Understanding Coating Weight Designations For Zinc-Based Coatings On Steel Sheet
Understanding Coating Weight Designations For Zinc-Based Coatings On Steel Sheet
Understanding Coating Weight Designations For Zinc-Based Coatings On Steel Sheet
Introduction
One of the most confusing aspects of coated steel sheet products are coating weight designations and
what they mean, particularly with respect to product performance. This article is intended to clarify this
issue.
Coating Weight [Mass] Measurement Systems
Each coated steel sheet product has its own coating weight designation system, which is defined in the
appropriate ASTM standard. For example, the most widely used ASTM metallic-coated sheet standard is
A 653/A 653M, which covers hot-dip galvanized products. One of the coating weight designation systems
in this standard uses descriptors such as G60, G90, etc. The “G” means the coating is galvanize (zinc),
and the numbers refer to the weight of zinc on the surface of the steel sheet in inch-pound
(English/Imperial) units. Taking G90 as an example, the coating weight on one square foot of sheet (total,
both sides of the sheet) shall have a triple spot test (TST) average minimum of 0.90 ounces. If equally
applied to both sides of the sheet, there would be a minimum of 0.45 ounces on each surface.
The other measurement system in widespread use today is the SI (Metric) system. The conversion from
the inch-pound weight in ounces per square foot (oz/ft2) to the SI mass in grams per square metre (g/m2)
is:
1 oz/ft2 = 305.15 g/m2
To convert from oz/ft2 to g/m2, multiply by 305.15
Example: G90 (0.90 oz/ft2) = Z275 (275 g/m2)
If what we are interested in is the coating thickness, why do ASTM COATING WEIGHT MEASUREMENT
standards not use thickness measurements? The answer is simply
There is a very precise on-line
that it is difficult to directly measure the thickness accurately. For technique for measuring coating
example, a G90 coating contributes about 1.6 mils (0.0016 inches, thickness. The equipment required is
or about 42 microns) to the total thickness of the coated sheet. For expensive, uses sophisticated x-ray
or radio-isotope fluorescence
a coating equally applied to both sides of the sheet, this means devices, and requires considerable
there is about 0.0008 inches (21 microns) of zinc on each surface. expertise to operate. These gauges
To accurately determine the thickness of the coating, the coated repeatedly sense the coating
thickness on each surface, average a
thickness must be measured, the coating stripped off, and then the
large number of readings, and then
steel substrate thickness measured using a gauge capable of convert the results to the more
accurately reading to the nearest ten-thousandth of an inch. This is familiar coating weight units.
very difficult to do with good accuracy. On-line equipment is Laboratory versions of this equipment
are also available. Refer to ASTM
available that can nondestructively do this (see sidebar), but the Test Method A754 for more
most accurate manual method of determining the amount of coating information. These gauges require
present is to measure its weight [mass] on a given surface area calibration based on weigh-strip-
weigh testing.
using the “weigh-strip-weigh” technique. Weigh-strip-weigh refers to
the procedure of weighing a standard size sample of the product
using a very accurate scale, stripping the coating in an inhibited acid without removing any of the
substrate, then reweighing the coupon to determine the weight [mass] loss. This is the original method of
determining coating weight [mass], and, in fact, is still the referee and standard method used to check
and calibrate nondestructive on-line and laboratory coating thickness gauges. There are weigh-strip-
weigh procedures that can be used for all zinc-based coatings in commercial production today. For the
most common products, these procedures are defined in ASTM Standard A 90/A 90M, and cover
galvanized and galvannealed sheet, 55% aluminum-zinc alloy-coated sheet, and zinc-5% aluminum alloy-
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coated sheet. There are special procedures required for other types of alloy coatings such as aluminized,
and zinc-nickel alloy electroplated sheet. These are covered by other ASTM standards.
Designation System for Galvanized and Galvannealed Sheet Products
Galvanize – For galvanized sheet, common inch-pound coating weight designations (ordered as A 653)
are, in oz/ft2:
G30 G40 G60 G90 G115
These designations specify the minimum average TST, total both sides, tested per ASTM A 924/A 924M,
e.g., G90 requires a minimum average TST of 0.90 oz/ft2 total both sides. The specification stipulates
that TST samples shall be taken from defined positions at the edge-center-edge of the as-coated sheet.
There are designations for heavier coatings, such as G165 and G210, but these products are used for
very specialized applications and are generally not available on thinner gauge sheet.
In SI units (ordered as A 653M), the comparable coating mass designations for galvanized sheet are, in
g/m2:
Z90 Z120 Z180 Z275 Z350
These designations specify the minimum average TST, total both sides, tested per A 924/A 924M, e.g.,
Z275 requires a minimum average TST of 275 g/m2 total both sides.
In 2007 ASTM added the option of ordering single side, single spot test (SST) coating designations to A
653/A 653M. These are SI designations only (ordered to A 653M) and specify the minimum and
maximum allowable coating mass per side for any SST. They take the familiar form of automotive coating
designations (numeric characters first – signifying a per side requirement). No inch-pound designations
are used since single side coatings are traditionally ordered in SI units only. Examples are:
60G 70G 90G
These designations specify the minimum and maximum SST value on each surface, e.g., 60G requires a
minimum of 60 g/m2 and a maximum of 110 g/m2 of zinc on each surface for any SST.
When specifying single side single spot coatings, the designation for each surface must be shown, e.g.,
60G60G.
Coating weight [mass] versus coating life – For galvanized coatings in most applications
and environments, the corrosion performance is an approximate linear function of coating
weight (thickness). For instance, a G60 coating has twice the thickness of a G30 coating, and
the life of the product (defined, perhaps, as the time to 5% rust) in a given environment is
approximately twice as long. Similarly, a G90 coating is approximately 50% thicker than a
G60 coating, and thus would be expected to perform 50% better (in terms of time to 5% rust).
For a more thorough discussion on service life, see GalvInfoNote 3.1. Limits on maximum
acceptable coating weights for an application are usually determined by other factors such as
cost or formability. For a more thorough discussion of this topic see GalvInfoNotes 1.6 and
2.5.
For other metallic-coated sheet products, the life versus coating thickness is typically not
linear; thus determining the coating weight (mass) to use is not as simple as it is for
galvanized coatings. Also, when these products are painted, the behaviour is even more
complex. The subject of painted hot-dip products is addressed in GalvInfoNotes 4.1 and 4.2.
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Zinc-Iron (Galvanneal) – The common inch-pound coating weight designations (ordered as A 653) for
galvannealed sheet (zinc-iron alloy-coated) are, in oz/ft2:
A25 A40 A60
As with galvanized product designators, A40 for example, requires a minimum average TST coating
weight of 0.40 oz/ft2, total both sides. While the coating contains approximately 8 to 10% iron, resulting in
the density being slightly higher than a zinc coating and the coating thickness being slightly less than a
G40 galvanize coating, the difference is too small to be of concern. The effect of density is discussed in
the section on 55% Al-Zn coatings, and in the Appendix. Also, see GalvInfoNote 1.3 for a full explanation
of hot-dip galvanneal coatings.
The SI equivalent coating mass designations (ordered as A 653M) for galvannealed sheet are, in g/m2:
ZF75 ZF120 ZF180
ZF120, for example, requires a minimum average TST of 120 g/m2 total both sides.
As with galvanize, the option of ordering zinc-iron coatings to single side, SST coating designations has
been added to A 653/A 653M. Again, these are SI designations only (ordered to A 653M), specifying the
minimum and maximum allowable coating mass per side for any single spot, and taking the familiar form
of automotive coating designations (numeric characters first – signifying a per side requirement). No
inch-pound designations are used since single side coatings are traditionally ordered in SI units only.
Examples are:
45A 50A
These designations relate to the minimum and maximum SST value on each surface, e.g., 45A requires a
minimum of 45 g/m2 and a maximum of 75 g/m2 of zinc-iron alloy on each surface for any SST.
When specifying single side, SST coatings, the designation for each surface must be shown, e.g.,
45A45A.
………………………
For galvanized and galvannealed sheet, the relationship between coating weight (mass) and thickness is
as follows (based on zinc density of 446 1b/ft3 or 7140 kg/m3):
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These designations relate to the minimum and maximum SST value on each surface, as defined in ASTM
A 879/A 879M, e.g., 40G requires a minimum of 40 and a maximum of 90 g/m2 of zinc on each surface for
any SST.
Again, the designation for each surface must be shown, e.g., 40G40G.
nnGnnG A 879M zinc - EG g/m2 Min & Max NONE NONE NONE
2
nnGnnG A653 M – Table S2.1 zinc - HD g/m Min & Max NONE NONE NONE
2
nnAnnA A653 M – Table S2.1 zinc-iron - HD g/m Min & Max NONE NONE NONE
2
nnGnnG Auto (typical) 1 zinc - HD & EG g/m Min & Max NONE NONE NONE
nnAnnA Auto (typical) 2 zinc-iron - HD & EG g/m2 Min & Max NONE * NONE NONE
Notes: nn = numerals (2 or 3) specific to coating weight [mass]
HD = Hot-Dip
EG = Electrogalvanize
SST = Single Spot Test
TST = Triple Spot Test
* some auto manufacturers require a minimum TST
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For additional clarification, see Table 2 below, which provides the requirements of selected coating weight
[mass] examples for galvanized sheet made to ASTM specifications.
It is not easy to keep the terminology straight. Users should be aware that both units are in common use
today, and are advised to pay close attention when ordering, knowing precisely what is meant by the
terminology being used. See the Table 3 at the end of this article, which summarizes the designations
used for most hot-dip products, and may be useful in keeping terminology clear.
Table 2 Selected ASTM Galvanized Sheet Designations – Requirements
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therefore to the question: What 55% Al-Zn alloy coating is equivalent in performance to a G90 coating?
The major use of 55% Al-Zn alloy coated sheet is for construction industry building panels, and for this
application the most common coating weights are AZ50 and AZ55. As the differences in performance
between these two designators are subtle, ask your supplier which coating thickness they recommend for
your application.
For 55% Al-Zn alloy-coated sheet there is also a SI coating mass designator system (ordered as A
792M). The SI equivalents to AZ50, AZ55, AZ60 and AZ70 are, in g/m2:
AZM150 AZM165 AZM180 AZM210
These designations specify the minimum average of a TST, total both sides, per A 924/A 924M, e.g.,
AZM150 requires a minimum TST of 150 g/m2 total both sides.
Since 55% Al-Zn alloy coated sheet is produced only by the hot-dip process, there is no additional
terminology or specification related to the manufacture of an electroplated product. Also, there are no
SST, single side designations for this product.
For 55% Al-Zn alloy coated sheet, the relationship between coating weight [mass] and thickness is as
follows (based on a density of 234 lb/ft3 or 3750 kg/m3):
See GalvInfoNote 1.4 for a complete description of 55% Al-Zn alloy-coated sheet.
Summary
GalvInfo Center email: [email protected] Toll-free phone: 1-888-880-8802
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This article explains the complexities of coating designation systems and hopefully provides a better
understanding of why it is important to be sure that you and your supplier are speaking the same
language. Table 2 gives examples of some of the designators discussed above. See GalvInfoNote 1.5
for a further explanation of ASTM specifications for coated steel sheet products.
Copyright 2009 – IZA
Disclaimer:
Articles, research reports, and technical data are provided for information purposes only. Although the publishers endeavor to
provide accurate, timely information, the International Zinc Association does not warrant the research results or information reported
in this communication and disclaims all liability for damages arising from reliance on the research results or other information
contained in this communication, including, but not limited to, incidental or consequential damages.
Appendix
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Theoretical Mass
The formula for calculating the Theoretical Mass of galvanized sheet in kg/m2 is:
TM = t x 7.85 – CF (5)
2
Where: TM = Theoretical Mass in kg/m
t = actual sheet thickness in millimetres (7.85 is the mass in kg of 1 m2 of 1mm thick steel)
CF = Coating Factor in kg/m2
For example; galvanized sheet 0.50 mm thick with a Z275 coating has a coating factor of 0.029 kg/m2,
based on the relationship in (1) and a typical actual Z275 coating mass of 293 g/m2. Therefore:
TM = 0.50 x 7.85 – 0.029 = 3.896 kg/m2
Using the above relationships, Theoretical Weight [Mass] can be calculated for all combinations of sheet
thicknesses and coating types/thicknesses. For quick reference, producers of coated sheet usually have
tables available for their customers showing this information for the products and thicknesses they sell.
The above formulas can be used to interpolate between the thicknesses shown in these tables. If you do
not have access to such information, Table X.1 shows the coating factors for example coating weights
[masses] of most of the commonly ordered coating designations for galvanize, 55% Al-Zn alloy coated
sheet, and Zn-5% Al alloy coated sheet.
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Inch-pound SI (Metric)
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