How Is Structural Steel Fabricated?

Structural steel is the backbone of construction, providing strength and durability to buildings and infrastructure projects. This blog post will explore the fascinating structural steel fabrication process.

We will guide you through the key stages of fabrication, from planning to installation. Discover the intricate craftsmanship and expertise behind creating the building blocks of our modern world.

Structural Steel Fabrication Process

The structured steel fabrication process involves the following:

Project planning

Project planning plays a crucial role in ensuring the success and efficiency of structural steel fabrication. It involves collaboration between the client, design team, and fabricator to establish project requirements and specifications.

Material procurement

Material procurement is a critical stage in structural steel fabrication, encompassing the sourcing and acquiring of the required steel components, such as brackets, columns, and plates.

This section will discuss the material procurement process and emphasise the significance of sourcing materials from reliable suppliers to ensure quality and compliance with industry standards.

Process of material procurement

Material procurement involves the following:

• Determining material requirements: Based on the project specifications and engineering drawings, the metal fabricator assesses the quantity, dimensions, and specifications of the required structural steel components.
• Supplier selection: It is crucial to select reputable suppliers who have proven track records for delivering high-quality steel materials. Factors considered in supplier selection include reliability, product range, industry reputation, and compliance with relevant standards.
• Material specifications and testing: The fabricator ensures that the selected materials meet the required specifications, such as strength, chemical composition, and dimensional tolerances. Material testing may include tensile, impact, and non-destructive testing to verify compliance with standards.
• Ordering and delivery: The fabricator places an order with the supplier once the materials are selected. Proper logistics planning ensures the materials are delivered to the fabrication facility on time and in the required quantities.

Importance of sourcing from reliable suppliers

It is essential to source materials from reliable suppliers to ensure the steel's quality meets industry standards.

• Quality assurance: Sourcing materials from reputable suppliers ensures that the structural steel components meet the required quality standards and exhibit the desired properties, such as strength and durability.
• Compliance with industry standards: Reliable suppliers adhere to relevant industry standards and regulations, ensuring the procured materials comply with the required codes and specifications.
• Traceability: Established suppliers provide documentation and traceability for their materials, including certificates of compliance, mill test reports, and material identification, enabling transparency and accountability throughout the fabrication process.
• Consistency and reliability: Reputable suppliers have robust quality control processes, minimising material defects and variations risk. Consistency in material properties ensures consistent fabrication results.

Regulations and certifications in Australia

In Australia, structural steel procurement is subject to specific regulations and certifications, including:

• Australian standards (AS/NZS): These standards define the requirements for structural steel materials, fabrication, and welding practices. Compliance with these standards ensures the quality and safety of fabricated steel components.
• Steelwork Compliance Australia (SCA): SCA certification verifies that a fabricator's quality management system and fabrication processes comply with industry standards, ensuring consistent quality and performance.
• Welding certifications: Welding procedures and welder qualifications must comply with Australian standards, such as AS/NZS 1554, which cover welding of any steel structure.

Cutting and shaping

Cutting and shaping structural steel components is a crucial stage in the fabrication process. This stage involves transforming raw steel into the desired shapes and sizes required for construction using a press brake, saw, computer numerical control (CNC) machine, or any other machine.

Below are the various methods used for cutting and shaping structural steel and highlight the significance of maintaining proper dimensions and tolerances.

Methods for cutting and shaping structural steel

• Sawing: Steel can be cut using band or circular saws equipped with carbide or high-speed steel blades. Sawing is commonly used for straight cuts and is suitable for smaller structural steel components.
• Shearing: Shearing involves cutting steel using hydraulic or mechanical shearing machines. This method is ideal for straight cuts on flat steel plates and sheets.
• Thermal cutting techniques: Thermal cutting methods like oxy-fuel and plasma utilise heat to melt and remove steel. Oxy-fuel cutting combines fuel gas and oxygen, while plasma cutting employs a jet of ionised gas. These techniques are effective for cutting thick steel sections and complex shapes.

Welding and joining

Welding and joining are critical processes in structural steel fabrications that involve fusing multiple steel components to create strong and reliable joints. This section will explore the welding techniques commonly employed, emphasise the importance of skilled welders and adherence to welding procedures, and highlight relevant welding standards and certifications.

Welding techniques

• Arc welding: Arc welding, including (SMAW) shielded metal arc welding and (GMAW) gas metal arc welding, utilises an electric arc to create a high-temperature fusion between the steel components. SMAW uses a coated electrode, while GMAW employs a continuous wire electrode and shielding gas.
• MIG welding: MIG (Metal Inert Gas) welding, commonly known as (GMAW) gas metal arc welding, uses a continuous wire electrode together with a shielding gas to thoroughly protect the weld pool from atmospheric contamination. It is a versatile and commonly used welding technique in structural steel fabrication.

Surface treatment

Surface treatment protects structural steel from corrosion, ensuring its longevity and durability in various environments. Let us explore the surface treatment methods commonly used, emphasise the importance of surface preparation, and mention alternative treatments such as galvanising or powder coating.

Surface treatment methods

• Cleaning: The first step in surface treatment involves cleaning the steel to remove dirt, oil, grease, and other contaminants. This can be done through mechanical cleaning methods like power washing or abrasive blasting.
• Priming: Priming involves applying a corrosion-resistant primer to the cleaned surface. Primers act as a protective layer, promoting adhesion between the steel surface and subsequent coatings.
• Painting: Painting is a widely used method of surface treatment. It involves applying a coating system comprising multiple layers of paint. The paint acts as a barrier, shielding the steel from moisture and corrosive elements.

Quality control and inspection

Quality control is a crucial aspect of structural steel fabrication processing that ensures fabricated components' integrity, safety, and compliance.

Importance of quality control

• Integrity and safety: Quality control measures ensure that fabricated structural steel components meet the required strength, durability, and safety standards. This helps prevent structural failures and ensures the long-term performance of the constructed infrastructure.
• Compliance with standards: Quality control ensures that the fabrication process adheres to relevant industry standards and specifications. This includes compliance with Australian standards governing material properties, fabrication processes, welding practices, and dimensional tolerances.
• Minimising defects and rework: Effective quality control procedures help identify and rectify flaws and inconsistencies during fabrication, minimising the need for rework and avoiding costly delays.

Role of certified inspectors

• Inspection process: Certified inspectors play a vital role in conducting thorough inspections at various stages of fabrication. They examine the structural steel components, welding joints, and surface treatments to verify compliance with specifications and standards.
• Compliance assurance: Inspectors ensure that fabrication processes, such as material procurement, cutting, welding, and surface treatment, meet the necessary quality standards and adhere to approved procedures. They identify any deviations or non-compliance and facilitate corrective actions.
• Non-destructive testing (NDT): Certified inspectors may also perform non-destructive testing techniques, such as ultrasonic testing, magnetic particle inspection, or dye penetrant testing, to detect internal or surface defects that may compromise the quality of the fabricated components.

Delivery and installation

After the structural steel components have been fabricated, the next crucial step is their delivery and installation at the construction site. This section will explore the logistics involved in the delivery process, discuss considerations for safe and efficient installation, and emphasise the importance of collaboration between the structural steel providers, contractors, and other stakeholders.

Delivery logistics

• Transportation: Fabricated structural steel components are transported from the fabrication facility to the construction site. This requires careful logistics planning, including selecting appropriate transportation methods such as flatbed trucks, trailers, or cranes.
• Handling and packaging: Steel components must be properly handled and packaged to protect them from damage during transportation. This may involve securing the components with straps, protective coverings, or specialised racks or pallets for easy handling and loading.

Talk to a Structural Steel Fabrication Expert

Structural steel fabrication is a precise and intricate process that ensures strong, durable, and safe structures. Talk to a structural steel fabricator today if you need reliable and efficient services.

Their experienced team is ready to collaborate with you, delivering outstanding results and building the future with strength and excellence. Consult an expert and see the beauty of structural steel fabricated with excellence!