Meeting the expectation of a 30+ PV project

operation lifetime, from the ground up

4th February 2021

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Experienced in high quality production

of continuous galvanised steelsDeep knowledge of galvanised steels

durability mechanisms & performances

ArcelorMittal: strong & long lasting experience

in galvanised coated steels

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Galvanised coil production

Durability is key at each step of the lifecycle of solar PV

plants

Coil slitting Profiling / tubing

Operating Transporting, storing

and assembling

Engineering

MaintainingRetro-fittingRecycling

What matters = durability

What matters = range of grades & coating thickness / good processability

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Lifetime expectation for solar utility-scale plants is

continuously increasing

Source: Lawrence Berkeley National Laboratory – Survey June 2020

https://emp.lbl.gov/publications/benchmarking-utility-scale-pv

Project Life Expectations for Utility-Scale PV, over time

Average today is 32.4 yearsRange between

25 to 35 years

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Why longer durability expectations for mounting structures?

Why improved protection of steel?

Build in more

demanding locations

→ Islands, coastal deserts,

industrial roofs…

→ Poles in aggressive or

polluted soils

→ Floating solar

→ Agrivoltaic with fertilisers

Increase VALUE:

- Longer period for

pay back & amortisation

- Longer Private

Purchase Agreements

- End of life higher value

- Retrofitting potential with

newest PV panels on

initial mounting structure

Reduce O&M COSTS:

- Postpone time to 1st

maintenance

- Reduced repairs leading to

increased operation &

maintenance costs

- Risk avoidance of

mechanical failure in case

of heavy loads

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How to evaluate corrosivity? The theory

ISO 9223: corrosivity of atmospheres

• Experimental method: direct measure

corrosion rate / weight loss of specimen after

1 year of field exposure

• Calculation based environmental measured

data: temperature, relative humidity, and

measured Cl- & SO2 deposits

→ Local measurements needed for both

methods

ISO 9224: guiding values

• Mathematical extrapolation of 1st year measurement

• Applicable only to pure Zinc: Zn alloys not included

• Many restrictions:

→ “Performances for Zn might not be accurately

predicted”… even with B1 & B2 coefficients

→ Specific phenomena not considered (abrasion...)

→ Lifetime values only informative NOT contractual

ISO 14713 – table 2 : lifetime calculation (years)

=

Nominal coating thickness (µm)

/

Corrosion Rate (µm/y)

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In real life, durability is influenced by many other parameters

which require additional protection

Product variations - ISO1461 and EN10346Climatic variations

• Abrasion (sands)• Pollution (industrial…)• Vegetation (grass, leaves, moss….)• Animals (excrements, …)• Site maintenance (lawn mower, herbicide…)• Impacts (maintenance tools…)• Cleaning (tools & cleaning agents….)

Additional aggressions (mechanical & chemical)

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1. The basis = use coated steel with LOWER

corrosion rates than regular galvanised steels

→ Magnelis®

2. FIELD EVALUATION of the corrosivity of the site:

- field knowledge of product behavior

- field knowledge of weather data +

deposited Cl and SO2

3- Coating weight / thickness adjusted

- to the expected lifetime

- considering safety margin to protect against

additional aggressive parameters

How to increase durability ?

Corrosion

category (ISO 9223)Unit

Zinc

corrosion rate

C2 µm/year 0.1 < rcorr ≤ 0.7

C3 µm/year 0.7 < rcorr ≤ 2.1

C4 µm/year 2.1 < rcorr ≤ 4.2

C5 µm/year 4.2 < rcorr ≤ 8.4

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Magnelis® is the answer to longer lifetimes and

more demanding environments & applications

Continuous process

Automated

On-line control

A unique composition

A full range of grades

And thicknesses

Compact and stable structure

Porousstructure

Compact and stable structure

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Specific corrosion products

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RailsPurlins, rails, brackets (U, C, Ω, Σ...)

Torque tubesHF Induction or laser welded tubes

Poles, columnsRammed in soil, embedded in concrete

Electrical componentsCable trays, cabinets, …

Wind deflection (roof top)

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Magnelis® is already widely used for many

components of mounting structures

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El Romero, Chile, 255 MW (PV)

ACCIONA STI Norland (Spain )

Magnelis® for upper structures

NOOR III, Morocco, 100 MW

(CSP)

ACWA POWER, SENER

Magnelis® used for hollow

sections & stamped parts

Europe, main market for

Magnelis® (PV):

Spain, Germany, Poland, France,

Benelux, UK, Greece,

(Fix, trackers, roof top, floating California, USA, 250 MW (PV)

Magnelis® used for girder parts Delingha Supcon, China, 50 MW

(CSP)

SOLAR RESERVE

Magnelis® used for stamped parts

Saran, Kazakhstan 100 MW (PV)

GOLDBECK Solar / CWF

Magnelis® for rails

PV & CSP, racking & foundations, fix & trackers systems, ground mounted, rooftop & floating

Australia, 110 MW (PV)

Magnelis® used for

girder parts

UAE, 300MW

(PV)

DEWA III

PVH

Magnelis® for

upper structures

(trackers)

Abu Dhabi, 1177

MW (PV)

SWEIHAN -

FORMING

Magnelis® for

upper structures

(Fix)

~20 GW around the world installed on Magnelis®

Jordan, 10 MW (PV)

PHILADELPHIA SOLAR

Magnelis® used for

upper structures

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Field sites where Magnelis® is tested

Extensive product behaviour knowledge

has been collected for Magnelis® coating

• We have tested Magnelis® in various types of

environments covering the range of corrosion

categories– Rural

– Urban

– Industrial

– Marine

– Tropical

– Deserts (coastal, continental…)

– Floating (fresh / brackish / sea)

• Similar approach for corrosion in soils (geological,

physical, chemical & electrical parameters)

• Comparatively with pre- & batch- galvanised

steels

What we measure on atmospheric field tests:

Corrosion rates (weight losses)

Visual aspect of surface and along edges

Cut edges behaviour (image analysis)

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Magnelis® exhibits lower

corrosion rates.

Average improvement:

~ 3 compared to regular

galvanised steel

Large scale atmospheric testing around the world

demonstrates the lower corrosion rate of Magnelis®

Average improvement ratio of Magnelis® corrosion rate

vs regular galvanised after 6 years

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Al55Zn45

Magnelis®

6 months 1 year 2 years 4 years 5 years 7 years 10 years

Magnelis® protection

overperforms

Al55Zn45 and regular

galvanised steel

Galva

Improved protection of perforated steels

(surface & cut edges) with Magnelis®

Dense perforation rate on 2 mm steel coated with 20 microns

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Soils

Others testing fields

for specific harsh environments

Brest

Dunkerque

Dubai

Offshore

Magnelis® Batch galva

Significant reduction of corrosion rates vs batch galvanisation

and more stable behaviour

Magnelis® Batch galva

Magnelis® Batch galva

Average coating consumption (µm)

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Durability performance is linked to the coating composition

Magnelis® results can not be extrapolated to others ZnAlMg alloyed coatings

Dunkerque

Lower corrosion rate with Magnelis® in comparison to

other less alloyed Zn-Al-Mg coatings

Performance improvement

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Corrosion

category

ISO 9223

Magnelis®

ZM310

Magnelis®

ZM430

C2 > 50 y > 50 y

C3 30 y to > 50 y 40 y to > 50 y

C4 15 y to 30 y 20 y to 40 y

C5 15 y 10 y to 20 y

Magnelis® ZM310 offers a minimum 30 years of expected

design coating life in C3 environment

C3 category, the most

frequent case =

temperate / urban...

DESIGN COATING LIFE = average duration until 100% of the undamaged coating, exposed to outdoor

conditions only, will be consumed on the surface. At this point in time, the structural integrity of the part is

no longer ensured and a major repair is necessary. → Structural criteria

C4 category =

tropical /

industrial / coastal...

These durations are indicative and non binding.

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Thickness range → up to 6,0 mm

Coating range → up to ZM430

Surface:

Edges:

• Edges can remain unprotected

with ZM310 or ZM430 up to 6.0

mm thickness

• No aesthetical requirement &

corrosion allowance

Magnelis® ZM310

possible use in C5

corrosion category

with 15 years of

expected lifetime

Expected lifetimes with Magnelis® in atmospheric

conditions have been certified by third parties

http://publiccert.extweb.sp.se/ https://www.dibt.de/de/

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From lifetime to guarantees: Magnelis® can be guaranteed

by contract on a project basis

▪ Based on project locationafter location analysis by ArcelorMittal

▪ A contract per project

▪ For Magnelis® profiles(after bending & perforation)

▪ For Magnelis® tubes(after preliminary audit by ArcelorMittal)

Extension to soils or concrete foundations:

▪ On project basis

▪ Based on soil physical, chemical and electrical analysis

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How do we support the increase of lifetime?

Enlarged range of high

strength steels protected

with Magnelis®

Enlarged range of coating

weights

ZM200ZM250

ZM310

ZM430ZM620 S550GD HyPer®

S700GD HyPer®

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Site analysis: climate + corrosion tools

Thanks to Magnelis® range & performance knowledge

it is possible to increase durability beyond 30 years

Transportation / storageguidelines

Magnelis® coating weight recommendation

Design guidelines with respect to resistance to corrosion

ZM200

ZM250ZM310

ZM430ZM620

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Maintenance / inspectionguidelines

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Material Environmental Product Declaration (EPD) available

online to perform Life Cycle Analysis:

• Manufacturing: less resources (Zn) used in comparison

to continuous & batch galvanised steels

• Use phase: less zinc run-off in soils & waters

• End of life: steel is entirely and infinitely recyclable

NEW : Magnelis® can also be purchased with Green Steel

certificates in the frame of the existing and future

investments of ArcelorMittal in Green Steel production

processes

https://ibu-epd.com/en/published-epds/

Magnelis® contributes to reducing the environmental impact

of mounting systems

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jerome.guth@arcelormittal.com corinne.dieu@arcelormittal.com

More info industry.arcelormittal.com/magnelis

Watch the video www.youtube.com/watch?v=ER0R8K3nLXY

Thank you !

Your questions?

© Zimmermann