Description and application guidelines

Roxtec material and

surface treatment guide

Prepared for: Roxtec International AB

Date: 2020-02-10
Author: Jens Bohlin, Roxtec Group,
Box 540, Karlskrona, Sweden roxtec.com
Contents
Abstract. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Metals used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 Welded frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Table 1. Materials used in welded frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Pipe sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Table 2. Materials used in pipe sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Fittings and stayplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Table 3. Materials used in fittings and stayplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4 Cast and machined frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Table 4. Materials used in cast and machined frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

2 Surface treatments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Shop primer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.2 Hot dipped galvanization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Electro-galvanization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 Powder coating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Anodizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Chemical nickel-plating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 General corrosion classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.1 Corrosion classes and durability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 5. Corrosion classes for Roxtec frames. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Table 6. Immersed corrosion tests of Roxtec frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2 Preventive corrosion protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.2.1 Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Bolting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.2.3 Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
3.2.4 Mix of materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Appendix A – Cross-reference table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
 Abstract
Roxtec cable and pipe sealing solutions are designed to be installed in a variety of conditions covering
the roughest marine and offshore environments as well as advanced buildings and train sets. The inten-
tion of this document is to give the reader a general idea of the suitability of specific frame materials
and surface treatments used for Roxtec frame parts for specific applications and requirements.
For product descriptions and auxiliary information, see www.roxtec.com

1 Metals used
The majority of the frames produced by Roxtec is in metal. To cover most customer demands, the
primary materials are mild steel, acid-proof stainless steel and aluminum. For specific requirements
in aggressive areas such as chemical plants, offshore or process industries, other materials or higher
grades might be better in the design. This could be to match a specific hull material to simplify welding
or a high-end stainless steel for salt and wastewater.

1.1 Welded frames

Welded frames are generally produced from profiles that are welded together to form single or multiple
openings. This opening is defined to fit the sealing components used to achieve the tightness and fire
properties of the complete system. To make sure the welding operation is reliable and of high quality,
Roxtec follows standards EN ISO 5817-C and EN ISO 10042-C. Table 1 shows the chemical composition
of the standard material. Equivalent materials of other standards can be found in Appendix A.

Table 1. Materials used in welded frames.

C Si Mn P S Cu
Mild steel
% % % % % %
EN S355J2 ≤ 0.22 ≤ 0.55 ≤ 1.6 ≤ 0.03 ≤ 0.03 ≤ 0.55

C Cr Ni Mo Mn
Acid-proof stainless steel
% % % % %
EN 1.4404 ≤ 0.03 16.5-18.5 10-13 2-2.5 ≤2

Si Mn Cu Cr Fe Mg Zn Ti
Aluminum
% % % % % % % %
EN AW-6082 T6 0.7-1.3 0.4-1.0 ≤ 0.1 ≤ 0.25 ≤ 0.5 0.6-1.2 ≤ 0.2 ≤ 0.1
EN AW- 5754 H12/22 ≤ 0.4 ≤ 0.5 ≤ 0.1 ≤ 0.3 ≤ 0.4 2.6-3.6 ≤ 0.2 ≤ 0.15

3
1.2 Pipe sleeves
Pipe sleeves are mainly produced by extrusion to obtain the required tolerance as standard pipes often
have a too wide tolerance. Larger pipe sleeves are rolled from flat bars or sheet metal and closed by
welding. To make sure the welding operation is reliable and of high quality, Roxtec follows standards ­EN
ISO 5817-C and EN ISO 10042-C. Table 2 shows the chemical composition for the standard ­material.
Equivalent materials of other standards can be found in Appendix A.

Table 2. Materials used in pipe sleeves.

C Si Mn P S Cu
Mild steel
% % % % % %
EN S355J2 ≤ 0.22 ≤ 0.55 ≤ 1.6 ≤ 0.03 ≤ 0.03 ≤ 0.55
EN E355 ≤ 0.22 ≤ 0.55 ≤ 1.6 ≤ 0.025 ≤ 0.025 –

C Cr Ni Mo Mn
Acid-proof stainless steel
% % % % %
EN 1.4404 ≤ 0.03 16.5-18.5 10-13 2-2.5 ≤2

Si Mn Cu Cr Fe Mg Zn Ti
Aluminum
% % % % % % % %
EN AW-6082 T6 0.7-1.3 0.4-1.0 ≤ 0.1 ≤ 0.25 ≤ 0.5 0.6-1.2 ≤ 0.2 ≤ 0.1
EN AW- 6060 T6 0.3-0.6 ≤ 0.1 ≤ 0.1 ≤ 0.05 0.1-0.3 0.35-0.6 ≤ 0.15 ≤ 0.1
EN AW-5754 H12/22 ≤ 0.4 ≤ 0.5 ≤ 0.1 ≤ 0.3 ≤ 0.4 2.6-3.6 ≤ 0.2 ≤ 0.15

1.3 Fittings and stayplates

Stayplates and fittings used for anchoring of sealing modules and frames are produced from coiled
sheets and plates. The majority of fittings are of acid-proof stainless steel while the stayplates can be
in galvanized or acid-proof stainless steel versions. Table 3 shows the chemical composition for the
standard material. Equivalent materials of other standards can be found in Appendix A.

4
 Table 3. Materials used in fittings and stayplates.

C Si Mn P S Cu
Mild steel
% % % % % %
EN S355J2 ≤ 0.22 ≤ 0.55 ≤ 1.6 ≤ 0.03 ≤ 0.03 ≤ 0.55
DX51D-Z275 ≤ 0.18 ≤ 0.5 ≤ 1.2 ≤ 0.12 ≤ 0.045 ≤ 0.3

C Cr Ni Mo Mn
Acid-proof stainless steel
% % % % %
EN 1.4404 ≤ 0.03 16.5-18.5 10-13 2-2.5 ≤2

1.4 Cast and machined frames

Frames cast of aluminum are injection molded and the surface is treated with a powder coat or nick-
el-plating depending on requirements. Machined frames are manufactured from brass. Table 4 shows
the chemical composition for the standard material. Equivalent materials of other standards can be
found in Appendix A.

Table 4. Materials used in cast and machined frames.

Si Mn Cu Fe Zn Ti
Aluminum
% % % % % %
EN AC-44300 10.5-13.5 ≤ 0.55 ≤ 0.1 ≤ 1.0 ≤ 0.15 ≤ 0.15

Cu Pb Fe Ni Sn Al
Brass
% % % % % %
CW614N 57-59 2.5-3.5 ≤ 0.3 ≤ 0.3 ≤ 0.3 ≤ 0.05

2 Surface treatments
A frame made of acid-proof stainless steel or aluminum does generally not need any additional coat-
ing. To facilitate technical needs such as electrical conductivity in the EMC assortment or higher cor-
rosion resistance, there are several standard surface treatments in the product portfolio. The standard
surface treatment of the products can be changed in type and color in our customization process to fit
application specific demands and requirements.

2.1 Shop primer

To protect mild steel products during transportation to site, a minimum 20µm thick shop primer is
applied. This coating reduces surface corrosion during transportation and handling before the welding
operation. The shop primer can be welded and does not need to be sandblasted before the welding

5
 operation. After welding it to the structure, it is recommended to coat the frames and sleeves with a
paint system in accordance with the environmental conditions and application requirements.

2.2 Hot dipped galvanization

This galvanizing process is done by lowering the metal into a zinc bath. The general thickness of this
operation is 85µm in accordance with EN ISO 1461. This is a cost-efficient corrosion protection suitable
in most in- and outdoor application areas. If damaged, it can heal itself and it is easy to repair if big
potions of the coating are scratched off. Frames with this surface protection are intended to be bolted
or cast to the structure.

2.3 Electro-galvanization
The electro-galvanization process also applies a zinc layer but the coating is applied in a thinner way.
It is applied by adding a current through the metal piece, attracting the zinc ions to the surface of met-
al. This creates a much smoother surface than hot dip galvanization. The minimum thickness is 8 µm
according to ISO 2081. It works well in weather-protected areas and indoor applications.

2.4 Powder coating

The powder coating gives a great finish and increases the corrosion protection of the metal. Pow-
der coating is applied by placing the metal in a chamber with paint powder. Thereafter the metal is
charged electrically to attract an even layer of powder before being put in a hot oven. The melted
polyester powder coating thickness is defined by the corrosion requirement.

2.5 Anodizing
Anodized frames are exposed to electrolytic passivation to increase the oxide layer that forms natural-
ly on aluminum. This layer increases the corrosion protection and resistance to wear. The thickness is
generally minimum 20µm according to ISO 7599.

2.6 Chemical nickel-plating

By chemically applying a layer of nickel on frames, the resistance against mechanical wear and cor-
rosion is improved. This surface treatment also makes sure the electrical conductivity is sufficient over
time to support the efficiency of the EMC products. The chemical nickel-plating is done in accordance
with ISO 4527 with a minimum thickness of 10µm.

3 General corrosion classes

When combining different metal and surface treatments, the finished product reaches different corro-
sion classes. Roxtec frames are tested in accordance with the international standard EN ISO 12944-2
to simplify the choice of system in specific application areas. The environmental conditions can vary
over a system’s lifecycle so the corrosion classes should only be used as indicative. If in doubt, a higher
classed material should be considered. When selecting the proper material it is also important to iden-
tify the expected maintenance interval. In accordance with EN ISO 12944-2, the durability determines
when the first maintenance is expected to be needed. Periodical visual inspection is recommended on
a regular basis if the system is used in corrosive environments.

3.1 Corrosion classes and durability

The materials used in standard Roxtec frames are tested at third party laboratories to determine a cor-
rosion class for atmospheric corrosion in accordance with ISO 12944. This is to be used as a reference

6
 and depends on actual exposure to chemicals and pollution. Special types of aggressive media require
higher grades of steel such as Duplex. Table 5 shows the general corrosion classes of the materials used
in the frames produced by Roxtec.

Table 5. Corrosion classes for Roxtec frames.

C1 C2 C3 C4 C5 CX Expected time
Material to first major
Very low Low Medium High Very high Extreme maintenance*

Steel – Shop primed 1 X < 5 years

Steel – Hot dipped galv 2

X 5-15 years

Steel – Electro-galvanized 3
X 5-15 years

Steel – Acid-proof stainless* X > 15 years

Steel – Stainless X 5-15 years

Steel – Powder coated 4

X 5-15 years

Aluminum – Marine grade X > 15 years

Aluminum – Nickel-plated 5 X 5-15 years

Aluminum – Powder coated 6 X 5-15 years

Polyamide 7 X 5-15 years

ABS X > 15 years

AluZink X 5-15 years

Brass X 5-15 years

*Acids destroying the passive film accelerate the corrosion and shorten the life expectancy. Uniform corrosion is considered.
1) Minimum 20µm of shop primer used for transportation protection.
2) Minimum thickness of 70µm of zinc coating according to EN ISO 1461.
3) Minimum 8 µm according to ISO2081 (Fe/Zn c1).
4) Minimum 40µm. Specified by demand.
5) Minimum 10µm according to EN 4527.
6) Minimum 50-70µm. Specified by demand.
7) Glass-fiber 20-30% reinforced PA 6.6.

The products used for underground systems are designed for a long life underground and are tested
for immersion in saltwater and soil. If micro-bacteria or strong chemicals are expected in the ground-
water or soil, the material of the fittings must be considered to be of a higher grade than the standard
material.

Table 6. Immersed corrosion tests of Roxtec frames.

Expected time to first

Material Im 2 Im 3
major maintenance
Steel – Acid-proof * X X > 15 years
ABS X X > 15 years

*Acids destroying the passive film accelerate the corrosion and shorten the life expectancy. Uniform corrosion is considered.

7
3.2 Preventive corrosion protection
The expected lifetime of an installed Roxtec frame can often be prolonged by taking some simple de-
sign precautions.

3.2.1 Welding
A welded frame that is exposed to humidity and water from both sides benefits from a two-sided weld
seam protecting against crevice corrosion, see pictures 1 & 2. The aperture for a flanged frame should
not be too tight to the frame walls either as the final coating is easier to apply when a distance of min-
imum 15mm is respected, see picture 3.

Picture 1. Double-sided weld pass. Picture 2. Double-sided weld pass. Picture 3. 15mm clearance.

3.2.2 Bolting
A bolted frame using a gasket or sealant can benefit from a protective string of sealant at the perim-
eter of the frame. This prevents standing water and crevice corrosion but also frost wedging during
wintertime, pictures 4-6.

Picture 4. Gap between structure and Picture 5. Sealant applied. Picture 6. Sealant smoothed out.
frame.

3.2.3 Fasteners
Fasteners should be selected in accordance with the material used in the frame to avoid galvanic
corrosion. This means stainless steel fasteners for stainless steel and aluminum frames, and galvanized
fasteners for mild steel frames.

8
3.2.4 Mix of materials
Generally, it is recommended to avoid mixing different types of materials in the same transit. In envi-
ronments with presence of electrolytes, this can be harmful as galvanic corrosion can occur, making
the less noble material corrode. This can be prevented by avoiding standing water or by applying a
coating that electrically insulates the materials from each other. Gaskets between flanges and structure
also break the electrical contact. If electrical contact is unavoidable, the size of the less noble material
should be considerably bigger to reduce corrosion.
For primed and galvanized mild steel frames, it is recommended to use galvanized fasteners and
stayplates. Frames in aluminum and stainless steel are recommended to be installed with stainless steel
fasteners and stayplates.

O2

Water
O2
Fe2+

H2O

Rust

Cathodic site

Anodic site

e–

9
 Appendix A – Cross-reference table
The table shows comparable grades of different international recognized steel standards. The actual
chemistry can differ between standards but the performance of the Roxtec system is not affected.

Welded frames EN ASTM UNS DIN KS GB/T 1591-2008

Mild steel S355J2 A572-50 K02303 ST52-3N SM420C Q345-D
Acid-proof 022Cr17Ni12Mo2不锈
1.4404 316L S31603 1.4404 STS316L
stainless steel 钢，316L精钢
AW-6082 T6 6082 A96082 3.2315 6082 6082
Aluminum
AW-5754 T6 5754 A95754 3.3535 5754 5754

Stayplates EN ASTM UNS DIN KS GB/T 1591-2008

DX51D+­ DX51D+
Mild steel - – – –
Z275 Z275
Acid-proof 022Cr17Ni12Mo2不锈
1.4404 316L S31603 1.4404 STS316L
stainless steel 钢，316L精钢

Pipe sleeves EN ASTM UNS DIN KS GB/T 1591-2008

S355J2
Mild steel A572-50 K02303 ST52-3N SM420C Q345-D
E355
Acid-proof 022Cr17Ni12Mo2不锈
1.4404 316L S31603 1.4404 STS316L
stainless steel 钢，316L精钢
AW-6082 T6 6082 A96082 3.2315 6082 6082
AW-6060 T6 6060 A96060 3.3206 6060 6060
Aluminum
AW-5754
5754 A95754 3.3535 5754 5754
H12/22
Brass CW614N C37710 C37710 2.0401 CW614N

Cast frames
EN ASTM UNS DIN KS GB/T 1591-2008
and pipe sleeves
Acid-proof 022Cr17Ni12Mo2不锈
1.4404 316L S31600 1.4436 STS316L
stainless steel 钢，316L精钢
Aluminum AC-44300 A413.0 A14130 3.2582 – YL102

Note: The temper of the standard material must be respected when comparing materials.

10
 References
OO EN ISO 5817 – Welding – Fusion-welded joints in steel, nickel, titanium and their alloys (beam
­welding excluded) – Quality levels for imperfections
OO EN ISO 10042 – Welding – Arc-welded joints in aluminium and its alloys – Quality levels for
­imperfections
OO ISO 1461 – Hot dip galvanized coatings on fabricated iron and steel articles – Specifications and
test methods
OO ISO 2081 – Metallic and other inorganic coatings – Electroplated coatings of zinc with
­supplementary treatments on iron or steel
OO ISO 4527 – Metallic coatings – Autocatalytic (electroless) nickel-phosphorus alloy coatings –
­Specification and test methods
OO EN ISO 12944 – Paints and varnishes – Corrosion protection of steel structures by protective paint
systems
OO ISO 7599 – Anodizing of aluminium and its alloys – Method for specifying decorative and protective
anodic oxidation coatings on aluminum
OO ISO 4527 – Metallic coatings – Autocatalytic (electroless) nickel-phosphorus alloy coatings –
­Specification and test methods

11
DISCLAIMER
”The Roxtec cable entry sealing system (”the Roxtec system”) is a modular-based system of sealing products consisting of different components. Each and every one of the components
is necessary for the best performance of the Roxtec system. The Roxtec system has been certified to resist a number of different hazards. Any such certification, and the ability of the
Roxtec system to resist such hazards, is dependent on all components that are installed as a part of the Roxtec system. Thus, the certification is not valid and does not apply unless
all components installed as part of the Roxtec system are manufactured by or under license from Roxtec (“authorized manufacturer”). Roxtec gives no performance guarantee with
respect to the Roxtec system, unless (I) all components installed as part of the Roxtec system are manufactured by an authorized manufacturer and (II) the purchaser is in compliance
with (a), and (b), below.
(a) During storage, the Roxtec system or part thereof, shall be kept indoors in its original packaging at room temperature.
(b) Installation shall be carried out in accordance with Roxtec installation instructions in effect from time to time.
The product information provided by Roxtec does not release the purchaser of the Roxtec system, or part thereof, from the obligation to independently determine the suitability of the
products for the intended process, installation and/or use. Roxtec gives no guarantee for the Roxtec system or any part thereof and assumes no liability for any loss or damage what-
soever, whether direct, indirect, consequential, loss of profit or otherwise, occurred or caused by the Roxtec systems or installations containing components not manufactured by an
authorized manufacturer and/or occurred or caused by the use of the Roxtec system in a manner or for an application other than for which the Roxtec system was designed or intended.
Roxtec expressly excludes any implied warranties of merchantability and fitness for a particular purpose and all other express or implied representations and warranties provided by
statute or common law. User determines suitability of the Roxtec system for intended use and assumes all risk and liability in connection therewith. In no event shall Roxtec be liable for
indirect, consequential, punitive, special, exemplary or incidental damages or losses.”

PDF2020000401 ver_1/EN/2007/thoge
Roxtec ® and Multidiameter ® are registered trademarks
of Roxtec in Sweden and/or other countries.