IRON AS A BUILDING
MATERIAL (TYPES, USES,etc.)
Presented by-• Aiman• Sundus• M.Raghib• Bilal• Hamzah
• Iron(Fe) is the second most common metal on Earth, and the most widely-used metal.
• It is element26, a transition metal in Group 8.
• Its symbol is Fe, from the Latin word for iron, ferrum.
• Atomic number: 26
• Mass number:55.85
• It is used a lot because it is very strong and cheap.
• Iron is the main ingredient used to make steel.
INTRODUCTION
•Iron is a lustrous, ductile, malleable, silver-gray metal.
•It is known to exist in four distinct crystalline forms.
•Iron rusts in damp air, but not in dry air and dissolves readily in dilute acids.
•It has a very high tensile strength.
•Boiling point : 3000 °C(5,400 °F)
•Melting point : 1,536 °C (2,797 °F)
PHYSICAL PROPERTIES OF IRON
• Iron is the most widely used of all the metals,accounting for 95%of worldwide metal production.
• Its low cost and high strength make it indispensable in Engineering applications such as -
• The construction of machinery and machine tools,automobiles, the hulls of large ships, andstructural components for buildings.
• Since pure iron is quite soft, it is most commonlyCombined with alloying elements to make steel.
• Iron is also used for protection from ionizing radiation Cast iron has been used for centuries and was used in architecture in the pre-modern period.
APPLICATION AND USES OF IRON
• The main disadvantage of iron is that pure iron, and most of its alloys,
suffer badly from rust if not protected in some way.
• Painting, galvanization, passivation, plastic coating and bluing are all used to protect iron from rust by Excluding water and oxygen or By cathodic protection.
DISADVANTAGES
TYPES OF IRON
IRON IS AN IMPORTANT BUILDING COMPONENTHAS BEEN USED IN MANY FORMS:
1. WROUGHT IRON
2. CAST IRON
01 CAST IRON
8
Iron Ore
Blast Furnace
Pig Iron
Smelted, Hammered, Re- heated, Rolled
Smelted (separate the metallic constituent)
,Alloyed, Rolled
Wrought Iron Cast Iron Mild Iron(Steel)
Re- melted,Poured into sand molds
PROPERTIES
• Cast iron.: 2.0 – 4.5% Carbon content
• Carbon (C) and silicon (Si) are the main alloying elements.
• Great for the environment. Can be recycled more easily than PVC.
• It is strong in compression, but weak in tension and bending.
• Prefabrication enabled portability—entire buildings could be constructed in one place and shipped all over the world.
• Its strength and stiffness deteriorate when subjected to high heat.
• Its structure is crystalline and relatively brittle.
• They don't echo when water moves through as compared to PVC, because of dense material.
• It does not rust.
ARCHITECTURAL USES• Its use gradually spread from architectural elements like shutter
and door frames to facades because it is relatively 1. inexpensive, 2. durable & 3. easily cast into a variety of shapes.
• As balusters, columns & Arches
• For transporting water, storm drains and sewage.
• Ornate facades.
Columns
Spandrel panels
Fire proof floor- mid 19th century Cast iron is strong in compression weak in bending. Wrought iron High in elasticity and tensile strength.
Cast iron beams
Thin webs could easily crack. Sharp angles where web joins flanges were also vulnerable.
This is slightly thicker web and rounded internal angles, which is less prone to cracking during casting.
Cast iron beams
General uses
• Construction of machines and structures(High Tensile Strength)
For a garbage disposal because it is highly resistant to the grinding and abrasions. (The process of wearing down away by means of friction)
Machines
Design made on column Gate design Decorative pieces
Arches in bridgeUse of cast iron in facade
FAILURE
Oxidation or rusting occurs rapidly when cast iron is exposed to moisture or air.
Common problems encountered with cast iron construction include Badly rusted or missing elements. Impact damage Structural failures Broken joints Damage to connections Loss of anchorage in masonry
CLASSIFICATIONS OF CAST IRON
1. WHITE CAST IRON
2. GREY CAST IRON
3. DUCTILE (NODULAR) CAST IRON
4. MALLEABLE CAST IRON
1/04. WHITE CAST IRON
• These are iron-carbon alloys having more than 2.11% carbon.
• All the carbon is present in the combined cementite form.
Properties• Hard and wear resistant.
• Tensile strength 20000 to 70000 psi.(per square inch)
• Compressive strength 200000 to 250000 psi.
Microstructure of White Cast Iron
LIMITATIONS
Because of extreme brittleness and lack of machinability, white irons find limited engineering applications.
APPLICATIONS
• Liners For Cement Mixers, • Ball Mills, • Certain Types Of Drawing Dies• Extrusion Nozzles
Liners For Cement MixersBall Mills
Nozzles
Decorated furniture
2/04. Grey cast iron
Iron-carbon alloys containing flakes of graphite
embedded in steel matrix, which show a grey-blackish
coloured fracture due to graphite’—the free foam of
carbon, are called grey cast irons.
The strength of grey iron depends on the strength of steel
matrix and the size and character of graphite flakes in it.
Microstructure of Gray Cast Iron
Microstructure of Gray Cast Iron
PROPERTIES OF GREY CAST IRON
1. Low cost of production.
2. Low melting point: (1150°—1250°C)
3. Cast irons have excellent fluidity and take good mould-impressions easily.
4. High compressive strength.
5. High thermal conductivity, and have ability to withstand thermal shocks.
6. Good resistance to atmospheric corrosion due to high silicon and perhaps other factors, than mild steels.
7. High damping capacity -due to the graphite flakes, which breaks the continuity of the metallic matrix, and thus, vibrations are not allowed to transfer from one side of flake to other.
APPLICATIONS
• Internal Combustion Engine• Pump Housings • Valve Bodies• Electrical Boxes • Cast iron cookware• Disc brake
Internal combustion engine
Pump Housings
Disc brakeGrey Cast iron cookware Decorative pattern
3/04. Malleable cast iron
24
Malleable iron is produced by heat treatment of cast iron.
The properties of malleable cast iron are more like mild steel.
Microstructure of Malleable Iron
• Graphite in module(knot/lump) form.
• Produced by heat treatment of white cast iron
• Graphite nodules are irregular clusters
Properties
• Similar to ductile iron
• Good shock resistance
• Good ductility
applications• Malleable iron is better for thinner castings• Vehicle components
1. Power trains, frames, suspensions and wheels2. Steering components, transmission and differential parts, 3. connecting rods
• Railway components• Pipe fittings• Electrical fittings
Rail tracks Pipe fittingswheels
4/04. Ductile (nodule ) cast iron
In ductile irons, the graphite is in the form of spherical nodules thus prevent the creation of cracks and providing ductility.
PROPERTIES
• Strength higher than grey cast iron.
• Low cost
Microstructure of Ductile Iron
APPLICATIONS
Pipe and pipe fittings
Major industrial applications include Highway diesel trucks, Agricultural tractors, Oil well pumps.
– Crankshafts, – Front wheel spindle supports,– Steering knuckles,– Disc brake callipers
used for water and sewer lines. Pipes
Machinery products:
oil well pumps
Crankshafts in motor engineDisc brake callipers
02-WROUGHT IRON
Wrought Iron Is A form of Iron With A Very Low Carbon Content (0.25%) In Contrast To Cast iron (2.1% to 4%)."Grain" Resembling Wood, Is Visible When It Is Bent To The Point Of Failure.
Wrought Iron Is Tough, Malleable, Ductile And Easily Welded.
Purest form of iron in which the total impurities do not exceed 0.5%.
Wrought iron is much more expensive to produce than cast.
Most wrought iron work are joined by riveting.
MAJOR EXAMPLE ARE-
1. Iron pillar at Delhi, India, containing 98% wrought iron.
2. The Eiffel tower
PROPERTIES
•It can be used to form temporary magnets but cannot be magnetised permanently.
•It fuses with difficulty.
• high elasticity and tensile strength
•Unaffected by saline water.
• If pulled apart, the fracture shows a fibrous break.
• Capable of bearing 24 tons per square inch ultimatetensile strain, & 20 tons of compression and shearing..
In fencing In main entrance gates
In railings As balusters
USES
• Used for rivets, chains, ornamental iron work, railway couplings, bridges, water and steam pipes.
• Roofing sheets, corrugated sheets.
• It is manufactured for bolts and nuts, horse shoe bars, handrails, straps for timer roof trusses, boiler tubes, roofing sheets, etc.
1. 3 I beams used. The inner beam is riveted through it flanges to the webs of the outer beams by four lines of rivets. (permanent mechanical fastener.)
2. 2.channels are used outside in place of I beams, the flanges being turned inward gives the column a better finished appearance.
3. 3. composed of two channels and plates riveted to the flanges of channels with four lines of rivets.
4. The rolled segment is composed of 4 segments riveted together through the projecting flanges, and made from 4-18” outside dia.
---3 to 24 inches deep (75mm to 600mm) and with flanges about 200mm wide
Fig-4
Pipes
Chains
Wire
RIVET Nail
EXTERNAL USE
Jubilee Bridge (1887) in Derbyshire.
• It's a good example of a structure made from different wrought iron sections riveted together.
• The bridge spans 85 feet, about 26 metres.
COMPARISON BETWEEN WROUGHT IRON ,CAST IRON& STEEL
Wrought iron Cast Iron Steel
Composition Purest Contains up to 0.25% C
Crude form containing 2-4% C
Midway
Melting point 1500 degree Celsius 1200 degree Celsius 1300-1400 degree Celsius
Hardness Cannot be hardened or tempered
Hard, hardened by heating & sudden cooling
Can be hardened & tempered
Strength compressive strength is 2.0 tonnes/sq cm ultimate tensile strength 3.15 tonnes/sq cm
Comp. strength 6.3-7.1 tonnes/sq cmUltimate tensile strength 1.26 to 1.57tonnes/sq cm.
Comp strength 4.75 -25.2 tonnes/ sq cm Ultimate tensile strength is 5.51 to 11.02 t /sq m
Wrought iron Cast Iron Steel
Malleability Ductility
Tough, malleable, ductile & moderately elastic
Brittle & cannot be welded or rolled into sheets
Tough, malleable & Ductile
Reaction to sudden shock
Cannot stand heavy shocks
Does not absorb shocks
Absorbs shocks
Welding Easily welded Brittle and cannot be welded or rolled into sheets
Can be welded
Different types of iron used for pipes
• Galvanized• Cast• Ductile
Comparison disadvantages
Galvanized corrodes; produces discolored water; has a short life;
Ductile deteriorates in some soils
Cast Iron no longer manufactured; deteriorates in some soils
CAST IRON PIPE1.Cast iron pipe
CHARACTERISTICS
Versatile
Adaptable for use in all types of building
Low-Cost Installation.
Cast iron soil pipe can be preassembled
Product readily available
SIZE AVAILABILITY
11/2” to 12” diameter 5’ AND 10’ length
USES
transporting water,
storm drains and sewage
chosen over options like PVC, especially in high rise projects like draining from the roof
garbage disposal because it is highly resistant to the grinding and abrasions
FEATURES
Cast Iron flanged pipe and fittings are usually cast in the larger diameters. Smaller sizes have loose flanges screwed on the ends of double spigot spun pipe.
Pipes are supplied in 3.7 m to 5.5 meters lengths and a variety of joints is available
including socket and spigot and flanged joints.
The pipes have been classified as LA,A and B according to their thicknesses. Class LA
pipes have been taken as the basis for evolving the series of pipes.
· Class A allows a 10% increase in thickness over Class LA.
· Class B allows a 20% increase in thickness over Class LA.
JOINING
• THREE METHODS• Compression Gaskets
• Hubless Joints
• Caulked Joints
Advantages
they don't echo when water moves through
good lasting qualities..
Disadvantages
heavy weight,
consequent high transport costs,
short length, leading to higher laying and jointing cost,
low tensile strength,
liability to defect of inner surface
2.Ductile pipes
. Nominal pipe sizes vary from 3 inches up to
64 inches
The ductile iron used to manufacture the pipe is
characterized
by the spheroidal or nodular nature of the graphite
within the iron
pipe is manufactured using centrifugal casting in
metal or resin lined molds
joints. Individual lengths of ductile iron pipe are
joined either by flanges, couplings, or some form of spigot and socket arrangement Flanges are flat rings around the end of
pipes which mate with an equivalent flange from another pipe, the two being held together by bolts usually passed through holes drilled through the flanges.
Spigot and sockets involve a normal pipe end, the spigot, being inserted
into the socket or bell of another pipe or fitting with a seal being made between the two within the socket. Normal spigot and socket joints do not allow direct metal to metal contact with all forces being transmitted through the elastomeric seal
The most popular, quickest, and easiest-to assemble joint for Ductile Iron pipe and fittings in underground applications is the push-on joint. This joint consists of a single rubber gasket placed in a groove inside the socket at the bell end of the pipe.
There are two types of push-on joints: the FASTITE®1 and TYTON®2 joints,which are shown in Figure
Advantages
Ductile iron pipe is made from 100% recycled ferritic scrap—and is itself a 100% recyclable material. . Ductile iron saves money. It requires very little maintenance once it’s installed and It is resistant to corrosion in most soils, and typically requires only effective, economical polyethylene It is strong enough to withstand the most severe conditions, Ductile iron pipe is rugged and resists damage during handling and installation
Disadvantages Similar rate of corrosion to grey iron and steel Prone to external and internal corrosion Internal and external protection systems required Polyethylene wrappings can be damaged
3. GALVANISED IRON PIPES(FEATURES)
Physically, galvanized steel pipes are slightly
darker than steel pipes because of zinc's darker color Economically, galvanized steel pipes
are inexpensive and recyclable.
USES These pipes are widely used for
conveying raw water & distribution of treated
water in majority of rural water supply schemes
Thank you………
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