Professional Documents
Culture Documents
Market Survey: Construction & Materials
Market Survey: Construction & Materials
MARKET
SURVEY
TOPIC : FERROUS
PRODUCTS
SUNMITTED BY:
SAURABH BAUNTHIYAL
SHIVAM AGGARWAL
SIMMI BANSAL
SHINALI KAPOOR
SHIVANI KULSHRESTHA
SHIVANGI GUPTA
IRON
SIMMI BANSAL
IRON –
Iron is a naturally occuring substance
extracted from iron ores.
IRON ORE-
Iron ores are compounds of iron with non-metallic
elements which contains impurities such as carbon , manganese etc.
PIG IRON
When Iron is
extracted from its
ores such as
Haematite , limonite ,
Magnetite , Pyrite and
Siderite ; the iron so
formed is impure and
crude. This impure
and crude iron is
known as pig iron.
MANUFACTU
RE
OF
Calcination
Dressing
PIG IRON
and
Roasting
Smelting
1- Dressing of Iron Ores-
• In this process, the dressing of iron ores is done. The ores which are obtained from mines
are crushed into the size of 25mm diameter.
• The crushing of ores is done so that the ore particles obtained are of equal size and to
reduce the gases which have been penetrated in the ores.
• Incase if the ores contains clay , loam or any other earthy material , they are washed in a
stream first.
3- Smelting-
• Smelting is the process of separating metal from its ore by melting the ore. This
process is carried out in blast furnace.
WORKING OF BLAST FURNACE
i. Raw materials consist of iron ores , fluxing materials, and
fuel. Fluxing materials helps in mixing the impurities
present in the iron ore to form a fusible slag. Limestone
is used as the most common fluxing material.
ii. Mixture of raw materials is prepared in a fixed
proportion. This mixture is then allowed to come to the
lower part through throat of the blast furnace.
iii. A blast of hot air is blowed through tuyeres. A high temp
of 1500°C to 1900°C is obtained in the lower part of the
furnace.
iv. The raw material melts and the iron thus formed collects
in the lower part of the hearth furnace and the slag
formed gets collect in the upper part of the blast furnace.
v. The hot gases escape out through the outlet provided in
the upper portion of the blast furnace.
vi. The slag obtained is removed after two hours and the pig
iron formed is removed after four hours from the outlet.
vii. The pig iron so obtained contains 95% of iron and about 4
to 5% of carbon.
PROPERTIES OF PIG IRON-
i. It can be hardened but not tempered.
ii. It cannot be magnetised.
iii. It cannot be welded or riveted.
iv. It does not rust.
v. It is difficult to bend.
vi. It is hard and brittle.
vii. It is neither ductile nor malleable.
viii. It melts easily and its fusion temperature is 1200°C.
ix. It posesses high compression strength but weak in tension and shear.
5. Refining
Oxidising of cast iron and casting them into moulds to make them cool and brittle.
This is known as refined pig-iron.
2. Puddling
The conversion of pig-iron into wrought- iron by stirring in a molten state is known
as the puddling.
i. Puddling is carried out In reverbatory furnace.
ii. A reverbatory or pudding furnace is of
rectangular in shape. It is built with refractory
materials such as fire- bricks. The combustion
chamber and chimney are located in opposite
ends.
iii. The grating is provided in combustion chamber
to collect ash in the ash pit.
iv. The hearth consists of molten slag or rich iron
ore.
v. The various openings for fuel feeding, working
and slag removal are provided.
vi. The refined pig iron is broken into lumps and it is
melted in hearth.
vii. During the process of puddling, most of the
carbon content and other impurities of pig-iron
are oxidised.
viii. Slag is removed through slag removal door.
ix. The purified iron are in the form of white spongy
iron balls known as puddle balls.
SHINGLING-
3. The removal bof slag from puddle balls by power
hammering or passing the balls through squeezing
machine. Shingling also helps in binding or welding
different particles of puddle balls. The material
obtained at the end of shingling is known as bloom.
ROLLING –
4. The bloom is passed through groove rollers and flat
bars are obtained which are of poor quality. To improve
the quality of wrought iron these bars are tied together
by wires and they are heated and rolled again. This
process is repeated several times to get wrought iron of
desired quality.
PROPERTIES OF WROUGHT IRON-
Roofing Sheets
Some more products manufactured from iron
MILD
STEEL
SHIVANGI GUPTA
FERROUS METAL
FERROUS METALS INCLUDE ALL
FORMS OF IRON AND STEEL
ALLOYS.
FEW EXAMPLES INCLUDE :
WROUGHT IRON
CAST IRON
LOW CARBON STEELS
MEDIUM CARBON STEELS
HIGH CARBON STEEL
MILD STEELS
STAINLESS STEEL
ALLOYS STEELS
TOOL STEELS
MILD STEEL
DEFINATION
• Mild steel is a type of carbon steel with a low
amount of carbon – it is actually also known as
“low carbon steel.”
PROPERTIES
• THE MOST COMMON FORM OF STEEL AS IT
PROVIDES MATERIAL PROPERTIES THAT ARE
ACCEPTABLE FOR MANY APPLICATIONS.
• MILD STEEL HAS MEDIUM CARBON CONTENT OF
0.25% ,SULPHUR IS 0.055% AND PHOSPHOROUS IS
0.055%
•MILD STEEL :
CARBON CONTENT-0.25%
SULPHUR -0.555%
PHOSHOROUS -0.555%
THEY ARE LESS DUCTILE AND STRONGER
THAN LOW CARBON STEELS
HEAT TREATABLE
(AUSTENITIZING,QUENCHING AND
TEMPERING)
HARDENING IS INCREASED BY ADDIND Ni,
Cr, Mo.
CORRODES QUICKLY
EASILY FORGED, WEILDED AND RIVETED
NOT MUCH AFFECTED BY SALINE WATER.
VARIETY OF MS STEEL
MILD STEEL SHEETS:1
M.S. Sheets and mild steel sheets are used for structural,
mechanical and general engineering purpose.
M.S. sheets and mild steel sheets are available in
different grades, thickness, length and weight as per the
requirements of the clients.
Plain sheet
PLAIN
SHEET SIZE
•OVER RADIATIORS
•WALLS
•PANELLING,SCREENS ETC
MANUFACTURING
PROCESS
INSTALLATION PROCESS
ADDING FLASHES
FLAT BARS
flat bar made from alloy, steel,
aluminum, brass, tool steel, and more.
It is broadly used for industrial tools,
mechanical parts, structure
construction, base plates, ornamental
fence construction, and more.
SIZES
• FLAT BARS ARE GENERALLY
AVAILABLE IN SUITABLE
WIDTHS VARYING FROM 10MM
TO 400 MM
• GENERALLY AVAILABLE IARE
3MM TO 40 MM
• USES
• FRAMEWORK CONSTRUCTION
• RENEWABLE ENERGY
• general fabrication and repairs
• agricultural implements and
transportation equipment.
• It is easy to weld, cut, form, and
machine frequently used in
framework, braces, supports,
plates and straps
ROUND BARS
USES
• Round bar is commonly used to
separate mesh in concrete slabs and
is used in a range of commercial and
infrastructure applications.
• Round bar has a range of
applications from reinforced
concrete piers, bored piles, footings,
walls, beams, columns, slabs, and
precast products.
• Round bar is a Class N (normal
ductility) bar and is available in 250
MPa for diameters 10 mm - 36 mm.
SQUARE BARS
• MS Square Bars are used in cranes gantry,
bullock carts axles, conveyors, truck trailers
and tippers, bright bars, anchor bolts and
many more engineering industries.
MANUFACTURING
PROCESS
STEEL
MAKING
HOT ROLLING
MANUFACTURS
• SUBHASH ABHISHEK STEELS PRIVATE LIMITED
• RATE: RS 35000/TON
• PH STEELS
• RATE: RS 32000/TON
• SARAN IRON AND STEEL CO.
• RATE: RS 40000/TON
• JSW TMT
• RATE:10MM@38500
STEEL
SAURABH BAUNTHIYAL
ANGLES
WHAT IS STEEL
ANGLES
Steel ?
angle, also named angle iron,
or steel angle bar, is basically
manufactured by hot-rolled carbon
steel or high strength low alloy steel. It
has L-cross shaped section with two
legs - equal or unequal and the angle
would be 90 degree.
TYPES OF STEEL
ANGLES
USE OF EQUALE AND
UNEQUALE STEEL ANGLES
• Equal angle steel is widely used in engineering
structures, such as bridges, towers, and ships.
I-BEAM
an iron or steel beam that is
I-shaped in cross section
CHANNELS
The structural channel, also known
as a C-beam, is a type of (usually
structural steel) beam, used
primarily in building construction
and civil engineering.
USE OF I-BEAM
Steel beams are extremely crucial and necessary for
the construction any building or structure, such as
bridges, etc. They come in a wide range of sizes and
shapes. ... Any supportive structural item that spans
an area and is designed to support a load is broadly
termed as 'steel beam'.
USES OF CHANNELS
.
USE OF T-BEAM
CIRCULAR TUBE
MANUFACTURING
PROCESS
APPLICATIONS
• 1.BUILDINGS AND HALLS
(COLUMNS,FRAMES FOR ROOFS)
• 2.DOOR FRAMES AND BARRIERS
• 3. OFFSHORE STRUCTURES-
CRANES,BRIDGES, STADIUMS
• 4.SECONDARY STRUCTURE-
STAIRCASE , LADDER
WELDING
•WELDING IS A FABRICATION OR SCULPTURAL PROCESS THAT JOINS MATERIALS,
USUALLY METALS BY CAUSING FUSION.
• OXY FUEL
1. WELDING
• ELECTRIC
2. RESISTANCE
WELDING
OXY FUEL WELDING
AIM:
to increase hardness and strength of steel
prevent corrosion
improve appearance
ALLOY
PROPERTIES
Color of brass vary from reddish brown to silvery
yellow
brass is stronger and harder than copper
Not as hard as steel
Good conductor of heat
Resistant to corrosion form salt water
USES
water filter ,screws
BRONZE
Bronze is a mixture of copper and tin.
Copper is the main component
copper + tin
90% 10%
PROPERTIES
It is hard and brittle
Resistant to corrosion
USES
Used to make statues
STEEL
SHIVANI KULSHRESTHA
IRON CARBON
STEEL
STEEL
STEEL IS AN ALLOY COMPOSED OF IRON
AND CARBON IN A SPECIFIC RATIO
IRON IS AN ELEMENT AND IS PRESENT IN A
GREATER QUANTITY
THE CARBON CONTENT IN STEEL CAN
RANGE FROM 0.1-1.5%, BUT THE MOST
WIDELY USED GRADES OF STEEL CONTAIN
ONLY 0.1-0.25% CARBON.
STEEL IS USED ON A LARGE SCALE IN THE
CONSTRUCTION INDUSTRY
Different types of steel are produced according to
the properties required for their application
various grading systems are used to distinguish
steels based on these properties.
For example, if chromium is added to steel,
stainless steel is the product. It is durable and doesn’t
rust easily.
Stainless steels
Tool steel refers to
a variety of carbon
and alloy steels that
are particularly well-
suited to be made
into tools
Tool steels
STAINLESS
STEEL
Stainless steel is a steel alloys which
contain a minimum of 10.5% chromium.
Stainless steel doesn’t stain, corrode or
rust as easily as ordinary steel
The chromium reacts with oxygen in the
air to produce a very thin film on the
surface of the steel.
The film provides corrosion resistance.
the layer of chromium seals the base
metal from exposure to atmosphere
It is self-healing as the chromium
exposed by damage will oxidize to form
new layer
MANUFACTURING
PROCESS
Scrap steel are fed into the a rolling furnace along with
chromium and nickel for added strength and rust
proofing
enormous electrode heat the mix to melting point
creating a dramatic firework display
After several hours the molten mix goes into a refining
furnace
Argon and oxygen gas some impurities to gas
a bit of scrap is added to bulk up the mixture as it
melt ,scrap cause chemical reaction that help fuel the
refiner
Steel goes to refining furnace, roller guided as it cast
long ribbon of steel , they are cut into slabs
Slabs are reheated to soften them
Slabs are again send to roller than stretched longer and
thinner
Water spray cools the steel little but not too much
because it has to be flexible enough to be folded into
coils or sheet rolls
TYPES OF STAINLESS STEEL
Different type of stainless steel are obtained by varying the amount of
chromium ,nickel, manganese and carbon alloy
Addition of
(i)nickel stabilize austenite structure of iron, make steel non
magnetic and less brittle at low temperature , manganese also do the same
but at low cost
(ii)carbon adds strength and hardens the steel
WELDING
RIVETING
BOLTING
RIVITING
Rivit is a permanent mechanical joint means it can’t be disassembled without
failure of machine components which are broadly used to join structures
Rivit is a cylindrical shape joint consisting of two part
Thus ,the process by which two plates are joint together by use of Revit is
called reviting
mechanical force applied makes the joint strong and leak proof
• two holes are created in both plates and
the rivet is inserted between these
holes.
• At the other end a force is applied through a
die which deform the tail and form a required
shapes which hold the rivet in the hole
LAP JOINT
BUTT JOINT:
LAP JOINT
When the plates to be joint, are bring together
which overlap each other at face, and rivet
inserted in overlap section the joint is known
as lap joint.
SPANGLE
GALVANIZATION
Galvanizing is a electrochemical plating of highly corrosion
resistant material on the surface of another metal. This
technique is widely used to coat zinc over the iron and steel.
Galvanized sheet metals are available in the market for their
commercial use. This technique is very popular and widely
accepted due its effectiveness and economy. A number of
methods can be employed for galvanizing of zinc to the metal
substrate.
METHOD
1.PICKLING(Hcl)
First the rust is romeved from metal
2. running water
for removel of acid from metal
3. water flexing
material applied on metal to make a bonding steel and zinc
4.Drying
drying of metal & removel of water because presence of water make
zinc oxide which is not good for metal
5. Zinc bath
molten zinc applied on metal
6. Quenching
running water increase the hardness of zinc
7.Dichromating
sodium applied on metal.
ADVANTAGE OF GALVANIZED STEEL
• ZINC is extremely durable especially in hard
water where it comes in contact to make a
passive layer of carbonates
• Galvanized surface is scratch resistant
• Appearance that gives aesthetic value to
product
• This is cheaper as there is no artificial heating
and no electric current is required
APPLICATION
It is extensively used in
• Automobile industry
• Signage
• Electric equipment
• And other industry requiring a metal with
good printability and long reliable service life
SPRAY COATING
SHIVAM AGGARWAL
Need For Surface Hardening
1. Substrate preparation
5. Coating formation
Thermal Spray Hardening
• Gas Combustion
• Oxy fuel process using
• Wire feed
• Powder feed
• Rod feed
Wire Processes