Theoretically Expected Lifetime GEOBRUGG SUPERCOATING® and GEOBRUGG ULTRACOATING® Products

Standard
Expected lifetime in years 1)
C1 2) C2 2) C3 2)
Dry or cold zone, atmospheric environment with very Temperate zone, atmospheric environment with low Temperate zone, atmospheric environment with
low pollution and time of wetness, e.g. certain pollution (SO2 < 5 µg/m3), e.g.: rural areas, small 3
medium pollution (SO2: 5 µg/m to 30 µg/m ) or
3

deserts, central Arctic/Antarctica. towns. Dry or cold zone, atmospheric environment some effect of chlorides, e.g. urban areas, coastal
with short time of wetness, e.g. deserts, sub-arctic areas with low deposition of chlorides, subtropical
areas. and tropical zones with atmosphere with low
minimum pollution.
coat weight assumed coat weight loss of assumed coat weight loss of assumed coat weight loss of
wire diameter Brands Coating class required < = 0.7 g/m2/year of Zn 0.7 - 5 g/m2/year of Zn > 5 - 15 g/m2/year of Zn
(mm) (g/m2) Zinc SUPERCOATING® ULTRACOATING® Zinc SUPERCOATING® ULTRACOATING® Zinc SUPERCOATING® ULTRACOATING®
2 DELTAX®, TECCO® B 115 23 - 120 69 - 120 > 120 7.7 - 23 23 - 69 46 - 120
4 TECCO®, SPIDER®, B 150 >120 30 - 120 90 - 120 >120 10 - 30 30 - 90 60 - 120
3 ROCCO®, QUAROX®

Exceptional conditions, special applications

Expected lifetime in years 1)
2)
C4 C5 2) CX 2)
Temperate zone, atmospheric environment with high Temperate and subtropical zones, atmospheric Subtropical and tropical zones (very high time of
3 3 3
pollution (SO2: 30 µg/m to 90 µg/m ) or substantial environment with very high pollution (SO2: 90 µg/m wetness), atmospheric environment with very high
3
effect of chlorides, e.g. polluted urban areas, to 250 µg/m ) and/or important effect of chlorides, pollution (SO2 higher than 250 µg/m ), including
3

industrial areas, coastal areas without spray of salt e.g. industrial areas, coastal areas, sheltered accompanying and production pollution and/or
water, exposure to strong effect of de-icing salts, positions on coastline. strong effect of chlorides, e.g. extreme industrial
subtropical and tropical zones with atmosphere with areas, coastal and offshore areas with occasional
minimum medium pollution. contact with salt spray.
coat weight assumed coat weight loss of assumed coat weight loss of assumed coat weight loss of
wire diameter Brands Coating class required > 15 - 30 g/m2/year of Zn > 30 - 60 g/m2/year of Zn > 60 - 180 g/m2/year of Zn
(mm) (g/m2) Zinc SUPERCOATING® ULTRACOATING® Zinc SUPERCOATING® ULTRACOATING® Zinc SUPERCOATING® ULTRACOATING®
2 DELTAX® B 115 3.8 - 7.7 Needs to be analysed, preferred 1.9 - 3.8 Needs to be analysed, preferred 0.6 - 1.9 Needs to be analysed, preferred
4 TECCO®, SPIDER® B 150 5 - 10 TECCO® INOX or 2.5 - 5 TECCO® INOX or 0.8 - 2.5 TECCO® INOX or
3 ROCCO®, QUAROX® TECCO® PET TECCO® PET TECCO® PET

Mean >= 120 years

Mean >= 90 years
Mean >= 60 years
Mean >= 30 years
Mean < 30 years
1)
The life expectancy of the mesh and net, if it is not subjected to accidental damage, can be estimated from the minimum Zn coating loss according to EN ISO 14713-1 (EN ISO 12944-2 and EN 12500).
2)
Atmospheric corrosivity category according to EN ISO 14713-1 (EN ISO 12944-2 and ISO 9223).
® ®
SUPERCOATING Based on EN 1993-1-11, AS/NZS 4534 and independent test report 9811 from Dr. Ing. Prof. Nünninghoff, Germany the lifetime of Zn-Al coating (SUPERCOATING ) is at least three times better than zinc coating.
®
ULTRACOATING Factor of 2 between SUPER- and ULTRACOATING ® based on salt spray test results, both final drawn.
®
SUPER- and ULTRACOATING are final drawn. Redrawn wire has a smoother surface and a better bond than end coated wire and offers therefore a very good corrosion protection.

161222 Lifetime Supercoating and Ultracoating.xlsx 1/1 Dezember 2016 / Roa1

Author: Armin Roduner
Visa: Ro GEOBRUGG SUPERCOATING®
Date: 04.08.2014
Page: 1/1 Standards

GEOBRUGG SUPERCOATING® provides 3 times corrosion protection better than Zinc

European and National standards

The following European and National standards support the fact that Zn/Al Coating such as Geobrugg
GEOBRUGG SUPERCOATING® provides a up to 3 times better corrosion protection that standard zinc
coating:
EN 1993-1-11: 2006
Eurocode 3: Design of steel structures
Part 1-11: Design of structures with tension components

C3 Durability of Zinc/Aluminium coated wires and ropes (Zn95/Al5)

cl. 4.2, Note 2, page 15: “Wires coated with a Zn95/Al5 alloy have a much improved corrosion protection
than galvanizing with zinc of the same coating thickness”

cl. 4.4, Note 2, page 15: “Zn95Al5 coated wires provide up to 3 times better resistance compared with heavy
zinc-coated wire under identical conditions.”

AS/NZS 4534:2006
Australian/New Zealand Standard

Zinc and zinc/aluminium-alloy coatings on steel wire

F1 Indicative coating durability

F6.3, page 33: "Studies under Australian (external atmospheric) field conditions, complemented by
laboratory salt-spray testing to AS 2331.3.1, have shown that zinc/5% aluminium-alloy coatings on wire offer
from about two up to about three times greater protection, per unit coating mass, than do zinc coatings. The
higher value (i.e. about three times) is realized at high to very high levels of corrosivity, such as those in
close proximity to surf beaches".

Independent test reports

The following independent test reports on GEOBRUGG SUPERCOATING® support the fact that this Zn/Al
provides at least 3 times better corrosion protection than zinc:

Bergische Universität Wuppertal,

Dr. Ing Prof. Nünninghoff, Germany.
Test report 9811

Salt Spray tests according to DIN 50021SS (ASTM B 117) and SO2 spray test (DIN 500018, Kesternich
Test).

p.2, results of corrosion laboratory tests:

"the lifetime of Zn-Al coating (SUPERCOATING® is at least three times better than zinc"
Long term field comparison tests over 22 years by the same University showed the actual field
decomposition of GEOBRUGG SUPERCOATING® may be even 4 – 6 times lower than for zinc, depending
on the environmental conditions.

140804 Geobrugg Supercoating 3 times better than zinc References.doc 11.4.2011 MD

Author: A. Roduner
Visa: Ro
Date: February 2012 Salt spray test certificates
Page: 1/1

External salt spray test certificates for the 2 mm diameter wire

The average performance of the three different coatings is compared using salt spray tests according to DIN
SS 50021, ASTM B117 and EN ISO 9227. Thereby the used abort and comparison criterion is the
occurrence of 5 % dark-brown rust.

Salt spray test results Zinc coating SUPERCOATING® ULTRACOATING®

(BEZINAL) (BEZINAL 3000)

Coating weight 148 g/m2 176 g/m2 123 g/m2

Hours in the salt spray test until 5%

328 hours 1508 hours 1884 hours
dark brown rust

Calculated hours in the salt spray

test until 5% dark brown rust with the
328 hours 1268 hours 2267 hours
zinc coating weight of 148 g/m2 as
reference.

Reached factor compared to zinc

1 3.9 6.9
coating

Summary:

Based on these tests and considering the coating weight of each wire the following factors between the
individual coating types are confirmed:

 SUPERCOATING® is at least 3 times better than zinc coating (3.9 times better in these tests)

 ULTRACOATING® is at least 6 times better than zinc coating (6.9 times better in these tests)
Author: A. Roduner
Visa: Ro
Date: February 2012 Salt spray test certificates
Page: 1/1

External salt spray test certificates for the 3 mm diameter wire

The average performance of the three different coatings is compared using salt spray tests according to DIN
SS 50021, ASTM B117 and EN ISO 9227. Thereby the used abort and comparison criterion is the
occurrence of 5 % dark-brown rust.

Salt spray test results Zinc coating SUPERCOATING® ULTRACOATING®

(BEZINAL) (BEZINAL 3000)

Coating weight 190 g/m2 186 g/m2 167 g/m2

Hours in the salt spray test until 5%

551 hours 1856 hours 3771 hours
dark brown rust

Calculated hours in the salt spray

test until 5% dark brown rust with the
551 hours 1896 hours 4290 hours
zinc coating weight of 190 g/m2 as
reference.

Reached factor compared to zinc

1 3.4 7.8
coating

Summary:

Based on these tests and considering the coating weight of each wire the following factors between the
individual coating types are confirmed:

 SUPERCOATING® is at least 3 times better than zinc coating (3.4 times better in these tests)

 ULTRACOATING® is at least 6 times better than zinc coating (7.8 times better in these tests)
Author: A. Roduner
Visa: Ro
Date: February 2012 Salt spray test certificates
Page: 1/1

External salt spray test certificates for the 4 mm diameter wire

The average performance of the three different coatings is compared using salt spray tests according to DIN
SS 50021, ASTM B117 and EN ISO 9227. Thereby the used abort and comparison criterion is the
occurrence of 5 % dark-brown rust.

Salt spray test results Zinc coating SUPERCOATING® ULTRACOATING®

(BEZINAL) (BEZINAL 3000)

Coating weight 176 g/m2 185 g/m2 175 g/m2

Hours in the salt spray test until 5%

380 hours 1467 hours 2959 hours
dark brown rust

Calculated hours in the salt spray

test until 5% dark brown rust with the
380 hours 1396 hours 2976 hours
zinc coating weight of 176 g/m2 as
reference.

Reached factor compared to zinc

1 3.7 7.8
coating

Summary:

Based on these tests and considering the coating weight of each wire the following factors between the
individual coating types are confirmed:

 SUPERCOATING® is at least 3 times better than zinc coating (3.7 times better in these tests)

 ULTRACOATING® is at least 6 times better than zinc coating (7.8 times better in these tests)