Heavy industrial construction is the backbone of modern infrastructure. From power plants and refineries to chemical facilities and manufacturing plants, heavy industrial construction creates the structures we need to keep the world turning. There are many materials crucial to construction, but the indispensable backbone of many large structures is steel. It provides strength, durability, and versatility, and remains an essential part of most industrial construction projects.
In today’s blog, we will discuss what makes steel such a reliable construction material, the different types of steel, and the requirements needed for heavy-duty construction. If you have any further questions about heavy industrial construction, contact RUS Industrial.
Why Steel is the Material of Choice for Heavy Industrial Projects
Why is steel so popular for heavy industrial construction? Here are just a few reasons:
- High Strength-to-Weight Ratio — This refers to the ability of steel alloys to maintain a high tensile strength while having a relatively low density. Its high strength-to-weight ratio means that steel can handle stress without adding unnecessary mass, which reduces strain on foundations and simplifies transportation and handling.
- Durability and Longevity — Steel is a highly durable metal, making it perfect for construction projects. It’s also resistant to corrosion and can withstand a wide range of weather conditions.
- Versatility — Steel can be shaped and molded to make it suitable for various structural components like frames, beams, and columns
- Recycling — The steel used in construction can be recycled repeatedly without losing any strength or quality. Recycling saves energy, minimizes waste, and provides an alternative to landfills and incinerators. It’s estimated that the steel industry has reduced greenhouse gas emissions by about 35% in the past 30 years.
- Predictable Performance — Steel’s consistent properties can help simplify engineering. It is a reliable building material that remains popular for a reason.
Types of Steel Used in Heavy Industrial Construction
Structural Steel
Structural steel is specifically designed for construction, and is known for its strength and durability. Common grades include ASTM A36, A572, A992, A500, A514, A516, A242, A588, A709, and A913. This type of steel forms the backbone of many large structures, including bridges and buildings. It is often used in the form of hot-rolled and cold-formed shapes, like beams and columns, that can be bolted and welded together. It requires high yield strength, weldability, and impact resistance.
Reinforcing Steel
Reinforcing steel, also known as rebar, is used to reinforce concrete and masonry structures to enhance their strength and resistance to tension. Common grades include ASTM A615 and A706. Concrete is weak in tension, so reinforcing steel is embedded to resist tensile forces, prevent cracking, and increase the overall strength of the structure.
Rebar is used for foundations, concrete slabs, equipment pads, and more. It requires ductility, bond strength, and corrosion resistance. In some instances, it is coated in epoxy or stainless steel to help with corrosion resistance.
Stainless Steel
Stainless steel has been used in construction for as long as it has existed. It is strong, resistant to corrosion, and needs little maintenance. The most common grades are 304 and 316. Stainless steel is commonly used in chemical processing plants, food and beverage facilities, and high-temperature or corrosive environments. It’s also used for architectural elements requiring aesthetic appeal. It requires specific corrosion resistance for different chemicals, high temperature, and stability.
Alloy Steels
Alloy steels are steels with added alloying elements, such as nickel, chromium, and molybdenum, to enhance their properties. It is a common choice for construction due to its strength, durability, and ability to withstand harsh conditions. Common grades include ASTM A514 and A517.
It’s commonly used for pressure vessels, high-strength pipelines, and components subjected to extremely high temperatures or pressures. It requires specific mechanical properties, like tensile strength and toughness at elevated temperatures.
Critical Design Considerations for Steel Structures
When working with steel in heavy industrial construction, there are many different factors to consider. The first is a load analysis. This is an analysis of the forces acting on the structure, considering the impact on its components. Dead loads are the static, non-moving weight of a structure, while live loads refer to variable, moving components like furniture, vehicles, and people.
There are also environmental loads to consider, (wind, earthquakes, and snow) and dynamic loads like vibration from machinery. These may seem like small factors, but if they exert any force on the structure, it needs to be considered during construction.
Something else to consider is applicable codes and standards. Adhering to these codes is essential for safety and regulatory compliance. Some of the most common include the International Building Code (IBC), AISC (American Institute of Steel Construction), API (American Petroleum Institute), and ASME (American Society of Mechanical Engineers).
The environment can also affect heavy industrial construction. Extreme temperatures can cause the expansion or contraction of materials, and atmospheric and chemical corrosion can pose a problem as well. Lastly, connection design (welded or bolted connections) can have a significant impact on the structure. For ideal construction and performance, all of these factors need to be considered
Fabrication and Erection During Heavy Industrial Construction
Steel has to be fabricated before being used for construction. The first step is usually cutting, where the metal is cut to the desired length in a controlled environment using laser or plasma cutting. Then it is bent to form the needed angles and curves using press brakes, bending rollers, and other machinery. Holes are drilled to allow for bolting and riveting, and then they are joined together using welding techniques. Once all of these components are complete, they are assembled into a larger structural element.
During the erection phase, special equipment must be used to assemble steel structures, including cranes and temporary bracing. Additionally, safety protocols are of utmost importance, from fall protection to rigging. Erection crews should be experienced and follow safety instructions exactly.
Challenges of Steel in Future Innovations
Like any other construction projects, heavy industrial construction comes with its own challenges. For example, although steel is resistant to corrosion, it can still corrode when exposed to aggressive environments. Oversized components need intense planning to ensure the structure is secure and sound. And last but not lease, there are labor shortages in many industrial sectors currently, one being heavy industrial construction.
Steel plays a critical role in heavy industrial construction, and must follow multifaceted requirements for its successful application in a project. Ultimately, all requirements are in place to ensure structures are as stable and safe as possible. Meticulous planning, adherence to standards, and continuous innovation are key to building robust and reliable industrial facilities.
If you are ready to partner with an experienced industrial construction company, contact us today!
