Zincal®Steel coated with
Aluminium and Zinc.

Safal Steel’s Zincal® coated steel provides a superior alternative to galvanized steel. The technique of coating steel with Aluminium and Zinc (55% Aluminium, 43.5% Zinc and 1.5% Silicon) has been extensively researched and surpasses the performance of traditional galvanized steel.

Innovative methods and production techniques are taking steel to new levels of strength, formability and versatility. In Zincal®, the durability and service life of modern coated steel is extended even further. Zincal® is produced by a unique, efficient process whereby rolled steel is continuously hot-dipped into a 55% Aluminium, 43.5% Zinc and 1.5% Silicon Alloy. This patented coating protects the steel in two ways:

1The aluminium component of the coating provides a tough physical barrier between the extreme atmospheric conditions and the inner core of steel.

2The zinc in the coating provides sacrificial protection and also protects the steel at the cut edges.

[A] Passivation [B] AZ Coating [C] Low Carbon Steel

Zincal® is the only African-licenced manufacturer of the patented Al/Zn technology based on the continent.

As a licensee of the world-famous BIEC-technology, our systems are subject to monitoring and audit by our principal.

They are also subjected to:

ISO quality system testing

Quality inspection during production

Artificial weather testing

Live test sites

Quality assurance of the finished product (SABS product quality conformance)

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Benefits

Thermal Attributes

The thermal mass of Zincal® is significantly lower than traditional galvanised steel and clay tile roofs, due to the addition of aluminium. This increases the reflection of the sun’s rays, creating a cooler building in summer and a warmer building in winter.

A roof is a key component of the interior climate control of any building. By their nature, solar panel-mounted roofs are cool roofs. The panels shade the roof below from the direct rays of the sun for a considerable amount of time during the day.

Good engineering practice suggests that a high solar reflective index (SRI) roof provides optimal performance. Zincal® offers exceptionally good solar reflectance and transmittance performance, transferring only 65 watts/m2 of heat compared to 120 watts/m2 of other traditional roofing solutions.

Zincal® and Solar Panels together

Zincal® steel supports the longevity of Solar Panel Lifespan. Produced locally to fit every South African building and minimize the cost of ownership.

The durability of a metal roof is impacted by both the PV panel system and roofing assembly, so both should be considered during the design and installation process, and in follow-on maintenance routines.

In scenarios involving incompatible metals, galvanic corrosion can lead to a breakdown of the surface of the solar/PV panel. The advanced AZ coated alloy used with Zincal® is less prone to galvanic corrosion when combined with any solar/PV panel compatible aluminium frame.

Our aluminium-zinc coated steel product is an efficient choice to galvanised roofing. Designers and building professionals are encouraged to avoid cheap imported alternatives that originate from unknown sources, often in the Far East. There is only one original Zincal®. You will know us by the stamp mark of our brand on the back of the formed roof sheet..

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Benefits

Made to last 4 times longer.

Research shows that aluminium-zinc coated roofing systems like Zincal® can last 60 years and more while the industry standard for solar/ PV panels is about 25 to 30 years. This means you shouldn’t experience the hassle of having to remove and reinstall a PV system when you replace your roof.

The majority of PV installations are retrofit. However, with the strong movement towards energy efficient design and making the building impervious to loadshedding, a large number of new build warehouse and commercial buildings are designed with fitted PV arrays.

To ensure we produce a product that not only satisfies quality standards, but also performs under weathering conditions, we have commissioned the following test methods:

Salt Spray Testing (Q Fog Testing)
Products are exposed for predetermined time periods to salt fumes at fixed temperatures. The time periods are determined by the various coating categories.

Live Test Stations
Live test stations have now been installed at various locations for monitoring the visual performance of Zincal® under everyday weathering conditions.

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Quality Testing

During the quality testing of the product, we focus on various characteristics such as mechanical properties and coating performance. Zincal® is tested using the following methods:

Mechanical property testing
– Hardness testing (HRB and HR30T)
– Tensile and Yield testing (MPa)
– Elongation (%)

Coating performance
– Impact testing
– Bend testing (0T to 3T)
– Coating mass (g/m2)
– Cupping test
– Lock forming testing

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ISO Quality System Testing

The successful implementation of the ISO quality system is at the core of our business. This ensures all processes are managed to ensure a consistent product is produced.

Quality
Inspection

To ensure products sent to our customers are defect-free, we have trained quality inspectors who are present during our various production processes.

Longer Lasting Protection

The Aluminium coating component provides a tough physical barrier.

Last Up To 4 Times Longer

The Zinc in the coating provides sacrificial protection and also protects the steel at the cut edges. The superior corrosive property increases the life of the steel core up to four times longer than that of galvanized steel.