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Details and tools on construction site with crane lifting prefabricated concrete framework, unloading and cargo details

Advantages of Precast and Rebar Detailing in Construction

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When constructing or assembling a building using prefabricated components, precast detailing is one of the first steps implemented. It is an extremely complex enterprise, where accuracy remains the key to efficient executions. Also, rebar detailing is an important procedure in the construction and structural steel fabrication industries since the solidity and stability of a building depends on the design and structural integrity of building which in turn relies on structural elements that contributed in its making, i.e., Rebar. So, what are the various advantages of precast and rebar detailing which make them essential in the construction industry? Let us find out more in this blog.

Precast Detailing Advantages

  • Saves Construction Time: Precast Concrete construction saves time; the risk of project delay is also less. The precast concrete casting can be carried on simultaneously with other works on site such as earthwork, survey, etc. and thus saves time.
  • Quality Assurance: The key factors which regulate the quality of construction such as curing, temperature, mix design, formwork, etc. can be monitored for Precast Concrete. So, improved quality construction can be performed.
  • Usage of Prestressed Concrete: By using prestressed precast, structural materials of high strength and load-bearing capacity (such as I-beams in structural steel construction) can be achieved, which can result in greater clear span, reduced size of the cross-section of structural members, etc.
  • Cost-effective: The simplified construction process reduces the time, increases the productivity, quality, and safety and thus the cost is reduced.
  • Durability: Precast Concrete structure has a longer service time period and minimal maintenance. The high-density Precast Concrete is more durable to acid attack, corrosion, impact, reduces surface voids and resists the accumulation of dust.
  • Aesthetics: As the structures are prefabricated in a controlled factory environment, several combinations of colors and textures can be used. A wide range of shapes and sizes are available to choose from with smooth finishing and thus the aesthetic value of products is increased.
  • Safe Construction Platform: No raw materials must be stocked in site for Precast Concrete construction. It reduces the requirement of traditional formworks and props, wastage, workers, etc. and thus provides a safe working platform.

Rebar Detailing Advantages

Rebar Detailing helps to sort out the practical structural projects as it clearly specifies the bar bending using heat induction bending services that includes beams, columns, girders, and walls. It also specifies the material specification with errors so that engineers can eliminate the mistakes at the initial stage. Rebar Detailing Services has also given birth to other new services in the structural metal product manufacturing industry in Australia such as Melbourne steel fabrication connection details, pile and raft foundation details and rebar estimating. Some of the advantages of rebar detailing services are described as follows: –

  1. Detailing services helps in avoiding delay in work and waste of materials along with the investment of the time.
  2. Rebar detailing services showcase the required information that is related to the anchors and laps details.
  3. The contractors are assisted and given a clear picture related to the production or rebars.
  4. Every rebar is detailed showing diameter, length, shape, and quantities in Rebar Detailing Drawings.
  5. It also provides bar bending schedules.

Bringing it Together

It can be observed that, in precast detailing, the emphasis is on creating and detailing structures for fabrication to be used as reusable molds for creating concrete members. Rebar detailing services are offered with certain standards and codes when engineering services provide them, such as the American Association of State Highway and Transportation Officials (AASHTO) and Reinforcing Steel Institute of Ontario (RSIO). Hence, both these detailing services are significant steps performed regarding structural engineering projects.

industrial metal and steel drilling tools in factory. Metal indu

Shot Blasting – Link to Finished Fabrication

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The completion of a fabrication job means that the fabricated product is ready to be welded, machined etc. as part of the next stage in its manufacturing journey. However, this unfinished material may become dirty and oxidized, covered in mill scale, dirt, and other debris from its manufacturing process. Any type of steel with an uneven surface will need to undergo some form of treatment to smooth and clean its surface so that it can achieve proper adhesion. Here is where shot blasting plays a major role in preparing steel to be aesthetically appealing and resilient for operations. This blog will provide an overview of the shot blasting process, including its benefits and applications in industry.

What is Shot Blasting?

Whilst there are many custom metal fabrication finishing processes, ranging from simply wiping down the surface with a soapy rag to immersing the steel in a bath of complex and often expensive chemicals, shot blasting is one of the most popular and effective methods to clean and prepare dirty or oxidized steel. It is a mechanical cleaning process in which tiny spheres of material are shot at the steel at high speed to remove oxidization and other dirt or debris from the surface. Shot blasting is similar to sand blasting in that material is propelled using pressure vessels at the metal to remove the dirt from its surface, although shot blasting is a much more efficient way to achieve this.

Nuts and Bolts of Shot Blasting

Shot blasting works by propelling spheres of material known as shot media against the steel, which removes debris, oxidization and other contaminants from the surface, leaving behind a completely smooth medium ready for sheet metal fabrication techniques, such as welding and machining. This can be superior to other methods of cleaning steel as shot blasting is more abrasive than alternatives such as sand blasting, getting the job done more efficiently and more effectively. In order to use shot blasting as an effective method for cleaning and smoothing unfinished steel, it’s essential to be aware of the propulsion method as well as the form of shot media. The most effective method of shot blasting involves the use of a centrifugal wheel. This wheel is filled with the shot media and spun to create the necessary velocity. The media is then released from the wheel into the gun, allowing the media flow to be directed to the surface of the steel or other material. Frequently, shot blasting apparatus will also include a recovery system. This often consists of a vacuum used to collect the shot blasting media, allowing the recovered material to be used again.

Final Remarks

Shot blasting is effective for all types of steel and metal that steel fabrication firms work with including Engineering Steel, Stainless Steel, Cast Iron, Black Steel and Carbon Steel. It is a safe and effective way to clean and prepare steel surfaces for the adhesion needed in welding and machining. However, it is not advisable to attempt shot blasting unless the individual is an experienced professional in steel fabrication finishing techniques. Also, if shot blasting is not carried out with diligence and thoroughness, the steelwork could be subjected to corrosion and damage down the line. This could lead to a significant reduction in the lifespan of the fabricated product. Hence, shot blasting is a necessary technique for finished fabrication products – and fabrication firms should make it a priority to leverage its manifold benefits in their ultimate quest to gain more market share!

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Form Energy to Build Battery Plant in West Virginia

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Form Energy Inc, a start-up hoping to make long-duration storage batteries from materials including iron to store power from renewable energy, will partner with West Virginia to build a manufacturing plant in the state, the company and politicians said on Thursday. The plant is slated to be built starting next year in Weirton, once a top steel making town. West Virginia Governor Jim Justice and Form Energy, backed by supporters including Bill Gates’ Breakthrough Energy Ventures, said the plant will be built with a total investment of up to $760 million. They said the factory will begin making battery systems in 2024 and to create at least 750 jobs in the state, which has suffered for years from a lack of high paying jobs as coal production falters amid the transition towards renewable energy and products such as battery electric vehicles.

“Weirton is long overdue for some incredible news,” Governor Jim Justice said. “At one point, Weirton was one of America’s most important steel towns— a national leader in steel fabrication and production. Now, this historic city is looking toward the future, and it’s very bright with Form Energy opening its doors. We structured a unique financial incentive package worth up to $290 million in asset-based, performance financing to support their decision to locate in Weirton. The funds put toward this project are guaranteed, secured, and collateralized through ownership of all land and buildings by the state”.

Form Energy aims to build batteries using iron, air and water. It said the batteries will be charged by a process of “reversible rusting” where batteries will be charged by rusting iron pellets and reversing that process to turn them back to iron. When discharging, the battery breathes in oxygen from the air and converts pellets of iron to rust, the company said. While charging, the application of an electrical current converts the rust back to iron and the battery breathes out oxygen, it said. Form says the batteries can store power for days, much longer than ones based on lithium-ion, and using less expensive materials. The private company has not publicly released data showing how the batteries will store power on a commercial basis. Form Energy intends its batteries to store electricity from solar and wind power that only operate intermittently, when the sun shines and wind blows. This is in line with the move towards cleaner energy such as the new UK strategy which leverages different energy sources.

Company co-founder and chief executive Mateo Jaramillo said Weirton was chosen from among 500 locations across 16 states. Jaramillo said that Weirton “is the ideal location for our first commercial battery production factory”  and it has “the rich heritage and know-how to make great things out of iron.” In October, Form said it had raised about $452 million from backers including pipe fabrication company ArcelorMittal SA. Senator Joe Manchin of West Virginia, a conservative Democrat and founder and partial owner of private coal brokerage Enersystems, who has been reluctant to rein in fossil fuels, praised the project. “The path forward is innovation, not elimination, and with this announcement West Virginia and Form Energy are doing just that,” Manchin said in a statement.

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Advantages and Uses of I-Beams in Structural Steel Construction

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As global consumption starts picking up in the post-pandemic world, structural steel fabrication and construction projects in cities has increased globally. For instance, in Australia, construction of large buildings rose 0.4% in the June 2022 quarter and this is expected to pick up in the next few months. In this regard, it is interesting to analyze a feature of building construction which is a mandatory requirement. This is the I-beam, installation of which is a must-have else the entire building structure is likely to collapse. So, what are the applications and benefits of I-beams in structural steel construction? This blog will cover this aspect in detail.

Advantages of I-Beams

Advantages of I-Beams

As the name implies, the I-beam looks like the letter “I” as a cross-section. They are made using two long planes known as the “flange,” with a middle section that holds the two together called the “web.” These beams are generally made out of steel, although they are also made out of other types of alloys, such as aluminum alloys and low-alloy steel. It is used in both heavy and light metal fabrication; the benefits of I-beams are detailed as follows:-

  1. Bears Higher Loads – The design of an I-beam makes it capable of bending under high stress instead of buckling. As the beam receives the load, the force is transmitted perpendicularly, thus supporting other members of the beams.
  2. Has a High Moment of Inertia – The section at the center of the beam, or the neutral axis, does not resist bending due to the uniform distribution of the weight across the beam. Due to the distance between the flange and the axis, I-beams have a high moment of inertia.
  3. Helps in Fabrication – Metal fabrication involves the cutting, bending, and shaping of structural steel. I-beams are very versatile and can be used in any steel construction projects. I beam steel fabrication is fast, efficient, and affordable to fulfil the orders and meet the demands of the project.
  4. Reduces, Reuses, and Recycles – The production of I beams means minimum waste during construction. There are green practices in different countries making I-beam affordable. Almost half of the world’s steel is produced in electric plants to generate no CO2 emissions. Steel products can be recycled over and over again without compromising on their strength.
Where are I-beams used?

Where are I-beams used?

I-beams are extensively used in different applications of steel construction, especially by heavy steel fabrication companies. They are used more in manufacturing as compared to fabrication. Frames and vital support elements are where generally these beams are used. A strong and supportive structure is ensured with the usage of steel I-beams. The usage of these beams can be economically beneficial since they reduce the necessity to use too many support components. Their versatile and dependable nature makes them indispensable for contractors and engineers. I-beams are frequently used in constructions because they are simply functional. The unidirectional bending behavior is one of their best unique properties. The web component is responsible for withstanding shear stresses while flanges put resistance against bending. They are capable of meeting a variety of loads with no buckling. Since the I-shape does not require the usage of excessive steel, they can be considered cost-effective. There always exists a suitable type of I-beam for every construction purpose.

The Final Word

I-beams play a significant role in mitigating risks of deflection, bending, buckling and vibration during construction projects. As observed, I-beams possess multiple characteristics which enable stronger and more durable construction and these are leveraged by engineers globally. If the I-beam is bent side to side, it functions as an H where it will not be as efficient as an H-beam. However, the ubiquity of I-beams in all construction scenarios indicates that it is called “universal beam” for a good reason!

© K999 Engineering & Construction Co. Ltd. 2023