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What is Materials Processing in Structural Steel Fabrication?

Date 23 Jan 2025

Steel plays a key role in modern construction and engineering. Whether that’s the steel footbridges we cross every day as part of our commute or the towering skyscrapers that define city skylines, steel’s versatility and durability makes it a dispensable material.

Beyond these everyday applications, many of our projects involve using steel to create structures for specialised industries, such as mining, energy production and transportation infrastructure.

As an integral construction material, the processes for taking it from raw material to finished component are equally as important. The intricate and precise nature of materials processing ensures that the steel used in structural fabrication meets the high standards required for safety, efficiency and longevity. 

In this blog, we’ll explore the concept of materials processing in steel fabrication, how steel is produced, the steps involved in its transformation, and how modern techniques like those used by the expert engineers at Carver ensure sustainability and safety in this vital industry.

What is materials processing?

Materials processing refers to the techniques used to transform raw materials into finished components or products. In steel fabrication, this involves shaping, cutting and treating steel. Ultimately, the aims of processing steel are achieving precision, efficiency and structural integrity in the final product.

a drill being used as part of the material processing

Whether our team of engineers are producing beams for a bridge or custom components for industrial machinery, materials processing helps make sure every piece of steel meets the exact specifications required for its application.

Where does steel come from?

The primary component of steel is iron. Iron ore is a naturally occurring mineral found in the earth’s crust and is mined all over the world. Once extracted through mining operations, the iron is transported to steel production facilities before being processed into steel.

On its own, iron ore has many impurities, like silica, sulphur and phosphorus, which weaken the iron. Processing the iron into steel removes these impurities and adds carbon to give the final material its renowned strength.

Key raw materials used in steel production include:

  • Iron ore: The primary source of iron.
  • Coke: A carbon-rich material derived from coal, used as a fuel and reducing agent in the smelting process.
  • Limestone: Used as a flux to remove impurities during smelting.

The combination of these materials, along with advanced industrial processes, results in the production of steel.

How do you make structural steel components from iron ore?

Taking the raw material of iron ore and turning it into useful components made from structural steel is a multi-step process. Here’s a quick overview:

  1. Mining and transportation: Iron ore is extracted from mines and transported to steel production plants.
  2. Smelting: The ore is combined with coke and limestone in a blast furnace. The intense heat from the furnace reduces the iron ore to molten iron, making it easier to remove impurities as slag. 
  3. Refining: The molten iron is further processed to remove excess carbon and other impurities, resulting in crude steel.
  4. Alloying: Elements such as manganese, chromium, or nickel are added to improve  the steel’s properties, depending on its intended use.
  5. Casting and rolling: The steel is cast into billets, slabs, or blooms and then rolled into various shapes, such as beams, sheets, or bars, suitable for structural applications.

This refined steel is now ready to be processed further to create specific components used in construction and engineering projects, like the ones we complete here at Carver Engineering.

Materials processing for structural steel

Thanks to its strength and workability, steel is a top choice for creating structural components and products in many industries, including construction, machinery and the marine sector

a plasma cutting machine preparing steel for a project

Here’s how the team at Carver Engineering transform refined steel into useable structures with materials processing:

  1. Cutting: First, we cut the steel to size using tools such as CNC machines, band saws, plasma cutters or water jet cutters. At Carver Engineering, our 16.5 x 3m water beds allow for precise cutting with minimal waste.
  2. Shaping: Then, the steel is bent, rolled, or formed into shape using press brakes or rolling machines.
  3. Pre-heating: At Carver, our dedicated pre-heating area ensures that materials are heated to optimal temperatures. That means more efficient cutting and shaping, and less stress on the steel.
  4. Welding: We join the steel components together using welding techniques to create a larger complete assembly.
  5. Surface treatment: Steel may undergo processes such as sandblasting, galvanising, or painting to protect it from corrosion and give it a durable finish. This finish depends on the final structure’s intended use and environment.
  6. Quality control: We inspect each component to make sure it meets precise specifications and standards for structural integrity.

What kinds of steel components are processed at Carver Engineering?

Carver Engineering specialises in processing a wide range of steel components for various applications, including:

  • Beams and columns: Essential for structural frameworks in bridges.
  • Plates and sheets: Used in cladding, flooring, and industrial equipment.
  • Custom components: Our experienced detailed design team can create tailored components to meet specific project requirements, such as machinery parts or architectural features. 
  • Specialist steel: We work with specialised materials for projects requiring unique properties. For example, our recent fabrication of the Tilbury Port hopper saw us use AR450 steel for the resilience required to offload high volumes of granite.

room dedicated to materials processing

Our state-of-the-art workshop, equipped with CNC machines, band saws and two 10t cranes, allows us to deliver precision-engineered products efficiently and reliably to the UK and at a global scale.

How sustainable is metal processing in the steel industry?

Sustainability is a growing priority in the steel industry, and for many of our clients. While steel production has historically been energy-intensive, modern technologies are helping to reduce its environmental impact.

These key advancements include:

  • Recycling: Steel is one of the most recycled materials globally – 87% of steel is recycled in the UK. Scrap steel can be melted down and reused, reducing the need for raw materials.
  • Efficient processes: Innovations like CAD/CAM nesting software, such as Lantek Expert that we use at Carver Engineering, optimise material usage, keeping waste to a minimum.
  • Energy consumption: Modern blast furnaces and electric arc furnaces are designed to use energy more efficiently, cutting down on greenhouse gas emissions.
  • Long-life components: All of our products and components meet high standards of quality, and we can provide steel refurbishment and maintenance as part of our aftercare.

At Carver Engineering, we’re committed to sustainable practices, leveraging advanced technology to reduce waste and minimise our ecological footprint. In 2024, we recycled 2.272 tonnes of paper and plastic waste. By managing resources responsibly, we’re able to lessen our environmental footprint while maintaining high standards of production.

Health & Safety: Protecting our engineers during materials processing

Working with heavy machinery, high temperatures, and sharp materials means having stringent health and safety measures in place throughout our entire steel fabrication process, including materials processing. 

The safety of our workforce is a top priority at Carver Engineering. Here’s how we protect our engineers:

  • Dedicated pre-heating area: By isolating high-temperature processes, we reduce the risk of heat exposure for our engineers.
  • Ergonomic machinery: Equipment such as cranes and automated cutting systems minimise the need for manual handling, which in turn reduces the risk of injury.
  • Protective gear: All engineers are provided with personal protective equipment (PPE), including gloves, helmets and safety glasses.
  • Training: Regular safety training keeps all team members aware of best practices and potential hazards.

A safe working environment not only protects our engineers but also ensures consistent quality and reliability of our products.

Conclusion

Materials processing is an important part of steel fabrication, transforming raw materials into the structural components that form the backbone of modern infrastructure. From mining iron ore to producing custom-engineered steel parts, we play a key role in turning this sturdy, long-lasting material into parts that will be useful for decades to come.

Start your structural steel project

At Carver Engineering, we’re known for our exceptional structural steel projects, using cutting-edge technology, sustainable practices and high standards of safety and quality in everything we do. Whether it’s a large-scale footbridge fabricated to your tried-and-tested design or something completely bespoke, our skilled team has the right tools and know-how to deliver. 

Get in touch today to enquire about your next project, or check out our latest work to see what we can do for you.

 

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