Things to consider before choosing a fabricator

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Things to consider before choosing a fabricator

Fabricators are the professionals who work with different forms of metal and convert them into final products. They are involved in creation of metal structures by welding, cutting, forming, machining and assembling processes. Metal Fabrication is a value-added process involving the construction of structures and machines from various raw materials. Standard raw materials used include plate metal, fittings, castings, metal tubes, formed and expanded metal, sectional metal and welding wire.  Sometimes this is done by hands but most often this is done by machine that makes the process faster & more precise. Fabricators generally work for construction and manufacturing companies. Metal fabrication projects include everything from handrails to heavy equipment.

6 Things to Consider Before Choosing Metal Fabricators:

Experience & Reputation:

When choosing a fabricator, their skill level and reputation for excellence are extremely important. The metal fabrication work should be legally compliant with standards. Because of the way metal is used, the experience and reputation of metal fabricator must be without question.

Quality:

The chosen metal fabricator should be aware of quality standards and prepared to deliver quality work that will pass all levels of inspection. Having a certified inspection testing procedure help fabricators in producing high-quality products.

Brand of raw material:

While selecting a fabricator, look for the brand of the raw material being used by them. Branded raw material provides greater ease of fabrication, safety, and convenience to the fabricators.

Capability:

The most important thing to consider is the availability of the right fabricator. Most metal fabricators specialize in certain areas. It is also important to consider whether or not the fabricator is capable of handling project in-house from start to finish. It’s important to verify that the fabricator you choose has the equipment, materials, skilled staff, and production capacity required to complete the project on time and on budget.

Customer service:

When choosing a fabricator, look for those whose guiding principles include craftsmanship, vision, hard work, and superior service.

Pricing:

Depending on your budget, you will be able to decide which fabricator is the best for your job. Make sure that the pricing of a fabricator is in line with the market.

What is Pre painted galvalume steel?

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Pre painted galvalume steel

What is Pre painted galvalume steel?

Pre-painted galvalume steel is manufactured by colour coating galvalume treated steel substrate. The typical composition of galvalume coating is 55% aluminium, 43.4% zinc and 1.6% trace elements. Galvalume coated steel is usually produced in a continuous galvalume line. They are then applied with various layers of organic coatings which can be paints, vinyl, or laminates. Pre painted galvalume steel has superior long term corrosion resistance in most atmospheric conditions. This is achieved through the combination of the sacrificial protection of the zinc and the barrier protection of the aluminium.

Excellent corrosion resistance and lower heat conductivity make Pre-painted galvalume steel, the preferred choice for roofing and cladding applications. They find their usage in a myriad of constructional purposes like Pre Engineered Buildings, Rain Ware, Landscaping, and Recreational Centres. They are also widely accepted in construction of white good appliances & automotive body parts.

Let us see what make Pre painted galvalume steel an ideal choice for use in an array of applications:

Better corrosion resistance: Superior resistance to corrosion means longer service life for buildings, appliances etc.

Heat reflectivity: Pre painted galvalume steel doesn’t allow too much conduction of heat and ensure a safe and cool environment within the building.

Durability: They can also bear high loads without getting damaged. Such steels are durable and assure longevity.

Environmental friendly: These steels are easily recyclable.

Weather resistant: Pre-painted galvalume steel can withstand harsh weathers conditions such as extreme summers, winters or rainfall.

Ease of fabrication: They are easy to form, shape, cut & fasten

Pleasing surface finish: They look attractive and impressive with pleasant surface finish & aesthetics.

All of the above reasons make Pre painted galvalume steel, a value added futuristic building material. India’s 60% of Pre-painted galvalume steel is being used as roofing & cladding sheets. Today, most of the buildings use colour coated roofing sheets in garages, offices, restaurants, parking, warehouses, industrial shed etc. Color coated roofing sheets not only add the aesthetic value to the structure but also offer longer life. APL Apollo RoofTuf provides a world-class solution of metal roofing systems. These roofing sheets are not just strong and beautiful but also excellent resistant to extreme weather conditions.

What are HFIW steel tubes

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HFIW

What are HFIW steel tubes

HFIW (High Frequency Induction Welding) tubes are manufactured by cold forming of steel coil into desired shape followed by welding using high frequency induced current. A high frequency coil develops current into the tube ahead of the squeeze rolls. The edges are pushed together between squeeze rolls to produce a joint of welding. The welding of the edges forms a small bead inside and outside the tube. These beads are then scarfed from the tube to give a smooth surface finish. Surface heating by induced current and the squeezing action by rollers are the two main principles behind production of high frequency induction welded steel tubes.

HFIW steel tubes do not need any filler material. This makes the process very fast and highly efficient in production. High frequency induction welding allows us to produce variety of shapes of tube with an almost invisible weld joint that is stronger than the parent material and are suitable for critical applications. The ability to manufacture a high quality and critical welded product, offers architects a flexible solution to design the perfect profile shape for their end application. HFIW is commonly used in manufacturing structural steel tube, transportation & mechanical tubes.

Let’s take a look at the benefits of HFIW process to manufacture steel tube:

1) High Efficiency: High frequency induction welding is an efficient welding process to manufacture tubes as it consumes less electricity than other welding processes.

2) Able to weld very thin walled tube: HFIW is suitable for steel tube with a wall thickness as low as 0.15 mm.

3) High welding speed: High-Frequency allows high welding speeds up to few hundred m/min.

4) Produces welds with very narrow heat affected zones: HFIW process is capable of producing focused heat thereby protecting the work piece from damage. The focused heat produces very narrow heat affected zones near weld bead.

5) Superior weld quality: It provides stronger & uniform weld seams which make the steel tube suitable material for structural applications.

6) Easier cleaning processes afterwards: Induction welding offers cleaner work pieces once they’ve been welded than other welding processes.

7) Highly automated: Most of the steps in the HFIW process can be performed automatically which makes the operation streamlined & time-saving.

How does the use of structural steel help in creating the greener environment around us

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How does the use of structural steel help in creating the greener environment around us

Structural steel is a fast, safe and efficient building material. It comes off as the best material for construction owing to its various features like high strength, fire resistance, flexibility, long lasting, offsite manufacturing, reusability and recyclability. These characteristics of structural steel result in many social, economic and environmental benefits to satisfy sustainability’s ‘triple bottom line’.

Here’s what makes structural steel an environment friendly building material:

  1. Structural steels don’t decay or decompose: Steel structures mature with age, rather than deteriorate and decay. The longevity of a building is indispensable to its sustainability. Steel frame do not require any type of special treatments to prevent mold, decay or insect infestation. Steel cannot absorb moisture and therefore cannot host any bacteria that would compromise the health of the home’s habitants.
  2. Reusability of structural steel: Steel structures are intrinsically reusable. Steel-framed buildings can be dismantled, and reused. Any steel which cannot be reused is recycled for further use in construction. Designers & Architects can take responsibility for sustainability by efficient deconstruction of steel building. Research shows that 99% of structural steels are reused or recycled.
  3. Steel is endlessly recyclable: Structural steel can be recycled indefinitely. This referred as multicycling. The multicycling of steel lessens the environmental issues. Over 500 million tonnes of steel are multicycled worldwide each year and that’s a whopping amount. Because of its unmatched magnetic property, it’s easy to remove from waste land. This makes steel the most recycled building material in the world.
  4. Offsite construction: Steel construction is carried out by small group of skilled workers in a accordant manner which is safe and predictable. Reduced time at site means lower costs, quicker returns and fewer disruptions to the local community. Structural steel is manufactured in a factory controlled environment and delivered at site when needed.
  5. Reduces overall energy cost: With advancement in engineering & technology, the energy required to produce raw steel has dropped by 60% since 1960. Off-gases from the furnaces can be totally reused. Electric arc furnaces allow steel production from scrap metal. Producing steel from scrap requires much less energy than producing new steel.
  6. Protect humans & environment: Steel releases no harsh chemicals or toxins and can easily be retrieved from the environment with magnets. It’s not harmful to the humans as well as the environment. Steel is also resistant to natural calamities such as flood, snowstorms, and earthquakes. Use of structural steel also reduces pollution as compared to other building methodology.

Role of steel in the aerospace industry

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Role of steel in the aerospace industry

The aerospace industry is one of the fastest-growing industries globally. This Industry is one among the key drivers of the economic growth of India. The segments in the aerospace industry include civil aviation, military aviation and space. This industry manufactures aircraft, space vehicles, guided missiles, aircraft engines, and related components. The industry requires the highest standards of equipment, parts, components and designs. Steel is one of the most widely used materials in the industry due to its fantastic strength to weight ratio. Steel typically comprises around 13% of the materials used in an aircraft.

Steel forms a significant part of the aerospace industry. Owing to its excellent properties, steel is widely employed in the making of engines, exhaust ducts, landing gears, motor cases, fuel tank, springs, fasteners etc. The most important characteristic of steel is its durability. Its strength, hardness and resistance to heat make it ideal for the use. Moreover steel is cost-efficient along with being light-weight. Steel is also easy to weld and can be reformed easily. All these reasons come together to make steel the most favorable material to be used in aerospace industry. 

Let’s take a look at the applications of steel in aerospace components: 

  • Shaft for engines: High quality steel is used for the construction of main shaft of engine owing to the combinations of very high strength and creep resistance. The steels used in the shafts are of medium carbon grades.
  • Landing gears: Steel is also used for landing gears. The high strength and toughness of steel makes it far more suitable to handle incredible amounts of pressure involved during both take-off and landing.
  • Motor casing: Low alloy steel is a perfect choice for motor casing due to its ultra-high strength, wear resistance & ability to withstand tremendous pressure.
  • Exhaust & Engine: The higher temperature resistance of steel makes it an exceptional solution for use in exhaust & engines.
  • Steel Skins: High-speed and supersonic jets also utilize steel in their skin as it is resistant to the heat caused by the friction in the air created by such extensive speeds.
  • Fuel Tank: These too are again made of steel.  

Well, the list goes on and on. The bottom line is that the contribution of steel particularly in the aerospace industry, is beyond match and highly incomparable. Known for its strength and durability against heat and force, steel has become an integral part in the aerospace industry. 

Role of steel in the automobile industry

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Role of steel in the automobile industry

The automobile industry manufactures and sells automobiles like cars, buses, trucks, and other vehicles. It is one of the key drivers of the economic growth of India. One material that forms the backbone of this industry is steel. It is widely used in the auto industry. Approximately 55% of a car’s weight comes from steel and on average, a vehicle weighs 1200kg – so that’s a large amount of steel.  

Steel forms a significant part of the automotive industry. Owing to its excellent properties, steel is widely employed in the making of vehicle bodies. Steel is very tough and thus is the go-to-choice for making vehicles. It lends strength and ensures safety. Moreover, steel is cost-efficient along with being light-weight. Steel is also easy to weld and can be reformed easily. All these reasons come together to make steel the most favorable material to be used in manufacturing automobiles. 

Let’s take a look at the uses of steel in the making of an automobile: 

  • Structure of the vehicle: The structure of the automobile makes use of a large amount of high-quality steel. One of the main reasons that steel is used in the making of body frames is because of its ability to absorb the impact energy produced in a crash. This ensures safety. It also keeps the overall structure lighter, yet sturdy. As the steel has high tensile strength, it works in favor of the vehicle and enables it to withstand tremendous pressure and force. 
  • Propeller shaft: High-quality steel is used for the construction of a propeller shaft. It is because the propeller shaft should be powerful enough with a high wear-resistant property so it can tolerate bending and torsional load. 
  • Seat frame: The seat frame too utilizes steel. The reason being, steel is strong and this makes it possible for the seat to withstand everyday rigors. Moreover, steel can be easily formed into the desired shape for comfort. 
  • Exhaust Tubes: These too are again made of steel.  

From the total amount of steel used in an automobile, 34% of it is applied in the body structure, panels, trunk closures, and doors. Apart from that, the drive train makes use of 23% of the steel. Another 12% is used in the suspension. The rest of the steel is utilized in the making of the fuel tank, wheel, steering, and braking system. Thus, steel forms an integral part of the automobile industry.

How does zinc contribute to the steel industry

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How does zinc contribute to the steel industry

Zinc is found in Earth’s crust in abundance and comes with an array of uses. It is widely used for industrial and biological purposes. Zinc is blue-white in appearance at the room temperature and is the fourth most widely consumed metal. Zinc is used for various purposes. However, 50 percent of it is applied in corrosion protection of steel and iron. 

Zinc is a blessing for steel. Without it, all the steel buildings and bridges are at risk of getting corroded away and collapsing. However, thin layers of zinc are added to the steel to prevent rusting and protect it. The process is called zinc galvanizing. 

The reason zinc is used out of all the material is that it won’t oxidize when exposed to water and air. Moreover, it becomes a strong barrier between the corrosive environment and steel. It prevents the steel from getting corroded by keeping the moisture away from the steel. Moreover, it provides sacrificial cathodic protection and losses itself first if there’s any scratch exposing the steel to moisture.  

The most common process to galvanize steel is called Hot-dip galvanizing. The process requires the steel to be immersed in molten zinc to produce a uniform layer coating. A metallurgical reaction takes place between the molten zinc and the iron in the steel, causing a uniform coating through-out the surface. After it cools down, the steel and zinc form a solid bond that has the ability to last for up to 50-years in normal conditions and with very little maintenance. 

The steel galvanized zinc has various applications: 

  1. Protecting underwater structures: Due to its properties, zinc will corrode first and provide cathodic protection to steel. Thus, it is quite beneficial for structures that are underwater like a ship’s hull, pipelines, bridges, and drilling equipment. If there’s an uncoated area on the steel surface, the surrounding zinc will sacrifice itself to protect steel. 
  2. Automotive: There are numerous parts of car structures composed of steel that are susceptible to corrosion. For these parts, steel galvanized with zinc is used. The zinc coating is very seamless and there is no visible difference in appearance after coating the surface. This coating protects the vehicle’s structure to a large extent from getting corroded and damaged. 
  3. Buildings and construction purposes: This industry makes use of two-third of the zinc-coated steel. The zinc-coated steel is applied in roofing and cladding of buildings. Thus, it protects the buildings well from corrosion.