BUILDING CONSTRUCTION & MATERIAL V

Simran Kaur | 1818242 | Batch 2k18

CAST IRON
Cast iron is obtained from the pig-iron which is re-melted with coke and
limestone. Pig iron is nothing but impure iron which is obtained from the iron
ore. Cast iron has lot of engineering properties so, that it can be used in many
ways like for sanitary fittings, rail chairs, casting molds etc.

CAST IRON AS A BUILDING MATERIAL

 Grey cast iron

 Malleable cast iron

 Mottled cast iron

 Toughened cast iron

 White cast iron

 Ductile cast iron

Figure 1. Molted Cast Iron
 Chilled cast iron

Figure 2. Malleable Cast Iron Figure 3. White Cast Iron

Figure 4. Chilled Cast Iron Figure 4. Grey Cast Iron

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 Figure6. Ductile Cast Iron

Figure 5. Classification of Cast Iron

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 CHARGING DOOR- RAW MATERIAL IS ADDED
(PIG IRON+COKE+LIME STONE)

AIR BLAST INTRODUCED USING AIR BLAST INLET

(REMOVES IMPURITIES IN PIG IRON)

BOTTOM OUTLET-PURE CAST IROM OBTAINED

MOLDING- DESIRED SHAPE

MANUFACTURING

Figure 6 Couple Furnace

This process takes place in a furnace called couple furnace. The furnace is 5
meters in height and cylindrical in shape with 1 m diameter.

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PROPERTIES

 HARDNESS: Good corrosion resistance, so it can be used for water

carrying pipes etc.

 TENSILE STRENGTH: Tensile strength is about 150 N/mm 2 and

compressive strength is about 600 N/mm2.so, it is good in compression.

 DUCTILITY: It becomes soft when placed in salt water and it shrinks on

cooling.(ability to deform without fracture)

 Does not get attracted to magnet.

 Specific gravity is 7.5.

 Melting point is about 1250oC.

 It cannot be useful for forging work because of lack of plasticity.

USES

 Many types of sanitary fittings like manholes, sewer pipes, water pipes,
cisterns are manufactured using cast iron.

 Metal columns and column bases can be made using cast iron.

 Casting molds for making metal staircases, lamp posts, gates etc. are
made using cast iron.

 Rail chairs and carriage wheels are manufactured.

 Several types of agricultural implements can be made.

 Machinery parts can be manufactured but shock cannot be resisted by

cast iron.

Its use gradually spread from architectural elements like shutter and door
frames to facades because it is relatively

 Inexpensive,
 Durable &
 Easily cast into a variety of shapes.

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 • As balusters, columns & Arches, balconies.
• For transporting water, storm drains and sewage.
• Ornate facades. Columns Spandrel panels
• Pre-fabricated iron buildings

Figure 7. Malleable iron is used for Figure 8. Abrasion-resistant White Iron Is

heavy-duty bearing surfaces such as Used to Produce a Variety of Machine Parts
drive train and axle components Such As Slurry Pump Housings

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 Figure 9. Cast iron has excellent cast Figure 10. Cast iron design details are
ability due to the combination of high produced by smelting metal and
carbon content and silicon pouring it into a mold

WROUGHT IRON
Wrought iron considered to be pure iron, is produced by removing the
impurities of cast iron. It is soft, ductile, magnetic, and has high elasticity and
tensile strength. It can be heated and reheated and worked into various shapes.

Wrought ironwork tends to be quite ornate and delicate, as the material is so

workable. Scrolls and foliage are common motifs, and patterns and designs
typically vary slightly as wrought iron is worked by hand. Blacksmiths hammer
the iron into shape, and then assemble it by fire welding and using collars,
rivets and other mechanical means.

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The term ‘wrought iron’ is often mistakenly used for any form of worked steel.
But wrought iron is not the same material as mild steel.

Figure11. Puddling Furnace for Manufacturing of Wrought Iron

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BLAST-C, SI, MN, P AND SULPHUR IS BURNT IN A
PUDDLING FURNACE.
(RAW MATERIAL PIG IRON)

BOILING-IRON PUDDLER AND MORE

IMPURITIES WERE REMOVED
(MAKING THE IRON STIFFER.)

THE IRON WAS THEN FORMED INTO BALLS

MOLDING- DESIRED SHAPE

REHEATED AND REWORKED

(TO OBTAIN DESIRED GRADE)

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 MANUFACTURING OF WROUGHT IRON

USE

 Wrought iron was used as a building material in 13 th century and

Wrought iron furniture was made in 17th century

 It is also used to make home decor items such as baker's racks, wine

racks, pot racks, table bases, desks, gates, beds, candle holders, curtain
rods, bars and bar stools.

 Roof coverings, rivets, chains, ornamental iron works such as gates, etc.
are made of wrought iron.

PROPERTIES

 Wrought iron is ductile, malleable, tough and moderately elastic.

 ULTIMATE CRUSHING STRENGTH: 200 N/mm2

 ULTIMATE TENSILE STRENGTH: 40 N/mm2.

 COMPOSITION: Alloying elements used in wrought iron include nickel

(beneficial in preventing reductions of impact strength at subzero
temperatures.), copper (increase corrosion resistance properties) and
molybdenum.

 It can be forged and welded

 Wrought iron effectively resists corrosion.

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  It is tough and withstands shocks and can neither be hardened nor
tempered.

Figure 12. Elaborated Gates and Railings Figure 13. Street Lamp

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 Figure 14. Pool Side Outdoor Furniture Figure 15. Door Knob of
Wrought Iron

Figure 16. Shaping of Wrought Iron Figure 17. Eiffel Tower

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STEEL
Steel is used because it binds well to concrete, has a similar thermal expansion
coefficient and is strong and relatively cost-effective. Reinforced concrete is also used
to provide deep foundations and basements and is currently the world’s primary
building material.

Steel is the most suitable building material among metallic materials. This is
due to a wide range and combination of physical and mechanical properties
that steels can have.

Steel is the ultimate sustainable construction material, supporting the environmental

strategies of building owners and tenants of all types.

THE ULTIMATE SUSTAINABLE MATERIAL CHOICE

PROPERTIES

HIGH TENSILE STEEL: It is also known as high strength steel and is essentially
a medium carbon steel.

 The carbon content in high tensile steel is 0.6–0.8%, manganese 0.6%,

silicon 0.2%, Sulphur 0.05% and phosphorus 0.05%.
 The ultimate tensile strength is of the order of 2000 N/mm2 and a
minimum elongation of 10 per cent.

MILD STEEL: Also known as low carbon or soft steel

 It is ductile, malleable; tougher and more elastic than wrought iron.

 Mild steel can be forged and welded, difficult to temper and harden.
 It rusts quickly and can be permanently magnetized.
 Ultimate compressive and tensile strengths 800–1200N/mm2 and 600–
800N/mm2.

HIGH CARBON STEEL: Also known as hard steel.

 The carbon content in high carbon steel varies from 0.55 to 1.50%.
 It is tougher and more elastic than mild steel.
 It can be forged and welded with difficulty.
 Its ultimate compressive and tensile strengths are 1350 N/mm2 and
1400–2000 N/mm2, respectively

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ROLLED STEEL SECTIONS: Structural steel can be rolled into various shapes
and sizes in rolling mills. Steel sections are usually designated by their cross-
sectional shapes.

Figure 18. I-Section, Channel Section, T-Section

Figure 20. Tube Figure 19.21.

Figure Angle
SteelSection
Bars Figure 22. Steel Flats
Section

I-SECTIONS which are also called as steel

beams or rolled steel joist are extensively used as
beams, lintels, columns etc. It consists two
flanges and a web connected.

Available in various sizes ranges from 75 mm x

50 mm at 61 N per meter length to 600 mm x 210
mm at 995 N per meter length.
Figure 23. I-Section

T-SECTION consists of flange and web arranged in “T”

shape. They are used in steel roof trusses to form built up
sections. Two angle sections can also be joined to get T
section.

Rolled T sections size varies from 20 mm x 20 mm x 3 mm

to 150 mm x 150mm x 10 mm with 9 N and 228 N as their
Figure 24. T-Section
corresponding weights per meter length.

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The channel section or C- section consists two equal flanges connected to web
at both ends. Channel sections are extensively used in steel framed structures.

They are available in various sizes ranging from 100 mm x 45 mm to 400mm x

100 mm. Corresponding unit weights are 58 N and 494 N per meter length
respectively.
Figure 25. C-Section
Round bars contain
circular cross sections and these are used as
reinforcement in concrete and steel grill work etc.
Round bars are available in various diameters
varies from 5 mm to 250 mm.

Figure 26. Round Bars

Square bars contain square cross sections and

these are widely used for gates, windows, grill
works etc. the sides of square cross section ranges
from 5 mm to 250 mm.

Figure 27. Square Bars

ANGLE SECTIONS
are manufactured in “L” shape. It contains two
legs. Some angle sections contains legs with
similar dimensions are called as equal angle
sections and some contains different legs are
called as unequal angle sections.

Angle sections are widely used for roof truss

constructions and for filler joist floors. Figure 28. Angle Section

Equal angle sections are available from 20 mm x 20 mm x 3 mm to 200 mm x

200mm x 25 mm with their corresponding weights as 9 N and 736 N per meter
length respectively.

FLAT BARS are also used for gates, windows,

grill works etc. Flat bars are designated with
width of the bar which varies from 10 mm to
400 mm. thickness of flat bars will be from 3
mm to 40 mm.

Figure 29. Flat Bars

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STEEL PLATES are well used items in
steel structures. They are used for
connecting steel beams, tensional
member in roof truss etc. They are
designated with their thickness which is
varying from 5 mm to 50 mm.
Figure 30. Steel Plates

MANUFACTURING OF STEEL

Figure 31. Bessemer converter for the

Manufacture of Steel

REINFORCING STEEL BARS

Concrete being extremely weak in tension requires reinforcement, which is in variably

steel. Steel reinforcement is available in the form of bars of specific diameters with
different chemical composition, e.g., mild steel and high tensile steel, and surface
characteristics—plain or deformed.

Steel bars can also be strengthened by cold drawing after rolling.

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HIGH YIELD STRENGTH DEFORMATION BARS, bars have lugs, ribs, or
deformations on the surface, which inhibit longitudinal movement of the bar relative
to the surrounding concrete.

THERMO-MECHANICALLY TREATED, bars

are extra high strength reinforcing bars,
which eliminate any form of cold twisting.
These bars can be used for general
concrete reinforcement in buildings,
bridges and various other concrete
structures. They are highly recommended
for use in high-rise buildings because of
the saving in steel due to the higher
Figure 32. High yield strength deformation bars strength.

ALUMINIUM

Aluminum was first used in quantity for building and construction in the 1920s.
Today, aluminum is recognized as one of the most energy efficient and sustainable
construction materials.

 Aluminum is the second most widely specified metal in buildings after steel,
and is used in all construction sectors, from commercial buildings to domestic
dwellings.
 The estimated recycled content of aluminum building materials used today is
between 50 and 85 percent.
 Aluminum-intensive LEED-certified buildings have won awards for Platinum,
Gold and Best-in-State sustainability across the country.

PROPERTIES

 Air tightness
 High strength to weight ratio
 Ease in fabrication and assembly
 Cryogenics
 Low handling and transportation cost
 High reflectivity
 Corrosion resistance
 Appearance
 High scrap value
 Sound proof

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  Maintenance

Figure 33. Aluminum used in Construction

REFLECTIVITY:

Reflectivity of aluminum is also very high. It does not absorb radiant heat and low
absorption heat. So, during summer it maintains the interior cooler and during winter
maintains warmer conditions.

CORROSION RESISTANCE:

Corrosion resistant of aluminum is very high. It does not get effected by weathering
conditions. They withstand against humid or hot dry condition. Due to this property
aluminum is widely used for power plants, chemical plants, paper mills, petroleum
refineries, etc.

FIRE SAFETY:

Aluminum does not burn and is therefore classed as a non-combustible construction

material. Aluminum alloys will nevertheless melt at around 650°C, but without
releasing harmful gases. Industrial roofs and external walls are increasingly made of
thin aluminum cladding panels, intended to melt during a major fire, allowing heat
and smoke to escape and thereby minimizing damage.

DESIGN FLEXIBILITY:

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The extrusion process offers an almost infinite range of forms and sections, allowing
designers to integrate numerous functions into one profile. Rolled products may be
manufactured flat, curved, shaped into cassettes, or sandwiched with other materials.
In addition, aluminum can be sawed, drilled, riveted, screwed, bent, welded and
soldered in the workshop or on the building site.

Figure 34. Aluminum roof Figure 35. Aluminum Reflective roof

sheet roll coating

COATED ALUMINUM ROOFS REFLECT UP TO 95 PERCENT OF SUNLIGHT

USES

 Long-span roof systems in which live loads are small compared with dead
loads, as in the case of reticular space structures and geodetic domes covering
large span areas, like halls and auditoriums.

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 Structures located in inaccessible places far from the fabrication shop, for
which transport economy and ease of erection are of extreme importance, like
for instance electrical transmission towers, which can be carried by helicopter.
 Structures situated in corrosive or humid environments such as swimming
pool roofs, river bridges, hydraulic structures and offshore super-structures.
 Structures having moving parts, such as sewage plant crane bridges and
moving bridges, where lightness means economy of power under service.
 Structures for special purposes, for which maintenance operations are
particularly difficult and must be limited, as in case of masts, lighting towers,
antennas towers, sign motorway portals, and so on.

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 BAUXITE MINING
(AN ALUMINUM RICH MINERAL, ALUMINUM HYDROXIDE FOUND IN
TROPICAL AREAS)

CRUSHING
(CRUSHED, DRIED AND GROUND IN MILLS + WATER = THICK PASTE
SENT TO STEAM TO REMOVE IMPURITIES)

DIGESTION
(ORE LOADED INTO AUTOCLAVES + LIME-CAUSTIC SODA = ALUMINUM OXIDE,
SLURRY WITH ADMIXTURES AS RED MUD)

PRECIPITATION
(SODIUM ALUMINATE STIRRED IN PRECEPITATORS = PURE ALUMINA OR AL 22033
AT BOTTOM.)

ELECTROLYTIC REDUCTION
(ALUMINA POURED INTO REDUCTION CELLS WITH MOLTEN CRYOLITE AT
950ooC + ELECTRIC CURRENT AT 400kA, BREAKS BOND B/T ALUMINUM AND
OXYGEN = LIQUID ALUMINUM SETTLING AT RECDUCTION CELL)

CASTING
(CAST INTO IGNOTS)

FOUNDARY ALLOY
(PROCESSED INTO DESIRED FORM)

ROLLING
(CAN BE ROLLED INTO DESIRED THIN SHEETS )

EXTRUTION
(FOR MACHINERY BODY)

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COPPER

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