Ferrous iron

• Pig Iron
The crude impure iron, which is extracted from iron ores, is known as pig-iron
and it forms the basic material for the manufacture of cast-iron, wrought iron and
steel.
The pig iron is manufactured by the following operations
(i) Dressing : Crushed into pieces 25mm, impurities of clay, loam and other
earthy matter removed by washing, magnetic separators are used for magnetic
impurities.
(ii) Calcination and roasting : Water and carbon dioxide are removing from ores
by calcinations. By roasting, making the ores hot and very dry after removal of
sulphur.
(iii) Smelting : Smelting is carried out in a special type furnace known as blast
furnace. The raw material consists of iron ores, the fluxing materials like
limestone and fuel like coal, charcoal is allowed to through throat portion of the
furnace. By the reduction, the pig iron collects in the hearth of furnace. The slag
formed is removed and hot gases dust escapes through outlet, which is provided
in the throat portion of furnace.
•Cast Iron
Cast iron is manufactured by remelting pig iron with coke and limestone. This
remelting is done in a furnace known as cupola furnace, which is more or less same
as blast furnace. Its shape is cylindrical with diameter about 1m and height of about
5m. The raw materials are led from the top and the furnace is fired. The impurities of
pig iron are removed to some extent by oxidation. The molten cast iron is led into
moulds of required shapes to form what are known as cast iron castings and slag is
removed from the top of cast iron at regular intervals.
•Composition of cast iron:
Cast iron contains about 2 to 4 percent of carbon.
Manganese makes cast iron-brittle and hard, so it may be kept below 0.75 percent.
Phosphorous makes brittle and percentage may be 1 to 1.5 percent.
Silicon decreases shrinkage and ensures softer and better castings and it may be less
than 2.5 percent.
Sulphur makes cast iron brittle and hard and should be kept below 0.10 percent.
• Uses cast iron:
For making cisterns, water pipes, gas pipes and
sewers, manhole covers and sanitary fittings.
For making ornamental castings like brackets,
gates, lampposts etc.
For making parts of machinery which are not
subjected to shock loads.
For manufacture of compression members.
For preparing rail chairs, carriage wheels etc.
• 3. Wrought Iron
• Wrought iron is almost pure and it hardly contains carbon more than
0.15 percent. But the process of its manufacture is laborious and
tedious. Wrought iron is manufactured by four operations
• Refining
• Puddling
• Shingling
• Rolling
• Properties of wrought iron:
• It can be easily forged and welded
• It can be used to form temporary magnets
• It is ductile, malleable and tough
• It is moderately elastic
• It is unaffected by saline water
• It resists corrosion in a better way
• Its melting point is about 15000C
• Its specific gravity is about 7.8
• Its ultimate compressive strength is about 2000 kg/cm 2
• Its ultimate tensile strength is about 4000kg/cm 2.
• Uses of wrought iron:
• It is used for rivets, chains, ornamental iron work, railway
couplings, water and steam pipes, bolts and nuts, horse shoe
bars, hand rails, straps for timber roof trusses, boiler tubes,
roofing sheets etc.
 Mild steel
• Carbon content – 0.25% (max)
Sulphur – 0.055%
Phosphorous - 0.055% ( I.S. 226: 1969)
• Dark bluish colour
• It is tough, elastic than cast iron and wrought
iron.
• It is malleable and ductile.
 Properties of mild steel
• Can be magnetized permanently
• Readily forged, riveted and bolted
• Easily hardened or tempered
• Malleable and ductile
• Specific gravity 7.8
• Melting point – above 1400°C
 Uses of mild steel
• Used as steel reinforcements (mild steel round
bars)
• Mild steel tubes are used in construction
• Mild steel sheets are used for roof coverings
• Used in manufacture of various tools,
machinery and other equipments
 STRUCTURAL STEEL SECTIONS:
• Angle sections
• Channel sections
• I-sections
• T-sections
• Flat sections
• Steel plates
• Corrugated sheets
• Round bars
• Square bars
 Structural steel sections
• Rolled steel bar section:
• Indian Standard Round Bars (ISRO):
 Designated as ISRO 10 (round bars having diameter
10mm)
 Available in diameter varying from 6mm to 25mm.
• Indian Standard square bars (ISSQ):
 Designated as ISSQ 10 (square bars of size 10mm)
 Used for grillwork, handrails for staircases etc.
• Rolled Steel Plate Section ( ISPL):
• Designated as ISPL 500 x 5 (500mm width and 5mm
thickness)
• Used for construction of water tanks and other storage
structures, built up beams, columns, base plate for
foundations etc.
• Rolled Standard Sheet Sections (ISSH):
• Plates having thickness less than 5mm.
• Designated as ISSH 1800 x 600 x 4 (sheet having length
1800mm, breadth 600mm and thickness 4mm).
• Used for construction of boxes and vehicle bodies.
• Indian Standard Strips (ISST):
• Mainly used as beedings.
• Designated as ISST 100 x 2 (steel strip with a width of
100mm and thickness 2mm).
• Indian Standard Flats (ISF):
• Designated as ISF 10 x 3(flat of width 10mm and thickness
3 mm).
• Available in suitable widths varying from 10mm to
400mm
• Thickness varying from 3mm to 40mm.
• Used for steel grillwork for windows and gates.
• Rolled Steel Tubes:
• Inner diameter varying from 15 to 150mm.
• Thickness varying from 2 to 5.4mm.
• Efficient structural sections for formwork and trusses
• Rolled Steel Angle Sections (ISA)
• Designated as ISA and width and length of legs
• Available as
 Equal angle sections
i. Two legs will be equal in length
ii. Available in sizes varying from 20mm x 20mm x 3mm
to 200mm x 200mm x 25mm
• Unequal angle sections
i. Two legs will be unequal in length.
ii. Available in sizes varying from 30mm x 20mm x3mm
x 3mm to 200mm x 150 mm x 18mm
 • Bulb angle sections

• Extensively used in structural steel works like roof trusses,

and as connecting members for different structures.
• Rolled steel Tee sections:
• Resembles the alphabet T
• Consists of web and flange
• Designated by overall dimensions and thickness.
• Available in sizes varying from 20mm x 20mm x 3mm to
150mm x 150mm x 10mm.
• Widely used as members of the steel roof truss and form
built – up sections.
• Different types available are:
 Indian Standard Normal Tee (ISNT)
 Indian Standard Heavy Tee (ISHT)
 Indian Standard Short Tee (ISHT)
 Indian Standard Junior Tee (ISHT)
• Rolled Steel Channel Sections:
• Consists of a web and two equal flanges.
• Designated by height of web and width of flange
• Available in sizes varying from 100mm x 45mm to 400mm
x 100mm.
• Widely used for beams and columns.
• The different types available are:
 Indian Standard Junior Channel (ISJC)
 Indian Standard Light Channel (ISLC)
 Indian Standard Medium Channels (ISMC)
• Rolled Steel I – Sections

• Known as rolled steel joists or beams.

• Consists of two flanges connected by a web.
• Designated of overall depth and width of flange.
• Available in sizes varying from 75mm x 50mm to 600mm
x210mm.
• Different types are:
 Indian Standard junior beam (ISJB)
 Indian Standard Light Beam (ISLB)
 Indian Standard Medium Beam (ISMB)
 Indian Standard Wide Flange Beam (ISWB)
 Indian Standard Heavy Beam (ISHB)
• Strongest and most economical of all sections
• Used as columns, purlins in trusses and grillage
foundations.
• Built –up sections:
• Composed of a combination of available basic sections
like plates, angles, channels etc.
• For increased strength and stability
• Different sections are joined by welding or riveting