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Based on the known positive effects of conventional hot-dip galvanizing under fire exposure and indicative results on zinc–aluminum coatings from smallscale tests, a series of tests were conducted on zinc-5% aluminum galvanized test specimens under fire loads to verify the previous positive findings under largescale boundary conditions.

The emissivity of zinc-5% aluminum galvanized surfaces applied to steel specimens was determined experimentally under real fire loads and laboratory thermal loads in accordance with the normative specifications of the standard fire curve. Both large and smallscale specimens were used in this study. The steel grade and surface conditions of the specimens were varied for both test scenarios.

Largescale tests on specimens with typical steel construction dimensions under fire loads showed that the surface emissivity of zinc-5% aluminum galvanized steel was significantly lower than that of the conventionally galvanized steel. Only minor influences from the weathering of the specimens and steel chemistry were observed. These results agree well with those obtained from smallscale tests. The design values of zinc-5% aluminum melt (Zn5Al) required for the structural fire design were proposed based on the obtained results.

The novel tests presented in this study are the first ones to study the behavior of zinc-5% aluminum galvanized largescale steel construction components under the influence of real fire exposure and their positive effect on the emissivity of steel components galvanized by this method. The results provide valuable insights and information on the behavior in the case of fire and the associated savings potential for steel construction.

Based on the advantages of conventional hot-dip galvanizing made from quasi-pure zinc melts in the event of fire, this article aims to perform a series of tests to verify whether a similar effect can be achieved with zinc-aluminum coatings.

The emissivity of galvanized surfaces, which were applied to steel specimens by the batch hot-dip galvanizing process, was experimentally determined under continuously increasing temperature load. In addition to a quasi-pure zinc melt serving as a reference, a zinc melt alloyed with 500 ppm aluminum and thin-film galvanized with a melt of zinc and 5% aluminum were used. For the latter, variants of post-treatment measures in terms of a passivation and sealing of the galvanizing were also investigated.

The results show that lower emissivity can be achieved at higher temperatures by adding aluminum to the zinc melt and thereby into the zinc coating. The design values required for the structural fire design were proposed, and an exemplary calculation of the temperature development in the case of fire was carried out based on the values. The result of this calculation indicates that the savings potential becomes apparent, when using zinc-aluminum coatings.

The presented novel tests describe the behavior of zinc-aluminum coatings under the influence of elevated temperatures and their positive effect on the emissivity of steel components galvanized by this method. The results provide valuable insights and information on the performance in the event of fire and the associated potential savings for steel construction.