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IRON AS A BUILDING MATERIAL (TYPES, USES,etc.) Presented by- Aiman Sundus M.Raghib Bilal Hamzah

CAST IRON & WROUGHT IRON

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Page 1: CAST IRON & WROUGHT IRON

IRON AS A BUILDING

MATERIAL (TYPES, USES,etc.)

Presented by-• Aiman• Sundus• M.Raghib• Bilal• Hamzah

Page 2: CAST IRON & WROUGHT IRON

• 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

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•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

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• 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

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• 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

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TYPES OF IRON

IRON IS AN IMPORTANT BUILDING COMPONENTHAS BEEN USED IN MANY FORMS:

1. WROUGHT IRON

2. CAST IRON

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01 CAST IRON

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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

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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.

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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

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Fire proof floor- mid 19th century Cast iron is strong in compression weak in bending. Wrought iron High in elasticity and tensile strength.

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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.

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Cast iron beams

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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

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Design made on column Gate design Decorative pieces

Arches in bridgeUse of cast iron in facade

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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

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CLASSIFICATIONS OF CAST IRON

1. WHITE CAST IRON

2. GREY CAST IRON

3. DUCTILE (NODULAR) CAST IRON

4. MALLEABLE CAST IRON

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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

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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

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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

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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.

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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

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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

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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

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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

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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

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02-WROUGHT IRON

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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

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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..

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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.

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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

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Pipes

Chains

Wire

RIVET Nail

EXTERNAL USE

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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.

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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

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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

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Different types of iron used for pipes

• Galvanized• Cast• Ductile

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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

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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

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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.

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JOINING

• THREE METHODS• Compression Gaskets

• Hubless Joints

• Caulked Joints

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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

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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

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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

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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

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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

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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

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Thank you………