Using Steel to Reinforce Concrete

Reinforced concrete bridgeConcrete embedded with steel reinforcement bars, plates, or fibers is one of the world’s most commonplace construction materials. Reinforced concrete, as it is known, can be found in everything from massive bridges and skyscrapers to individual home foundations and the roads underneath our feet. Here’s a quick look at why this composite material is so popular, and how it’s made:

Isn’t Concrete Strong Enough? Why Does it Need Reinforcement?

While concrete is an exceptionally tough material, resistant to compression forces, it’s also rather susceptible to cracking under extreme tensile stress. This makes it vulnerable to earthquakes, heavy vibrations, and other calamities against which architects must take consideration.

How Steel Helps

Consider reinforced concrete to combine the best of both worlds: concrete itself, while strong under pressure, is weak when stretched; while steel, somewhat more flexible, withstands bending and pulling forces better. The resulting composite material retains the inexpensive, easily moldable, weather resistant, and fireproof traits of concrete while standing up much more reliably to tensile stress.

 

How is the Reinforcement Done?

reinforced concreteReinforced steel is most commonly produced by pouring liquid concrete into a mold around a steel rebar or cable skeleton. These steel rods are typically placed at points where the greatest tensile stress is anticipated, if not throughout the entire structure.

Often, construction engineers will create pre-stressed concrete, in which the concrete is poured around heavy steel bars or cables that are already under considerable tensile stress. Once the concrete is poured and hardens, static friction transfers these tensile forces directly into it as compression. Subsequent tensile stress on the concrete is transferred directly onto the reinforcing structure.

Occasionally, small fibers of steel (or even other materials like glass or synthetics) may be incorporated directly into the concrete mix – this results in a material with improved resistance to cracking over regular concrete, though perhaps with less of a strength increase than is found in rebar-embedded concrete.

Questions about rebar or steel-based reinforcement in general? Contact the metal experts at Madison Steel today.


What is Welded Wire Mesh?

Also referred to as welded wire fabric, or simply “weldmesh”, welded wire mesh is a prefabricated grid of low carbon or stainless steel wires. These are welded together at each intersection, providing a highly durable and uniformly structured material suitable for a variety of applications.

weldmeshSteel wires come in an assortment of thicknesses, and depending on the size of the wires themselves as well as the openings between them, the resulting mesh may be sold in either rolls or flat panels. The openings themselves may be square or (oblong) rectangular in form.

 

Common uses for weldmesh

You’ll find welded wire mesh in a variety of industries, from agriculture and horticulture to transportation, mining, and construction. Here are just a few of the most common uses:

  • Rebar

Thicker instances of welded wire mesh can make a good internal framework for reinforced concrete structures. This addition provides substantially increased tensile strength to a material that is otherwise quite vulnerable to cracking under the forces of vibration, twisting, and warping.

  • Fencing

Those looking for a relatively cheap security solution that’s tougher than chain link and still allows visibility will often turn to welded wire mesh. Application sites range from lower-security prisons and military installations to private offices and residences. It may even be placed within factories and other industrial buildings as a guard material surrounding heavy machinery.

  • Grating

A perfect combination of strength, low cost, and ease of installation makes welded wire mesh a popular choice for grating roads – especially providing ventilation for subway systems – and for covering street-side drains.

  • Decorative purposes

Welded wire mesh is available in multiple colors and coatings, and can in fact make for a visually appealing framework for trellises, flowerbed enclosures, and birdcages – among others. Some find it a perfect fit for elevating plants above the ground, or for shelving in garden sheds, closets, and even retail stores.

 

Contact the expert suppliers at Madison Steel for all your welded wire mesh needs.


What are Alloys?

Alloys are simply a metallic solution of two or more elements, smelted together or otherwise combined into an inseparable mixture. They’re typically designed to overcome certain weaknesses that might be present in one of the component metals – for instance, a tendency to rust, physical weakness, or poor resistance to temperature extremes. The mark of a useful alloy is that it improves in some manner on the qualities of its individual parts.

Commonly Encountered Alloys

Alloys actually comprise the great majority of metals in commercial use today – here are just a few common examples:

• Steel

SteelDid you know that steel itself is an alloy? By adding small amounts of carbon to iron and burning off common impurities like nitrogen, phosphorus, and silicon, smelters create a product with greatly increased strength and resistance to rusting – there’s a reason that the advent of steel-making technologies was such a turning point in the development of industry! Today, steel is one of the most common materials in the world, and is used in everything from building construction and industrial machinery to home goods like automobiles, appliances, and tools.

• Solder

This mixture of tin and lead is heavily used in the manufacture of electronics, as well as in plumbing and for various sheet metal constructions. Different forms of solder are created from the combination of varying ratios of these two metals, but all work similarly to join together metal components. Combining tin and lead grants solder a hardness that exceeds that of either element alone, and also gives it a melting point lower than that of both metals – making it very easy to work with.

• Bronze

BronzeThis distinctive alloy is one of humanity’s earliest breakthroughs in technology, and still very much in use today. Bronze is primarily made of copper, with other metals (usually tin, but occasionally arsenic – especially in the past) added in smaller amounts, and appends additional strength and durability to the malleable and rust-resistant properties of regular copper. Though it’s been displaced in some aspects by the superior strength of materials like steel, you’ll still find it used in statues, musical instruments, and electrical contacts.  

If you have additional questions about alloy creation or uses, contact the experts at Madison Steel today.


Solid vs. Stranded Wire

Even with all the various sizes and shapes of wire, and their massive number of applications, it’s possible to break them down into just two basic categories – solid and stranded wires. Solid wires are exactly as they sound: a single, (relatively) thick thread of metal; while the alternative is actually a series of extra-thin wires wrapped together.

Though both styles are equally effective in conducting electricity, they do have some subtle distinctions that make them suitable for different purposes. Learning the differences will help you make the best pick for your specific situation.

Flexibility 

When the need of the hour is flexibility, stranded is the way to go. This loose rope of minute wires is highly flexible, easily bending and wrapping around corners. Extension cords and other long appliance cables are typically made of stranded wire, as Stranded Wirethey’re frequently folded, twisted, and tucked out of the way. For more static applications, where the wire won’t be subjected to repetitive movements, a solid wire is an excellent alternative.

Widths

Stranded wires tend to be larger than solid wires with the same current-carrying capacity (as defined by area of conductive material). This is because stranded wires are composed of rounded wire threads, which do not fit neatly against one another and will thus have small air-filled spaces between them. Solid wire offers a more compact option, if the rigidity is not an issue for you.

Cost

Though this will, naturally, be dependent on a number of factors like width, stranded wire tends to be slightly pricier than solid wire, as additional processing is needed to assemble this wrap of conductive threads. Of course, you should weigh installation costs against maintenance costs – running solid wire is cheaper initially, but in high-motion environments it will not last as long as stranded wire. Careful planning will ensure the most economical selection for your needs.

If you have questions or other inquiries regarding steel wires, contact the experts at Madison Steel today.


Is Recycled Metal as Strong as New Metal?

Almost all types of ferrous metals can – and should – be recycled. The process serves to reduce not only landfill waste, but also manufacturing costs and the labor and energy required to extract additional raw materials. Fortunately, this recycling can even be done without compromising the strength and integrity of the reclaimed product. To see how, let’s run through an example with steel – the most recycled metal in the world, and easily the most widely used and versatile, with applications from theRecycle Metal creation of common household items to the building of massive skyscrapers.

How is Steel Manufactured?

The creation of steel solely from raw components requires the combination of iron ore, limestone, and coke (a coal-based fuel) in a furnace, where it is smelted down to remove impurities and add carbon. Today, much of the steel we use is produced by recycling existing materials – for each ton of reused steel, we’re able to save 120 pounds of limestone, 1,400 pounds of coke, and 2,500 pounds of iron ore, according to the American Iron and Steel Institute

There are two primary methods of creating steel with reclaimed scrap: through an EAF (Electric Arc Furnace) or BOF (Basic Oxygen Furnace).

In the EAF process, the raw material is almost entirely scrap steel. High-powered electric arcs quickly melt the material down to liquid crude steel, after which it is refined further in secondary steelmaking processes. Much of the steel used in construction, such as reinforcement bars, steel plates, and structural beams, is made through the EAF process, since the end result produced is incredibly strong.

The BOF process, on the other hand, uses only about 30% recovered steel at most. Here, molten iron is combined with pure oxygen to blow out impurities. The steel produced by this method is used to make industrial drums, pails, cans, refrigerator encasements, and automobile fenders.

What Type of Scrap Metal can be used?

Thanks to steel’s versatility and popularity, there is a huge supply of scrap available cheaply. Common sources for recycled steel components include:

  • Scrap MetalBodies of old vehicles
  • Old machinery, engine blocks, pipes, and iron baths
  • Domestic scrap, such as old appliances, cans, water tanks, roofing sheets, etc.
  • Factory waste that remains after shaping or drilling metal
  • Industrial waste and commercial scrap such as old columns, beams, channels, plates, implements and more

How is this Material Recovered?

Since iron and steel have magnetic properties, they can be easily separated from other waste. Once segregated, these metals are kept in scrapyards and by heavy machinery, for ease of transport and to reduce necessary space on the conveyer belts that feed blast furnaces.

Recycling steel is both the economical and environmental choice, and provides an incredible end product for use in any application. For more information, contact Madison Steel today.