Professional Documents
Culture Documents
Metal
Metal
LECTURE CONTENT
1. Introduction
2. Ferrous metals
2.1 Iron
2.2 Steel
3. Types of steel used in construction
4. Steel tensile test (Concrete Workshop)
5. Steel protection
6. Structural steel
7. Structural connections
7.1 Riveting
7.2 Welding
7.3 Bolts
7.4 High strength bolts
8. Reinforcement
9. Other metals: Aluminium, Brass, Copper
INTRODUCTION
• Most metals have to be mined and refined from their
geologically based ores.
Ferrous Nonferrous
1. Wrought iron is made from pig iron with some slag mixed in
during manufacture.
3. The chemical analyses of wrought iron and mild steel are just
about the same. The difference comes from the properties
controlled during the manufacturing process.
4. Wrought iron can be gas and arc welded, machined, plated, and
easily formed; however, it has a low hardness and a low-
fatigue strength.
PRODUCTS OF FERROUS METAL
CAST IRON
1. Cast iron pipes are however, still in favour for the construction of
water pipes and sewerage, mainly due to their resistance to
‘corrosion’. Process of manufacturing are as follow:
STEEL
HOW STEEL IS PRODUCED:
1. Iron is a metal extracted mainly from the iron ore.
2. It oxidizes readily in air and water to form Fe2O3 and is
rarely found as a free element.
3. In order to obtain elemental iron, oxygen and other
impurities must be removed by chemical reduction.
4. The properties of iron can be modified by alloying it
with various other metals and some non-metals, notably
carbon and silicon to form steels.
Steel is manufactured from pig iron by decreasing the
carbonamount and other impurities and adding spec
ific amounts of alloying elements.
STEEL
METAL/IRON ORE/IRON/ALLOYING/STEEL
SOW
PIG IRON??
Pig Iron: Because blast furnaces produced increased quantities of iron from the
ore, the molten iron was cast into bars, called pig iron, for later
remanufacturing. The furnaces were built and operated for the purpose of
extracting iron from the native iron ores. The objective was to form bars of cold
cast iron for transfer to a foundry for later remanufacture. These were made in
molds pressed in the very dry sandy floor. A main trench directed the molten
iron to a distribution trench from which many side branches were formed. The
molten iron was cast into bars called "pigs"; hence, the common name of "pig
iron." The name pig iron is meaningless to non-farm people, as it is a figment of
the imagination of the blast furnace workers--all of whom were very familiar with
the keeping of pigs. Workers before World War I were, in almost all cases,
required to have a kitchen garden, and keep cows, chickens and pigs. This was a
matter of survival and considered part of the compensation in a company town
or village. The workers were very familiar with the appearance of a mother pig,
called a sow, and her dozen or more nursing piglets. As they looked at the
molten iron flowing from the hearth in the base of the furnace stack, the trench
of red iron with the many short side branches made them think of a sow (the
large feeder trench) and pigs (the end result).
STEEL MAKING
Blast furnace
Iron ore, coke, and limestone are loaded into the top of the
furnace, while air is blown in from below. The coke is converted
to carbon monoxide (CO), which then acts as the reducing agent:
2 C + O2 → 2 CO
3 CO + Fe2O3 → 2 Fe + 3 CO2
STEEL MAKING
Blast furnace (Cont’d)
The molten iron falls to the bottom of the furnace, and the
limestone reacts with silicate impurities to form a molten
slag, which floats on top of the iron.
The two layers are drawn off separately, and the iron is
poured into molds. Because the molten iron yields ingots that
resemble little pigs, the product is referred to as "pig iron."
TURNING ORE TO PIG IRON
TURNING ORE TO PIG IRON
STEEL MAKING
Steel furnaces
ENERGY OPTIMIZING
FURNACE or EOF
• These alloys are often used for rods and or wire strands in
pre-stressed and post-tensioned members where they need to
resist the high stresses applied.
High tensile steel –
Pre-stressing
TYPES OF STEEL USE IN CONSTRUCTION - Form
Jointing Methods
Riveting
Jointing Methods
Riveting
Bolting
Connectors
3. Wider range of section types with new forming techniques has greatly
increased steel versatility. Steel is now featured as architectural materials
in their own right.
1. The name for the metal comes from Kyprios, the Ancient Greek
name for Cyprus, an island which had highly productive copper
mines in the Ancient world.