Structural steel is one of the world’s most commonly used construction materials, particularly when it comes to bridges and buildings. It’s incredibly strong and can last for decades with minimal maintenance.
At Carver Engineering, our team specialises in structural steel fabrication, contributing to the design and carrying out all welding, shaping, delivery and installation of steel structures for construction projects in the UK, and beyond. In this article, we’ll explore exactly what structural steel is, how it’s used and provide an insider look into how it’s made.
What is structural steel?
Structural steel is a carbon-based steel used in the construction industry. It’s used to form the ‘skeleton’ frame of buildings, bridges, towers, walkways and other large structures.
Its excellent strength to weight ratio makes it ideal for handling heavy loads, without bending, twisting or stretching. Plus, with surface treatment, it’s corrosion-resistant and requires minimal maintenance, therefore ideal for structures that have to face the elements like those used in marine and mining environments.
Structural steel components come in a variety of shapes and sizes, including beams, columns and hollow sections, depending on the specific structural needs of the project. Steel fabricators are able to create detailed designs that consider the best shapes and angles to support weight and provide stability.
Key uses of structural steel
Structural steel is all around us, forming the core of many of the buildings and infrastructure we use every day. Here are some of the key ways it’s used:
1. Buildings & construction
From high-rise developments to office blocks, these commercial buildings often incorporate steel frames because they’re quick to build, flexible in design and cost-effective.
2. Oil & energy infrastructure
Structural steel plays a vital role in energy sector construction. Factories and processing plants need large, open spaces, which structural steel supports with fewer internal columns. Plus, thanks to its sustainability, it helps projects designed to meet the growing demand for a greener energy supply.
3. Transport & logistics
Steel’s strength and flexibility make it ideal for supporting long spans of bridges and roads, all while withstanding dynamic loads like traffic and wind. In airports, train stations and logistics hubs, steel structures are favoured for their scalability and speed of construction.
Why is structural steel important?
Structural steel offers a range of benefits that make it a smart choice for construction projects.
Primarily, steel is renowned for its high strength. It can support immensely heavy loads without bending or breaking, which means it can support stronger and taller buildings with smaller footprints. Plus, its longevity means it can be counted on for years to come.
Thanks to highly controlled fabrication environments, like our 24-hour, state-of-the-art fabrication facility, structural steel is manufactured under heavily controlled conditions. This means predictable performance you can count on every time.
While strong, steel is also incredibly customisable. Steel structures have the design flexibility to suit any kind of architectural style, application or engineering requirements. Whether it’s an open layout space like a sports stadium, or visually appealing curved and arched structures for modern railway footbridges, this versatile material allows for diverse design solutions.
We’ve already covered the sustainability of steel in a recent blog post, so you already know that it’s considered to be one of the most eco-friendly construction materials around. Structural steel is 100% recyclable – even when it’s no longer in use, it can be melted down and reused without losing quality. Plus, with its streamlined transportation and assembly, it produces less emissions from heavy machinery and transportation.
For most projects, steel components are made off-site before being quickly assembled on-site. This modular design and efficient on-site erection essentially means fewer delays and shorter project timelines. Alongside its speed of construction, the combination of durability, low maintenance and fast assembly leads to cost savings in the long-run too!
The fabrication process for structural steel
Structural steel fabrication means turning standard steel products, like beams and columns into the components that make up a structure. This process involves the following steps:
- Consultation – First, you can expect to have a consultation with your team of expert engineers to understand the key requirements of the project. During this session, you’ll be asked about the size and scope of the project, deadlines, and any additional requirements for delivery like working within specific hours to limit disruption or using specific types of steel. An example of this is when we worked with the Spencer Group to line the Port of Tilbury hopper with AR450 steel.
- Design and detailing – Once we’ve got an understanding of the project requirements, we’ll then bring your idea to life with technical drawings. We can use CAD design to create 3D models that act as a prototype – helping you visualise the final structure, and helping us identify any potential issues or challenges that we need to address at this stage.
- Cutting – Our engineers then cut the steel to size using machines such as saws, lasers or plasma cutters – here’s a little bit more about how plasma cutting works!
- Drilling and punching – Using the design for reference, we create holes for bolts and connections.
- Forming and shaping – Some parts of the structure may require bending or shaping. We do this using machinery like press brakes and rollers.
- Welding and assembly – We then weld the different components together, with quality inspections at every stage. Where conditions require it, we can transport pre-fabricated sections to your site and assemble them on location.
- Surface treatment – The steel is cleaned and treated to protect it against rust and weathering. Depending on the conditions and client specification, this can include galvanising, painting or applying other protective coatings.
- Delivery – We support with the delivery and installation of the steel structures, checking for snags as we go.
At Carver, we handle all of these steps in house, giving us complete control over the project. You’ll work closely with a single point of contact throughout for swift communication and better risk management.
Structural steel erection
Now that we’ve talked through the fabrication process, the next step in the process is the structural steel erection on site. At this point, the individual components come together to create a full, standing structure.
Working with the client, we will schedule deliveries once all foundations secure and in place.. Following this, we work with our trusted crane and lifting equipment partners to position the steel elements in place.
A final check and any adjustments help make sure everything is aligned, safe and ready for the next phase of construction.
Structural steel fabricators in the UK
The UK has a strong tradition of steelwork fabrication, and the right choice of fabricator can make or break a project.
At Carver Engineering, we’ve been delivering high-quality structural steel solutions since 1993. Based in the UK our expertise encompasses a wide range of industries, from rail and highways to construction and energy. We’re there for the entire process, from early design through to delivery.
The quality of our work is certified to ISO 9001, alongside other industry accreditations that show our commitment to doing things right. Combine this with our skilled workforce that brings decades of expertise to every project, and you’ve got a winning team in your corner.
Looking for reliable structural steel services in the UK?
Carver Engineering is here to help. Whatever the size and scale of your project, our team is ready to deliver. Get in touch today to see how we can help with structural steel fabrication for your project.
