Two stage pack cementation processes are developed to form dual Fe-Al-Cr layers on surfaces of SNCM439 steels. The first 550°C treatment assists to modulate adequate aluminum activity for the formation of iron-rich intermetallics. In the second 750°C treatment stage, simultaneous chromizing and aluminizing treatments are achieved by first forming a FeAl ferritic layer and then a surface layer with higher Cr content at later time. The current study examines the effects of second stage 750°C holding time, activator concentration, and Cr:Al ratio on coating structures. Fe-Al coatings consisting of Fe3Al and FeAl intermetallic phases are observed to form initially. This Fe-Al layer accounts for 25 to 32 μ m thickness of the coatings and show good adherence with the substrates. The coating thickness increases parabolically with 750°C holding time. With prolonged treatment at 750°C, surface concentration of aluminum in powder packs drops with treatment time and increasing concentration of activator. A peak concentration exists at a depth below substrate surface. Aluminum is back diffused from the steel surface into the powder packs. The growth of Fe-Al intermetallics slows down. Surface layer then forms a thickness of 6 μ m coating with 2-5 wt.% of chromium. Samples treated for longer than 6 h with over 12 wt.% of NH4Cl activator concentration or with Cr:Al ratio higher than 90:10 induce earlier chromium infusion and lead to porous coating structure due to Kirkendall effect. Eventually chromium carbide forms to cease further growth of the dual coating structures.