Umicore Building Products

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1 "VM ZINC " THE ORIGIN OF THE NAME ZINC ALLOY AND ITS COMPONENTS: Zinc has been used in roofing, as a rolled metal product, for almost 200 years in Belgium and France (Vieille Montagne was founded in 1837 and merged with the Union Minière group in 1993, to form VM ZINC ). Pre-formed products were also developed for the use of rainwater drainage systems such as gutters and downspouts. Throughout the years, the fabrication process and the production of zinc at VM ZINC evolved, and in 1960 alloys of copper and titanium were added to the zinc, hence the name Zinc-Copper-Titanium (or Titanium Zinc). The integration of these alloys enhances the properties of zinc used in the building industry: - Copper- increases the tensile strength resistance of the metal - Titanium- increases its creep resistance (i.e. the resistance to deformation over time) - Combining both alloys decreases the expansion coefficient. VM TITANIUM ZINC AND EUROPEAN NORMS: VM Titanium Zinc products conform to the official reference in European building norms, and more specifically to the European Norm EN 1179 Zinc and zinc alloys - Primary zinc, which specifies the classifications, chemical compositions, marking and other requirements for primary zinc. The components of the VM Titanium Zinc alloy are as follows: - Zinc purity at % - Copper 0.08 % = Cu = 1,0 % - Titanium 0.06 % = Ti = 0.2 % The alloy additives have also permitted the use of long sheets or strips which can offer an aesthetic and practical advantage over the non-alloyed zinc sheets used in the past. VM Zinc material is a top quality product. With the evolution of the rolling process, the metal is rolled at a constant thickness and dimensional tolerance. These thickness and tolerances are respected because they conform to the European Norm EN 988 Zinc and zinc alloys - Specification for rolled flat products for building, which specifies requirements for rolled flat products for building purposes made from zinc-copper-titanium alloy in the form of strip, sheet, or cut length. ZINC AND GALVANIZATION: Zinc, a non-ferrous metal, is self-protecting. Natural zinc forms its own protective layer, called a patina, when it is in contact over time with air (oxygen and carbon dioxide), and water. The protection against corrosion is also used on other metals by coating them with a thin layer of zinc: this process is called galvanization. 1

2 VM ZINC METALLURGICAL ASPECTS The extensive experience during almost 200 years in metallurgy and the continued research and development activities with zinc and zinc derivatives have permitted Union Miniere to acquire industrial expertise, which has resulted in a worldwide reputation of product reliability. ABUNDANCE OF ZINC ORE RESERVES: Zinc is an abundant metal available in large reserves throughout the world. Mining resources are mainly located in North America and Sweden. There is an estimated level of 300 million tons of zinc ore currently available in zinc ore reserves. Recycling accounts for about 20-30% of total zinc consumption (estimated at 6.7 million-tons/ year), and will increase with improved methods. Assuming future exploration for zinc ore reserves other than those that are currently being used, zinc needs, at the current annual extraction rate, should be satisfactory for many centuries to come. EXTRACTION and METALLURGICAL PROCESS: Described in summary, the principal steps in the metallurgical process consist of: ore extraction from the mines, grinding, and first phase of enrichment and purification roasting process electrolytic treatment and collection of pure zinc deposits on cathodes addition of alloys and melting of zinc into the form of ingots continuous casting and hot rolling for production of sheets and strips The processing and rolling of titanium zinc, which results in the VM ZINC sheets and coils, forms the basis for the production of derivative products in the VM ZINC range. INDUSTRIAL PRECISION: VM ZINC material is a top quality product: with the evolution of the rolling process, the metal is rolled at constant thickness and dimensional tolerances which are respected by conforming to the European norm EN 988 Zinc and zinc alloys - Specification for rolled flat products for building. 2

3 QUARTZ-ZINC LIGHT GREY PRE-WEATHERED ZINC DESCRIPTION AND CHARACTERISTICS: VM ZINC s rolled zinc products are available in different surface aspects. These different aspects are achieved at the moment of fabrication. QUARTZ-ZINC is the name given to the factory pre-weathered surface layer which is similar to the patina formed by natural zinc after a few years of exposure to the atmosphere (See Evolution of Shades). The pre-weathered patina: The pre-weathered patina of the QUARTZ-ZINC is the result of a chemical process, which consists of the modification of the external surface of natural zinc, called phosphatation. From the moment of fabrication, QUARTZ-ZINC provides an appearance similar to the patina of natural VM ZINC usually obtained after 6 months to 2 years (See Weathering Process ). One of the many advantages of QUARTZ-ZINC is that it offers a uniform and homogeneous patina and color from the moment of fabrication. The color of QUARTZ-ZINC is a light gray and its chromatic coordinates are: Y± 25 - x = 0,32 - y = 0,32 The patina of QUARTZ-ZINC remains absolutely stable over time. The patina s phosphatation layer is very dense and adherent and it is perfectly insoluble in water, unlike a sulfate-layer. This makes QUARTZ-ZINC totally environment-friendly. Installing QUARTZ-ZINC: QUARTZ-ZINC can be bent, folded, or profiled without any surface changes (similarly to natural VM ZINC ) and therefore allows the same exact methods of laying. As long as the laying respects recognized good practice. European Norms: QUARTZ-ZINC conforms to the European Norms EN 988 and EN 1179 for top quality titanium zinc used in the building industry. 3

4 ANTHRA-ZINC DARK GREY PRE-WEATHERED TITANIUM ZINC DESCRIPTION AND CHARACTERISTICS: VM ZINC s rolled zinc products are available in different surface aspects. These different aspects are achieved at the moment of fabrication. ANTHRA-ZINC is the name given to the factory pre-weathered surface layer. The pre-weathered patina: The pre-weathered patina of the ANTHRA-ZINC is the result of a chemical process, which consists in the modification of the external surface of natural titanium zinc. From the moment of fabrication, ANTHRA-ZINC provides a uniform and homogeneous dark gray color, similar to that of slate, and its chromatic coordinates of ANTHRA-ZINC are: Y± 5 - x = y = The patina of ANTHRA-ZINC remains absolutely stable over time and is perfectly environment-friendly. Laying ANTHRA-ZINC: ANTHRA-ZINC can be bent, folded, or profiled without any surface changes (similarly to natural VM ZINC ) and thus allow the exact same methods of laying. As long as the laying respects recognized good practice. European Norms: ANTHRA-ZINC conforms to the European Norms EN 988 and EN 1179 for high-quality titanium zinc used in the building industry. 4

5 VM ZINC PLUS WITH PROTECTIVE BACKSIDE COATING DESCRIPTION OF THE VM ZINC PLUS ROOFING MATERIAL: VM ZINC PLUS consists of rolled zinc, 0.70mm, 0.80mm, or 1.00mm in thickness, which is protected on its backside by a proprietary 60 micron coating of furnace-polymerized polyester and polyurethane-polyamide liquids VM ZINC PLUS is available in two pre-weathered surface aspects: QUARTZ-ZINC PLUS whose patina color is a light gray and ANTHRA-ZINC PLUS a dark gray zinc which is a color close to that of slate. Characteristics of VM ZINC PLUS : Allows direct lying of zinc roofing on an incompatible deck. Laying VM ZINC PLUS : VM ZINC PLUS can be bent, folded, or profiled without any surface changes (similarly to natural VM ZINC ) and thus allow the exact same methods of laying. As long as the laying respects recognized good practice. American Norms: VM ZINC PLUS properties: Coating on backside of the zinc must have a minimum abrasion resistance of 140 liters as per ASTM D-968, method A. European Norms: VM ZINC PLUS conforms to the European Norms EN 988 and EN 1179 for top quality rolled zinc used in the building industry. Please consult your VM ZINC partner for recommendations on use and handling. 5

6 VM ZINC WALLSHIELD underlayment VM ZINC WALLSHIELD by Proctor Group is a fabric underlayment and slip-sheet. It is a high permeability; double spun bonded non-woven polypropylene fabric. 1. Weight: 3 oz/sq. yd. (100g/sq.m.) 2. Thickness: inch (0.50 mm) 3. Water Vapor Transmission 2666 gm -2 day -1 Roll Lentgh: 164 feet (50m) Roll Width: 39 inches (1m) Roll Weight: 164 x 39 (50m x 1m) 17.6 lb. (8 kg) The VM ZINC WALLSHIELD can resist to a water head of 12 (302mm). It is then adapted for a temporary protection of the roof work. It is UV resistant and can stay uncovered for 3 months. Because of its water vapor permeability water trapped under the membrane before the installation of the zinc panels can be eliminated by vapor diffusion. Installation method: VM ZINC WALLSHIELD shall be installed horizontally over the wall sheathing per the plans with all fabric overlaps (horizontal and vertical) to be a minimum of 6. The maximum distance between fastening points shall not exceed 18. In addition where flashings, trims, etc. occur VM ZINC WALLSHIELD shall be installed between the flashings, trims, etc. and any VM ZINC wall cladding panels. Any cleats, clips, or strips used to hold any VM ZINC wall cladding panels shall be installed over VM ZINC WALLSHIELD. Finally, VM ZINC WALLSHIELD shall also not be installed were it will block any airflow. For additional protection, the VM ZINC WALLSHIELD can be used at the perimeters and/or wall penetrations (windows, doors, etc.) to avoid any water penetration before the installation of any VM ZINC wall cladding panels. In this application VM ZINC WALLSHIELD will again provide a maximum 3 months of temporary protection. This extra protection around the perimeters and/or penetrations shall be removed before the installation of the VM ZINC wall cladding panels as the membrane does block airflow. Cold wall application with corrugated steel deck support (back side of the steel deck is ventilated): The VM ZINC WALLSHIELD underlayment is used between the steel support and VM ZINC wall cladding panels. It shall be installed horizontally over the steel deck using screws with washers. It should also be installed on the bottom plate* of the steel deck. VM ZINC WALLSHIELD acts as a temporary protective membrane (maximum exposure 3 months) and as a separation membrane between the zinc and the support. Direct contact between the VM ZINC wall cladding panels and the steel deck shall be limited to the very strict minimum. * The bottom plate of the steel deck is the part attached to the building structure. The zinc panels shall be attached to the top plate of the steel deck Highwoods Blvd Suite 104 Tel: (919) cad.rdu@umicore.com 6

7 NATURAL WEATHERING PROCESS OF NATURAL ZINC Natural zinc and its weathering process: Zinc must be in contact with the air s elements (oxygen, water, and carbon dioxide) in order to weather properly. This process occurs in two main phases, beginning with the formation of a layer of zinc hydroxicarbonate. This layer is progressively replaced, when in contact with a proper balance of water and carbon dioxide, by a zinc carbonate layer. This is called the patina. This layer protects the zinc against further corrosion and offers the metal its long lifespan. The correct weathering of zinc will also primarily depend on proper storage conditions: a dry, well-ventilated warehouse at constant temperature is highly recommended to avoid condensation on the metal. Zinc hydroxide Natural Protective basic zinc Hydroxy-carbonate layer. Commonly Know as the patina. NATURAL ZINC Time scale 6 months to 2 years * 2 to 3 years * * This approximate time scale will depend on local climatic conditions such as the amount of exposure the zinc has to wind and the sun. It will also depend on environmental conditions like the type and amount of air pollutants, etc. 7

8 EVOLUTION OF SHADES THE PATINA OF NATURAL ZINC AND QUARTZ-ZINC ORIGINAL COLOURS OF THE NATURAL ZINC AND QUARTZ-ZINC: The rolled milled finish of zinc is that of a shiny metal. It will weather over time when in contact with air and water to form a self-protecting layer, called the patina. Over time the color of natural zinc changes to reach the light gray color of its patina. QUARTZ-ZINC is a pre-weathered zinc whose color is light gray, similar to that of the light gray of the natural patina. On a luminance scale from 0 to 100, where Y=0 is black and Y=100 is white, the Y of the two products at the time of fabrication are as follows: Y = 25 to 30 for natural zinc; Y = 20 to 25 for QUARTZ-ZINC. TIME REFERENCES FOR THE EVOLUTION OF THE PATINA: Natural zinc will create its natural patina over time (6 months to 2 years), depending on site conditions: rural non-polluted, urban medium-polluted, industrial highly-polluted. During the first years, the light gray color is attained rather rapidly and then it evolves slowly over the years until it stabilizes (after approximately 4 years). 30,0 28,7 25,3 25,0 Luminous luminance (tint) 20,0 15,0 10,0 18,6 16,6 20,8 14,5 20,3 16,1 19,8 18,4 5,0 0,0 Start 6 months 12 months 18 months 24 months Time of exposure Natural TZ tint QUARTZ-ZINC tint Source: Tests executed by the UM Group Research & Development laboratory in Calais (north of France)

9 ZINC HANDLING AND STORAGE (SHEETS AND COILS) Correct handling and storage of rolled zinc will contribute to the lifespan of the roofing and/or cladding material. The following precautions apply to pre-weathered zinc and to pre-weathered ZINC PLUS products, in the form of sheets or coils. HANDLING RECOMMENDATIONS: Avoid dropping zinc sheets, coils or formed pieces: blows or punches in the material can cause folds or «bumps» in one or several parts of the sheets or coils, which in turn damage the appearance of the product. Furthermore, cracks may occur in these places over time. Avoid dragging or sliding of all products over rough surfaces: deep scratches in the material can also cause cracks either during forming or after installation, due to the effects of expansion and contraction of the metal. Avoid large temperature variations during transportation: temperature variations can cause condensation build-up, which in turn will cause zinc hydroxide («white rust») on the metal. When shipped by containers, it is essential to ventilate the containers immediately upon receipt and store the products as soon as possible in the correct conditions mentioned below. STORAGE RECOMMENDATIONS: Sheets and coils of zinc must be stored in a well-ventilated, sheltered and dry warehouse, with a constant temperature so as to avoid condensation build-up. Sheets and coils of zinc must be separated from the ground by a pallet which allows sufficient air space for the correct ventilation of the products. In order to avoid deformation of the metal, sheets must be stored flat on the pallet. When coils are shipped, they may be placed either on their horizontal axis or vertical axis, depending on the client s request. It is recommended that the coils be stored in their original packaging. If coils are to be stacked due to lack of storage space, the following recommendations must be respected: - If the coils are delivered on their horizontal axis, the pallets must be stored in their original packaging, and preferably individually on separating racks; - If the coils are delivered on their vertical axis, the pallets may be stored on top of one another, up to a maximum of 4 pallets for reasons of stability. The time of storage of sheets and coils must be as short as possible, especially on site. Please consult your VM ZINC partner for further information and specific storage recommendations. 9

10 ZINC CLEANING CONDITION FOR USE AND MAINTENANCE Correct maintenance will contribute to the lifespan of the roofing and/or cladding material. The following precautions apply to pre-weathered zinc and to pre-weathered ZINC PLUS products used for wall and roof applications. The maintenance shall be at the owner s expense after the work has been completed. The maintenance work falls within the province of the different trades. NORMAL MAINTENANCE WORK: Periodic removal of leaves, grass, moss and other deposits or foreign matter. Maintaining the rainwater drains and keeping them in good operating condition. Maintaining the ventilation units of the roofing and keeping them in good operating condition (if necessary). Maintaining any elements which contribute to the roof being watertight (filets, drips, fascia, junctions roof to wall, etc.), and keeping them in good operating condition. FOOT TRAFFIC: Normal use implies traffic reduced to a strict minimum for normal maintenance defined above and other work, such as: chimney sweeping, installation and servicing of aerials, etc. It is advisable to take all the precautions and useful provisions necessary so as not to cause: Any punching of the flat parts or deformation of the joints, roll capping, roof vents, etc. For this, it is advisable to install walkways; Any deterioration of the pre-weathered layer. In the case where technical equipment requiring frequent inspections (air conditioning, for example) is installed on the roof, certain adaptive arrangements such as walkways should be considered. During installation, maintenance, or use of roofing which contains skylights, or other accessories made of glass fiber reinforced polyester, care should be taken not to press directly on these materials. Scaffolding, platforms, planks or ladders should be used. Note: it must be called to the owner s attention that when the ambient atmosphere becomes more aggressive (new type of pollution for example), the original coverings adaptation must be reexamined, and if necessary, the covering must be adapted to these new conditions. CLEANING: The rain will drain some of the dust deposits off the roof and walls. It is recommended to limit the cleaning of the zinc material to specific areas such as areas where decaying leaves cover the roofing panels. Precautions have to be taken to avoid any deterioration of the patina. We recommend cleaning the zinc material with warm water (no high pressure) with mild, thinned down detergent and gently rubbing the panels in the same direction as the grain, using a clean cotton cloth. On areas covered with graffiti we recommend using GRAFFITI REMOVER from KRYTON. FINGERPRINTS AND SCRATCHES: Because of the self healing nature of zinc fingerprints and scratches will be obscured by the formation of the patina over time. It is recommended to let them heal on their own. 10

11 SOLDERING ZINC SAL-AMMONIAC BLOCKS: Solid Sal-Ammoniac is used for tinning soldering coppers fast. Blocks are available in 1/4, 1/2 and 1 Lb. sizes, individually boxed. ITEM SINGLE PART NO. CASE PART NO. NO. IN CASE SHIP WT. CASE S-400, 1/4 Lb. Sal Block # S-200, 1/2 Lb. Sal Block # S-100, 1 Lb. Sal Block # STAY-CLEAN SOLDING FLUX (LIQUID): Recommended for tin/lead, tin/antimony and Stay-Brite solders; also for soldering virtually all metals (other than aluminum, magnesium or titanium). Not recommended for use in electrical or electronic applications. Stay-Clean Liquid Soldering Flux conforms to Federal Specification OF506C, Type 1, Form B and commercial spec. A-A-51145C. Liquid SCPF oz. brush cap disp. (24/ carton) SCLF oz. flip top (48/ carton) SCLF oz. Bottle (24/ carton) SCLF oz. Bottle (12/ carton) SCLF1G gallon jug (4/ carton) SOLDER: 50/50 Solder: This is composed of 50% tin and 50% lead. It is liquid at 421 F, solid at 361 F and has a pasty range of 60. This solder will produce a much "flatter" bead than 60/40. Because of its higher melting point, 50/50 solder is often used on the back (or inside) of a stained glass project to protect against "melt through" when soldering the front. Because it spreads and flattens out, 50/50 solder is often used when soldering lead came joints. 11

12 VM ZINC AND LEED Zinc is safe nontoxic natural metal that is all around us and is an integral part of nature. Here are some frequently asked questions and facts about zinc. Q: Can VM ZINC contribute to achieving LEED points? A: Yes. Page 24 of 47 LEED Material and Resources, Credit 2.1 (1 point) and 2.2 (1 point): Construction Waste Management: all zinc construction wastes can easily be sent to any local metal scrap dealer. The zinc in the US is then reused by the galvanisation industry. Page 27 of 47 LEED Material and Resources, Credit 5.1 (1 point) and Credit 5.2 (1 point): Local/Regional Material: Zinc panels formed at our facilities within 500 miles of the project or on the job site contributes to this credit. Zinc Weight per system: Double Lock Standing Seam.8mm 1.55 lbs./sf Flat Lock 1.00mm 1.84 lbs./sf Corrugated 1.00mm 1.80 lbs./sf PPS 2.45 lbs./sf Page 43of 47 LEED Material and Resources, Credit 4.2 (1 point) Recycled Content: Umicore is one of the world's leading players in the zinc industry with a total production capacity of over 600,000 tones. Umicore is the world's number one producer of zinc products for building applications. UMICORE is also the world's largest recycler of zinc, a position that reflects the Group's aim to provide a "closed loop" for zinc products. Concerning the total production of zinc from UMICORE (all applications included), the content of recycled zinc was 21 % in 1998, 23 % in 2000 and 26 % in Furthermore, the percentage of secondary materials used in our Auby plant (zinc smelting and rolling) is 11% in 2003 (Source 2003 UMICORE group annual environment and safety report) Q: Is VM ZINC environmentally sound? A: Yes. Zinc is a nonpoisonous and an environmentally sound product. It does not contain impurities that could be set free under atmospheric conditions or produce toxic fumes in case of fire. Zinc is an element essential for life and most organisms need it to survive. Q: What are the environmental aspects of VM ZINC production? A: Zinc is far friendlier to the environment to make than other metals. For instance it takes much less energy to refine zinc then say aluminum, copper, or stainless steal. For instance, the energy required to produce zinc from ore is 1/4 that of aluminum and 1/2 that of copper and steel. Zinc is also beneficial at the end of its useful life. Scrap of VM ZINC has a high metal content and is practically 100% recyclable. New zinc products are created from recycled zinc such as zinc oxides used in paint, rubber production, and pharmaceutical products. Q: Why is zinc an environmentally sound decision for building? 12

13 A: First zinc is all natural, VM ZINC has no paint or coatings that will wear off over time and adversely affect surrounding materials. It has incredible longevity a properly installed zinc roof or wall system can last up to a 100 years reducing the need for rebuilding. Unlike lead-coated metals there is no worry of lead contamination when using VM ZINC. VM ZINC AND LEED Cont d Q: Where does zinc come from? A: Zinc comes from almost all rocks and many minerals in varying degrees. It also exists naturally in air, water and soil. Zinc is most commonly found in the earth s crust. One third of the zinc used by comes from North America, another one third from Central and South America, and the remaining one-third from other sources. Q: Is zinc poisonous? A: No. Zinc is an essential element for all life, from man to the smallest microorganism. For plants and animals, zinc is obtained from their environment and used for specific functions in their metabolism. For humans, zinc plays an essential role in metabolism. For example, zinc is vital for the proper functioning of more than 200 enzymes, for the stabilization of DNA and the expression of genes, and for the transfer of nervous signals. Zinc is a trace element, as important as iron, magnesium or calcium. In fact, the lack of zinc is a much greater concern than excess. Zinc deficiency can result in several health problems including: skin changes, stunted growth, loss of taste and smell, mental lethargy, loss of appetite, and interference with the functions of the spleen and liver. "There is considerable evidence that zinc deficiency in humans is a serious worldwide problem " -Boston University School of Medicine 1995 " normal, healthy, non-occupationally exposed individuals are at potentially greater risk from the adverse effects associated with zinc deficiency than from adverse effects associated with normal environmental exposure to zinc." -U.N. Environment Program Health Criteria for zinc 1996 Q: Is zinc a heavy metal? A: Yes. However it is not a toxic heavy metal. Many people link heavy metals such as lead with poisonous materials. Let's first examine what a heavy metal is. Q: What is a heavy metal? A: A metal is classified as a heavy metal when its density is greater that 5 g/cm². Hence it is simply a physical property of the metal that puts it in that category of heavy metals, not its toxicity. Zinc has a specific gravity of 7.14 g/ cm². Thus, zinc is a heavy metal. There are many types of heavy metals, some that are toxic and some that are not. For instance gold is one of the heaviest of the heavy metals with a weight of g/cm² and is emphatically non-toxic (it is used in orthodontics). Zinc is also non-toxic (its is given as nutritional supplements). It is important to differentiate zinc and toxic heavy metals. 13

14 PRO-ZINC VM ZINC TECHNICAL SERVICES DESCRIPTION: PRO-ZINC is the name given to the practical technical training offered by VM ZINC. It is primarily meant for installers and contractors wishing to perfect their theoretical and practical skills with state-of-the-art techniques and machinery. Training in workshops: Different modules are available in the clients workshops to present and implement new products and systems, to perfect the knowledge and skills for a better understanding and use of VM ZINC material. PRO-ZINC is also meant for clients and specifiers such as engineers and architects wishing to know more about roofing and cladding products and techniques, or if they are in need of specific technical support. PRO-ZINC MODULES: The following modules are an indication of the topics and contents most often requested. Standing seam system with long sheets Roll cap system with long sheets Roofing solutions with zinc Curved roofs Soldering, Rainwater systems VM ZINC DELTA system Training modules may be adapted to the specific needs of an installer, client or specifier. The dates and duration of the training programs are to be scheduled and agreed upon by contract between the interested party and VM ZINC. Please consult your VM ZINC partner for more information Highwoods Blvd Suite 140 Tel: (919) cad.rdu@umicore.com 14