industrial environments.

Table 1: Barrier Series - Coating Thicknesses

Nominal Film Thickness (1) – Top (Exposed Side)

Nominal Film Thickness (1) – Reverse Side (4)

µm

200

200

200

300

300

300

100(5)

100(5)

Mils (2)

8

8

8

12

12

12

4(5)

4(5)

µm

Washcoat (3)

100

200

Washcoat (3)

100

200

Washcoat (3)

100

Mils (2)

Washcoat (3)

4

8

Washcoat (3)

4

8

Washcoat (3)

4

Barrier Series Prefinished Sheet Steel

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for long-term durability as demonstratedby the following high performanceattributes:

High Flexibility – A proprietary formulationprovides long term coating flexibilityretained after many years' exposure.Barrier Series can be factory or fieldformed at room temperature withoutspecial equipment. There is no cracking,chipping or loss of adhesion due tothermal stresses or from impact.

Toughness – Barrier Series is highlyresistant to through-coating damagecausing exposure of the zinc-coatedsubstrate.

Weatherability – All exterior Barrier Seriescolours resist photochemical degradationand colour change under exposure to solarradiation. Table 2 provides typical colourchange data.

Chemical Resistance - Barrier Series ischemically resistant and resists attack byalkalis, acids, salts or bleaching agents.

CASE HISTORIES

Barrier Series has been used by a widevariety of industries in every part ofCanada. Field surveys of selected severelocations are undertaken regularly to verifythat Barrier Series is providing the requiredprotection and fulfilling the supplier andthe customer's expectations. Presentedhere are case histories representing some ofthe oldest applications of Barrier Series invarious applications. Each of the sites hasshown outstanding maintenance-freeservice with the expectation of many yearsof satisfactory service ahead.

A) HEAVY INDUSTRIAL

Copper Mine and Refinery (Ontario) The expansion of a copper mine andrefinery in 1977 represents the firstcommercial use of Barrier Series. Severalbuildings on the site have been clad withBarrier Series, subjecting the product to arange of aggressively corrosive conditions.All were inspected, showing outstandingperformance, some up to 19 yearsexposure:

• Water Cooling Tower: The claddingabove the open tank of the watercooling tower is constantly subjected toa condensing water mist. There was noblistering or loss of adhesion at thetension bends or in the flats. Thevertical mill edges were in excellentcondition as were the sheared baseedges and the base flashing as can beseen in Figure 1.

• Sulphuric Acid Plant: The acid plantwas clad in Barrier Series panels andbase flashing. After 15 years exposure,it was observed that while the acid hadcaused deterioration of the concretefoundation, the cladding was generallyin excellent condition.

Figure 1: Mine water cooling tower. West exposure above the tanks.Insert: A quick cleaning showed that the drip edge was in excellentcondition. Eleven years exposure in Northern Ontario.

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• Copper Smelter: Here, the sulphide oreis roasted and SO2 gas can be released.After 19 years, bends and edges of theBarrier Series were in fine condition onthe interior liner and on the exteriorwalls including 45˚ exposures as shownin Figure 2.

• Refinery: Here, the acid coppersulphate solution is electrolyzed toform 99 per cent pure copper. Abovethe open electrolytic cells, the air iswarm, humid, and acidic. The BarrierSeries interior cladding on the exhaustwall had no blisters, rusting or edgedelamination. See Figure 3. Aftereleven years of constant wear frommine dust, sand and other airborneparticulates, the low intensityembossment on the surface of thecladding had not been abraded and haslargely retained its original appearance.

Pulp & Paper Mills (Ontario & Quebec)Barrier Series has proven to be an idealcladding selection for the corrosive,alkaline sulphate environment of the pulpand paper industry.

• Recovery Boiler Building (Ontario):Barrier Series was used here to enclosethe recovery boiler building, 11 yearsold at the time of inspection. Thecladding system used a 200/100exterior and 200/100 liner. Duringrecovery, the spent cooking liquor fromthe pulping process (black liquor) isfirst concentrated and then combustedto remove dissolved organic matter andreclaim alkali. The interior atmosphereis hot, the wall and the roof surfaces areconstantly contaminated with alkalinesulphate and the air is contaminatedwith sulphur-bearing gases. Theinterior liner sheet and deck were inexcellent condition. The exteriorcladding is subjected to an even moreaggressive situation. In addition to thealkaline sulphate, the exhausts from theother operations (including corrosive

chlorine vapours) can be windpropelled against the cladding. Theeast wall directly facing the otheroperations, the west wall at the base ofthe building (see Figure 4) and thesouth wall at an upper elevation (seeFigure 5) were all free of blisters on thepanel face, tension bends and milledges. The base edge was virtually in

Barrier Series Prefinished Sheet Steel

ProductPerformance & Applications

Figure 2: Mine smelter building exterior. Base edge and 45° angledcladding exposure. Nineteen years exposure in Northern Ontario.

Figure 3: Mine refinery building interior. The Barrier Series cladding isabove the exhaust fan. Eleven years of exposure in Northern Ontario.

Barrier Series Prefinished Sheet Steel

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perfect condition on all parts of thebuilding with the occasional exceptionoccurring at locations affected by millexhausts.

• Paper Finishing Building (Quebec):Similar performances can be seen inother paper mill applications of Barrier

Series since the initial applications inOntario. A large Kraft and fine papermill in Quebec used Bone White andSky Blue in many insulated, doubleskin construction areas. The colourretention advantage of Barrier Seriescan be seen in Figure 6 showing abuilding with both new and nine year-old cladding.

Potash Plant (Saskatchewan)Potash plant environments areexceptionally corrosive due to heavychloride contamination throughout theplant. Many construction materials have adifficult time providing durable service inthis industry. Barrier Series has proven tobe an excellent material for this demandingend-use.

• Raw Ore Storage Building: Thisbuilding was installed with a 300/100exterior and 200/100 liner sheet androof deck. After 10 years service, theexterior performance is further evidenceof the premium protection afforded byBarrier Series in this extremely harshchloride environment. The face of thepanels, including tension bends, wasfree of corrosion. All vertical mill edgeswere in good condition. There wassome minor (up to 15 mm) creep alongthe bottom edges, resulting fromexposure to intermittent chloride-contaminated water puddling. Theinterior of the plant is hot, humid, andcovered in potash, as shown in Figure 7.

B) ARCHITECTURAL, RESIDENTIAL,COMMERCIAL & AGRICULTURAL

Barrier Series is being used for cladding ofnon-industrial buildings where aestheticsas well as corrosion resistance are needed.Barrier Series is a cost effective and durablealternative to other building materials forhomes, schools, churches and offices incorrosive environments. These corrosiveenvironments can be the result of nearby

Figure 4: Pulp & paper plant, recovery boiler building. Ground level westexposure below exhaust duct showing contaminate build-up and minoredge creep on the cladding. Eleven years exposure in Northern Ontario.

Figure 5: Pulp & paper plant south wall,upper elevation of recovery boiler building.Eleven years exposure in Northern Ontario.

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industry, proximity to water (particularlysaltwater), protected exposures, orproximity to traffic in road-salt regions.The product can also be used for animalconfinement structures in agriculture,where the animal wastes create severecorrosion conditions.

In severe environments such as thosewithin close proximity to salt water, 200 µmBarrier Series should be used. In lesssevere environments, 100 µm Barrier Serieswill provide years of satisfactory service.The 100 µm product provides thetraditional toughness and corrosionprotection expected from Barrier Series at alower applied cost.

• Church (St. John's Newfoundland):Marine exposures, particularly onCanada’s east coast, are often classifiedas aggressive environments regardless ofuse because of the high saltcontamination. The church is locatedapproximately 2 km from St. John'sharbour and was clad with BarrierSeries 200/100 on sloped walls androof. After 12 years in service, therewas no deterioration evident on the flat,tension bends and side mill edges. Thebase edge of the cladding showed minorcreep in random areas from 0 to 2 mm.

• Residential Roof (Ontario): Residentialroofs are subject to a wide range ofenvironmental conditions due togeographic diversity and after-installation traffic across the product.The ability of the Barrier Series productto resist physical damage sets it apartfor the application shown in Figure 8.This installation is located in Ontario,on a cottage-country lake, and was cladwith Barrier Series 100/washcoat. After5 years in service, there is no evidenceof any corrosion or weathering-relateddeterioration.

APPLICATION NOTES

Colour: Barrier Series is available in avariety of exterior colours, as presented inthe colour chart provided. These coloursand the pigments used to produce themhave been specifically chosen to be colour

Barrier Series Prefinished Sheet Steel

ProductPerformance & Applications

Figure 6: Kraft fine paper plant, paper finishing building. Comparison ofnew and old nine-year cladding. The newer cladding is on the right. Locationin Northern Quebec.

Figure 7: Potash plant, raw ore storage interior. A hot and humid potashenvironment containing potash dust. Note potash build-up on light fixtures.Eleven years exposure in Saskatchewan.

Barrier Series Prefinished Sheet Steel

ProductPerformance

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fast and to retard ultra-violet degradationof the PVC resin. It is for this reason thatthe Barrier Series colour range is not asbroad as the other exterior prefinishedpaint series, and special colourdevelopment cannot proceed without athorough technical assessment. Note thatthe QC-1546 Interior White colour isspecially formulated to resist sulphidestaining in locations not subject to outdoorultra-violet weathering and should only beused for interior applications.

Surface Embossment: One side (the topside) of Barrier Series is given a mildembossment to enhance uniformity of thefinish. It is recommended that this be theexposed face.

Roof Decking: Barrier Series can be rollformed into a variety of profiles for roofdeck, and can be used in applicationswhere the underside of the deck is exposedto the building interior. The coil will beroll formed to place the topside coating onthe underside of the deck. A washcoat isnormally specified for the reverse side ofthe sheet. The vapour barrier needs to bemechanically fastened to the deck, sinceadhesives used to bond a vapour barrier toa Barrier Series coating have not beenapproved by all insurance agencies. Barrier

Series in not recommended for compositefloor deck.

Cut Edge Protection: The Z275 (G90)zinc coating provides sacrificial protectionto the steel substrate by corrodingpreferentially, including the mill edges of aprefinished product like Barrier Series. Itis possible that the exposed edges,resulting from normal fabricationprocesses, could in the long-termpotentially result in edge creep (corrosionof the steel and potential for peeling of thepaint) from the galvanic consumption ofthe zinc. In most applications, thisreaction is slow and marginal. In thoseisolated instances where heavy chemicalcontamination (e.g. chlorides) or extendedwetness is expected, the designer shouldconsider some form of edge protectioncompatible with the paint system. Edgescan be covered with thick film tape,waxed, hand painted or caulked with asealant as shown in Figure 9.

Flame Spread: According to the NationalBuilding Code of Canada (NBCC), paint isconsidered to be a minor combustiblecomponent and is permitted in a buildingrequired to be of noncombustibleconstruction. For the purposes of NBCC,it is understood that paint coatings can notbe more than 3 mm thick to be consideredas paint. The thickest Barrier Seriescoating is 12 mil or 300 µm thick.

Geographic Limitations: Barrier Series willexhibit a greater colour change in southernclimates. For this reason, white and pastelcolours should be considered for projectsoutside Canada in southern locations.

Forming and Fabricating Limitations:Barrier Series can be readily cold formedby cold rolling into almost any deck orpanel configuration. Barrier Series canbend back on itself (i.e. a bend radius ofzero times the thickness, or "0T") withoutfilm cracking.

Figure 8: Ontario cottage, roof clad with Barrier 100/washcoat. Fiveyears exposure.

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Touch-up: The thick and tough BarrierSeries film is difficult to penetrate, whichreduces the need for paint touch up.Should the damage be severe enough topenetrate the coating, the sheet must bereplaced.

Repainting: Weathered Barrier Seriesmakes a good substrate for repainting, toeither freshen the appearance, or changethe colour. Repainting new installations ismore difficult. In either situation, consultyour paint supplier for appropriaterepainting methods.

Brittleness and Heat Stability: The brittletransition temperature and the heatstability temperature provide a goodworking range for the system. The PVCfilm embrittles at -20˚C (-4˚F) and shouldnot be formed below this temperature.The film is heat stable to 100˚C (212˚F)for short periods. A maximum ongoingexposure temperature (servicetemperature) of 65˚C (150˚F) isrecommended.

Food and Drug Approvals: Contact yourCSSBI fabricator members for informationon approved systems.

Storage and Handling: Barrier Seriesproduct should be stored in cool, dryconditions prior to erection. Plastic tarpsshould not be used. Foam interleafing orsheet protection that traps moisturebetween the sheets should not be used.

FIELD PERFORMANCE

The exceptional performance of BarrierSeries in the broadest cross section ofcorrosive applications is the strongestconfirmation that it is the foremostcorrosion resistant cladding material.While Barrier Series has been used tostriking aesthetic advantage in claddingdesign, the principal attribute is long-term

performance. Appropriate acceleratedlaboratory tests were selected to examinethe ability of Barrier Series to satisfy thesetwo critical requirements.

Table 2 provides a summary of severallaboratory tests on Barrier Series product.Unless otherwise noted, the test samplesare 203 mm x 101 mm (8 in. x 4 in.), with200/100 (8/4 mil) coating i.e. 200 µm(8 mil) topside and 100 µm (4 mil)reverse. Where appropriate, test panels aregiven a 90˚, 1.6 mm (0.063 in.) insideradius brake bend at room temperature tosimulate profile tension bends. The resultsare typical values generated from randomproduct sampling. They are not minimumvalues and cannot, therefore, be consideredto be a specification.

When promising test results are combinedwith positive field performance in well-documented and well-definedenvironments, a solid information basebecomes available for a more insightfulassessment of new applications and enduses. The field performances referenced inTable 2 are representative of severalindividual field inspections carried out.

Barrier Series Prefinished Sheet Steel

ProductPerformance & Applications

Figure 9: Example of effective edge sealing with caulking on an exterior wall.

Barrier Series Prefinished Sheet Steel

ProductPerformance

& Applications

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SUMMARY

Barrier Series has proven itself overnumerous applications to be a durablecladding system for the harshestenvironments. Numerous laboratory testsand field evaluations of sites, some overtwenty years old, verify that itsperformance is excellent. Its long-termdurability makes it the unquestionedchoice for cladding and roofingapplications in aggressive environments.

Need More Information? Should a questionarise regarding the suitability of BarrierSeries for a particular application, pleasecontact your CSSBI fabricator foradditional guidance.

Table 2: Summary of Barrier Series Laboratory and Field Results

Test and ExposureConditions

Barrier Series Laboratory(1) Test Results

Barrier Series FieldPerformance

3000 hours – no blistering orloss of adhesion

100 L/mil of coating thickness tosteel exposure

0-T 180˚ Bend – no cracking

No cracking or loss of adhesionup to 18 Joules(2)

-20˚C to 65˚C(3)

All colours typically show ∆Eless than 10 after 20 years inSouthern Ontario

19 years corrosion- free serviceon a cooling tower

Excellent performance in erosivemining and potash environments

No significant tension bendcorrosion noted to date (20 + years)

Badly dented pulp warehousewall free of corrosion (after 8years)

Outstanding service in extremeclimates

20+ years of excellentperformance in demanding darkcolours

(1) Accelerated testing. See Appendix for description of testing conditions.(2) For 0.61 mm (0.024") thickness. The amount is thickness dependent.(3) Barrier Series should not be exposed to high temperatures for extended periods. Short term

exposures up to 100˚C will not damage the product, but for extended service a maximum temperatureof 65˚C should be observed.

Condensing Humidity

Sand Abrasion

Formability

Impact

Heat Stability

Colour Stability

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APPENDIX

Typical laboratory tests conducted onBarrier Series and their results aredescribed below:

CONDENSING HUMIDITY: Specification ASTM D 2247The test is a measure of performance inenvironments and exposures experiencinga long time of wetness in a neutralenvironment. Panels are exposed tocondensing humidity (100%) at 38˚C(100˚F). Result: Barrier Series has beentested in this exposure to 3000 hours withno blistering or loss of adhesion.

FALLING SAND ABRASION: Specification ASTM D 968This test examines the coating's resistanceto erosive actions such as blowing dust,sand, sleet, snow, etc. Sand is droppedfrom a height of four feet through a funnelonto an angled, flat sample. Result: Thecoating withstood 100 litres of sand permil of coating thickness before exposingthe substrate.

FORMABILITY: Specification ASTM D 522The test examines barrier coatingcontinuity and physical adhesion after asevere deformation. The panel ispreformed around a mandrel and thencompressed to the desired bend diameter in a vise. Result: Barrier Series can accepta 0T, 180˚ bend without cracking or loss ofadhesion.

DIRECT AND REVERSE IMPACT:Specification ASTM D 2794This test determines the organic coating'sability to withstand non-cutting forcesprovided that metal fracture does notoccur. At room temperature, a standardweighted ball is dropped from a height soas to deform the substrate and the coating.The coating is then checked for damage oradhesion loss due to the effects of rapid

deformation (impact). Result: BarrierSeries had no cracking or loss of adhesionat impacts to at least 18 Joules.

COLOUR STABILITY: Specification ASTM D 2244An exterior cladding should not exhibitexcessive colour fade when exposed tosunlight. For the purpose of measurement,colour can be defined as the location of apoint on a three-dimensional coordinatesystem where one axis represents the blue-yellow line, another the red-green line andthe last the white-black line. Fade (or anycolour change) is the difference in positionof the two points defining the colours inmuch the same way as the length of a linedefines the distance between two points. Thecolour change is measured in units of ∆E,

where, √(∆L)2 + (∆a)2 + (∆b)2

Result: All Barrier Series colours whenexposed 45˚ south on test racks inSouthern Ontario had ∆E less than 10 after20 years.

Barrier Series Prefinished Sheet Steel

ProductPerformance & Applications

QC1584Grey

QC1562Dove Grey

QC1508Bone White

Barrier Series Prefinished Sheet Steel

ProductPerformance

& Applications

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COLOURS AVAILABLE FOR BARRIER SERIES

QC1501White

QC1513Light Grey

QC1517Black

QC1570Greystoke

QC1575Alouette White

QC1593Pewter

QC1504Charcoal

QC1509Pacific Turquoise

QC1511Gold

QC1512Medium Brown

QC1516Monterey Blue

QC1518Dark Brown

QC1520Sea Green

QC1521Gulf Green

QC1524Canners Brown

QC1539Antique Ivory

QC1546Interior White(Interior use only)

QC1555Sky Blue

QC1556Sapphire Blue

QC1558Tile Red

QC1565Mocassin

QC1573Alouette Teal

QC1576Alouette Blue

QC1581Beige

QC1583Wickertone

QC1585Brown

QC1592Herringbone

QC1594Green

QC5875Light Gold

Note: Printed coloursmay vary from actualpaint samples.