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2 Product information
2.1Productdescription
The SABdeep deck family ofproductsconsists of14 steelroof trapezoidal profiles which are designed to support all typesof insulated roof systems. The SABliner trayprofile family of products consistsof 11 steelprofileswhich are designed to support alltypes of wallprofiles together with insulation. Both are manufactured from MagiZinc® hot dip zinc coated steel, with a Colorcoat® PE15 prefinished interior coating, a guaranteed minimum yield stressof 320N/mm2, and hasa fire rating of ClassA1to EN 13501-1 [9] .
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2.2Manufacturing
The manufacturing sitesincluded in the EPD are listed in Table1.
Table 1 Participatingsites
Sitename Product Manufacturer Country
IJmuiden Hotrolledcoil TataSteel NL
IJmuiden Coldrolledcoil TataSteel NL
IJmuiden Pre-finishedsteel TataSteel NL
IJsselstein Steelstructuraldeck/linertray SAB-profiel NL
The processof steelcoilmanufacture at Tata Steel begins with sinter being produced from iron ore and limestone, and together with coke from coal, reduced in a blast furnaceto produce iron. Steel scrap is added to the liquid iron and oxygen isblown through the mixture to convert it into liquid steelin the basic oxygen furnace. The liquid steelis continuouslycast into discrete slabs, which are subsequentlyreheated and rolled in a hot strip mill to produce steelcoil. The hot rolledcoilsare pickled and cold rolled, before being galvanisedand coated.
SAB135R/930 (Figure 1)has a profile depth of 137mm and a cover width of 930mm, to meet the designers’needsfor efficiency, aesthetics, and structuralperformanceand isan ideal choice of roof deck profilewhen securingto purlins, typicallyspanning 4m to 8m. It hasa 310mm profilepitch and thecrown is145mm, which provides an approximate 50% surface areaand ismore than sufficient for most adhesive systemswhen bonding to the deck. For thoselooking for additional architecturalfeatures, the SAB135R/930profile can be supplied perforated for additional acousticrequirements.
SABdecksare usually part of roof system with a foiland insulation layer, and Bitumen or PVC top layer (seeFigure 2), and liner trays are usuallypart of a built-up wall system with a steelprofileon the outside and insulation layer in between. Our dedicated and experienced technicalteam are available to help develop a specification for your project and assist with project specific adviceto ensure that alldesign aspects of the chosen system meet your project requirements.
Pre-finished steelcomprisesa number ofpaint layersandtreatments which are applied to the steelin an automated and carefullycontrolled processwith each layer ofthe product having a particular function. It isthe combined effect of allthese layersthat give the product its overallperformanceand ensuresa material that isrobust. During the organic coating process, a zinc based metalliccoating isfirst applied to the steelcoil. Apre-treatment isapplied and then a primer before adding the final top coat layer in the form ofliquid paint. Theseare cured at elevated temperaturesbefore being recoiled prior to use in the manufacture of the profiled product. For thispre-finished steel, the primer and topcoat are applied on the undersidesurface only, whilethe top side of the strip has no organic coating.
The pre-finished steelistransported byroad from IJmuiden to IJsselstein and isprofiled and cut into suitablelengthson a dedicated processline. An overviewof the processfrom raw materialsto transport of the steelroof deck or liner trayproduct to the construction site, isshown in Figure 3.
Processdata for the manufactureof hot and cold rolled coil, and prefinished steelat IJmuiden wasgathered aspart of the latest worldsteel data collection. The data collection was not onlyorganised by site, but also byeach process line within the site. In thiswayit waspossible to attribute resource useand emissionsto each process line, and using processed tonnage data for that line, also attribute resourcesand emissions to specific products. For the manufacture of the roof deck or liner tray, processdata was also collected from the profiling linesat IJsselstein.
2.3Technical data andspecifications
The generalpropertiesof the reference product are shown in Table2, and the property rangesof the product familyare in Table3. The technical specificationsof the product are presented in Table4.
135R/930roofdeckwithColorcoat® PE15 Thicknessofdecking(mm) 0.88
2.4Packaging
The profilesare packaged using wood basesupportsand plastic strapping in order to protect themduring delivery to site and prior to installation. The massof thispackaging is0.023kg of timber and 0.0025 kg of plastic banding per m2 of deck or liner tray product.
2.5Referenceservice life
Structuraldeep deck or liner trays are generally part of a compositeroof or wallsystem that also comprises an insulating materialsuch asmineral wool, slate or tiles, or felt, and the final construction application of the composite product isnot defined. To determine an accurate servicelife of steel structuraldeck and liner trays, all factorswould need to be included such as the type of roof/wallmaterial used, and the location and environment. However, the NMD refer to a knowledge database [27] which statesthat ‘for flat roofswith a galvanised steeldeck, the reference service life is shown to be 100years.’
CEmarking
Certification
DoP spec to EN 1090-1 [10]
Certifications applicable to SAB IJsselstein are; ISO 9001 [11], ISO 14001 [12], BES 6001 [13]
Under ‘normal’conditions, steeldeck and liner trayswould not need to be replaced over the life of the building and structure.
2.6BiogenicCarbon content
SABdeck&linertrayswithColorcoat® PE15
Thicknessofdecking(mm) 0.75 to 1.50
Cover(working)width(mm) 400 to 1120 Profileweight(kg/m2) 7.11 to 23.55
Massoffixings(kg/m2) 0.01
CEmarking
Certification
DoP spec to EN 1090-1 [10]
Certifications applicable to SAB IJsselstein are; ISO 9001 [11], ISO 14001 [12], BES 6001 [13]
Colorcoat® pre-finishedsteel
Metalliccoating Colorcoat® pre-finished steel is supplied with a zinc based metallic coating that conforms to EN 10346:2015 [14]
Paintcoating (organic) Colorcoat® PE15 polyester coating on the underside (exposed face)
All pre-finished steel products are fully REACH [15] compliant and chromate free
Certification Certifications applicable to Tata Steel’s IJmuiden site are; ISO 9001 [11], ISO 14001 [12] , BES 6001 [13] BBA (Colorcoat®) [16]
There are no materialscontainingbiogenic carbon in the deck or liner trayproduct. Timber isused to package the steeldecks and liner trays, and comprisesa measurable massof the total packaging as shown in Table 5.
