Structural steel fabrication is a process that involves bending, cutting, shaping and assembling structural steel components to create complicated and accurate industrial and residential structures. Structural steel fabrication has a very high strength-to-weight ratio. Because of this versatility and flexibility, engineers use structural steel fabrication extensively in various industrial, residential and commercial projects.
In this blog, let me walk you through the Advantages, Processes and applications of structural steel fabrication works. Here we go.
Structural steel fabrication – Stages and procedures
Structural steel fabrication involves multiple stages and requires highly skilled manpower. The training of manpower is essential for transforming raw materials into precise engineering structures. In the following sections, I will show you the processes involved in structural steel fabrication works and the involvement in crafting the structures.
Ideation and shop drawings/fabrication drawings
In the first stage of structural steel fabrication works the major processes involve ideating, blueprinting, and creating shop drawings. During this phase, the team conceptualizes the design and prepares detailed plans and drawings. We use software to create blueprint drawings, taking into account requirements, code compliances, and specifications. Blueprints and shop drawings ensure proper design and accurate pieces of information like dimensions, connections, and other specifications required for fabricating the structure.
Accurate and precise ideation, blueprints and shop drawings are the most important factors that exhibit the quality and speed of any structural fabrication work.
Material preparation for structural fabrication
The preparation of raw steel for structural fabrication involves the following stages:
a) Material selection and inspection
b) Cutting, bending, drilling
Material selection and inspection
We perform the material selection on the basis of project requirements and specifications. Generally, this step includes the selection of the appropriate grade of material and requisite raw material quality checks before using it for work.
Cutting, bending and drilling of steel
The cutting stage encompasses the precise cutting of raw material into accurate sizes as per the shop drawings. Mostly, cutting is done with the help of various techniques. This includes sawing, which involves using a saw blade, shearing, which uses specialized machinery to make straight cuts and advanced techniques like plasma or laser cutting or water jets. Generally, these processes take place in a fabrication shop/factory. However, the shearing process is limited to small and miscellaneous structural members.
During the bending stage, the structural steel undergoes deformation to the required shape and angles. We mainly employ rolling machines or press breaks in this process. Generally, there are five common methods of bending structural steel. This includes rolling, incremental bending, hot bending, rotary-draw bending, and induction bending. Fabrication of curved or angled structures requires bending.
Drilling of structural steel provides precise holes in structural members. This is generally done with the help of drill presses or specialized drilling machines. Drilling is basically done for bolted components.
Welding of structural steel
Welding is the process of creating a variety of welds for joining structural steel components using heat and pressure to produce continuous joints. Mostly, the welding process follows different stages:
The welding process starts with cleaning the surface and ensuring that any dirt and other impurities are not there. The next process is the fit where we assemble and align the steel sections as per shop drawings. Basically, this ensures an accurate fit-up for welding. On completion of the fit-up, we start the structural welding process.
Structural welding is done in any of the two methods. The heat from an electric arc, laser, or other welding methods is applied to melt the steel edges, forming a molten pool. Filler Material such as welding wire or rod, is added to the molten pool to strengthen the weld. The molten pool cools, solidifies, and forms a continuous bond between the steel components.
Common types of welding used in structural steel fabrication include:
- Shielded Metal Arc Welding (SMAW)
- Gas Metal Arc Welding (GMAW)
- Flux-Cored Arc Welding (FCAW)
- Gas Tungsten Arc Welding (GTAW)
- Submerged Arc Welding (SAW)
- Stud Welding
Engraving and assembly
Engraving in structural steel fabrication involves etching or inscribing markings, identification codes, or specific details onto the steel components. Specialized engraving tools or laser engraving machines perform this step.
Assembly is the final stage where we combine the fabricated steel components, often through welding, bolting, or riveting, to create the completed structure. These steps ensure proper identification, alignment, and secure connections, contributing to the structural integrity and functionality of the steel assembly.
Conveying for erection
The fabricated members are conveyed to the area of erection where these members are erected and aligned according to the drawings.
Advantages of structural steel fabrication
Structural steel fabrication offers a wide variety of advantages,
- High Strength and Durability: Structural steel possesses excellent strength-to-weight ratio and durability, providing long-lasting and resilient structures.
- Design Flexibility: Steel fabrication allows for versatile and customizable designs, accommodating complex architectural and engineering requirements.
- Fast Construction: Prefabrication of Steel components enables efficient and speedy on-site assembly, reducing construction time and costs.
- Structural Integrity: Steel’s inherent properties ensure structural integrity, capable of withstanding heavy loads, seismic forces, and extreme weather conditions.
- Sustainability: Steel is recyclable and reusable, reducing environmental impact and promoting sustainability in construction projects.
- Cost-Effective: Steel fabrication offers cost efficiencies due to faster construction, reduced labor requirements, and minimized maintenance needs.
- Precision and Quality: Since steel fabrication takes place under controlled conditions, it ensures high precision, quality, and dimensional accuracy.
- Fire Resistance: Steel is non-combustible and can withstand high temperatures, enhancing fire resistance and safety.
- Adaptability: Generally, steel structures give the option for easy modification, expansion, or retrofitting to accommodate future changes or renovations.
- Aesthetic Appeal: Steel’s sleek and modern appearance provides architectural versatility and visually appealing structures.
These advantages contribute to structural steel fabrication’s widespread use and popularity in various construction projects.
Applications of structural steel
Structural fabricated construction mainly has the following applications
- High-rise buildings
- Industrial Buildings
- Residential Buildings
- Parking Garages and multilevel parking
- Bridges
Shall we wrap up?
Conclusion
In this blog, we saw the advantages, processes and applications of structural steel fabrication works. I hope you found it insightful. In case of any queries, please feel free to ask in the comments.
Happy Learning.