Chapter 2.

METALS AND PLASTICS

AJAIAIA SIIN IMINIMGiiiiirAAIR

INTRODUCTION

Metals are obtained from natural deposits (ores) in the

earth's crust. They are called primary when produced directly
from one ore and secondary when extracted from scrap.

2.4.1 TYPES OF METALS USED IN CONSTRUCTION

2.4.1.1 Cast Ironn

Cast iron is an alloy of carbon and iron. Cast iron contains

more than 1.5% of carbon. Specific gravity of iron is 7.2.
These are used in structural portions where there is compression
force and not bending tension etc. They are cheap and very
resistant to corrosion and extensively used in rainwater pipes,
cisterns etc. They are available upto 3m in length.

Cast iron can be melted and cast into various shapes

and machined. Structural elements like columns are made from

cast iron.

2.4.1.2 Steel
Dteel is also an alloy of iron and carbon. Certain alloying
also added to
Ements like copper, m a n g a n e s e , nickel etc. are
containing less than.
m a k e special steels. Steel is iron
of carbon. Nowadays guod steel which are strong in both
1.5% arbon.
Compression an tension a r e produced. Specific gravity of
and
Hteel is 7.8.

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 2.4.1.3 Aluminium

Aluminium are nowadays extensively used in buila:.

construction. Auminiurm is very light and resists dingatmosphes
corrosion extremely well. Specific gTAvity of alumina
is
ospheric .2.7.
Its tensile strength is abdut 200
N/mm. Compared to steel
strength weight ratio is very favourable for
use in its
constructin n.
Aluminium is alloyed with metals ike copper,
magnesiumim,
silicon, manganese as pure aluminium is very soft and ductil.
As the moduhus of elasticity of aluminium is less
compared
to steel i.e. 68,900 W/mm2 to 206, 700 N/mm2 its
deflection duue
to load will be 3 times than
more
steel.
2.4.1.4 Galvanized iron (G.I.)
Zinc is extracted from its principal ore zinc blende (Zns
by heating it in an electric furnace and condensing the
zinc vapour to metalic zinc.

Itsimportant property is that it resists corrosion.

In pure distilled water, zinc forms a loosely adherent film
o fof hydroxide.
This film dries in the presence of oxygen and carbon
dioxide of air to a film which is quite insoluable in rain
water.

This affords protection from further attack.

*This is the property that it is a good material for roof
and flashings.
This is the reason why galvanized iron (Gi, et are
more lasting than plain steel sheets.
Galvanizing of sheets like roof sheet is the process o
coating iron or steel with zinc as a protection agal
nst

corrosion.
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 2.4.1.5 Stainless Steei

Stainless steel is a general term given to certain alloys of

chromium and nickel.
iron,
This type of steel has high resistance of corrosion.

They are designated by the percentage of chromium and

nickel.
Ths 18- 8 stainless steel irkdicates 18% chromium and
8% nickel.

2.4.2 MARKET FORMS OF STEEL

The important mark t forms of steel used in
building
construction are

1. Steel bars of many shades and grades of

strength.
2. High tensile steel for prestressed concrete
works.
3. Various shapes of I, channel, angle, plates and other
rolled sections for structural fabrication.
4. Stainless steel for special uses.

2.4.3 STEEL FOR REINFORCED CONCRETE

Steel rods used for reinforced concrete
work should be of
specified tensile strength and they should
develop good bond
strengths with concrete. The different types of steel available
are mild steel, torsteel and TMT bars. Rods of
different diameter
are used for R.C. work. The prices depend on bar
Dasicprice is for 16 mm bars and sizes below 16 mm size, i.e. the
cost more
and sizes above 16 mm cost less.
Following are the types of bars used in
O construction works.
s .1. Plain round mild steel bars (MS bars)
Ribbed mild steel bars.
High strength deformed bars also called as HYSD
bars.
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 4. Thermo-mechanically treated (TMT) bars.

5. Cold twisted deformed bars (CTD)

6. Hard drawn steel wire fabric.

2.4.4 STEEL FOR PRESTRESSED CONCRETE

High tensile steel is used for prestressed concrete, Th

ultimate strength of steel will be about 1400 to 1700 N/mm2
High strength is produced by alloying steel with carbon.
manganese, silicon, ete,
The different forms of high tensile steel are bars, wires
and strands made up of wires.

2.4.5 HOT ROLLED STEEL SECTIONS

Steel used for fabrication of trusses, column, beams, etc.

of buildings is made by rolling hot steel ingots into various
shapes in specially designed rolling mills. Hot-rolled steel
sections are illustrated in fig.2.2. These are the sections that
are popularly available.

LIT Fig. 2.2

1. Angle sections

Various sizes of equal and unequal

are

angle section
available. They are mainly used for truss-work aandn d filler

joist floors.

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 2. Channel sections

BIS classifies channels as junior channels ( ISJC) light

medium channels (ISMC). They are used
(ISLC) and
ehannels
structures.
steel framed
widely for
3. I s e c t i o n s

These sections are called rolled steel joists or beams. They

are classified a s

a. Junior beams (ISJB)

b. Light beams (1SLB)

c. Medium beams (ISMB)

d. Wide flanged beams (ISWB) and

e. Heavy beams (ISHB)

They are used in multistoreyed buildings, bridge and other

places where bending stresses are the maximum. The materials
in the I sections are distributed so that the maximum material
exists where bending stresses are the maximum.
4. T sections

These sections are used to make built up sections and

roof girders.
5. Other rolled sections
Plain sheets, corrugated sheets, plates, expanded metal,
neet piles, rail sections, flats of varying width and thickness
are also rolled in
rolling mills.
2.4.6 COLD
FORMED LIGHT GAUGE SECTION

hese steel sections are structural members, cold formed

to the desired
shapes from carbon or alloy steel by press-brake

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 operations. The thickness of tihe member ranges from 0.3s
.38 w
6.35 mm. Some of the struci ural shopes available in the mar
ket
are as shown in fig.2.3.

CCLL0 Fig. 2.3

These sections have much higher strengths than hot.

rolled sections. As these sections are thinner we can
get more
length of the material for the same weight of steel. Hence an
n
economical desigm can be made.

2.4.7 PLASTICS

Introduction
All plastics are polymers of carbon compounds along with
other elements like hydrogen, nitrogen etc. They are
oxygen,
called plastics because their resins are capable of plastie
deformation when heat and pressure are applied on them. There
are more than 10,000 varieties of plastics.

2.4.8 CHARACTERISTICS AND USES OF PLASTICS

Characteristics of plastics
CC

1. It can be made in attractive colours. 2

2. It has good resistance against almost all
chemica
3. It has good dimensional
stability as with otne
engineering materials.
4. Many plastics are quite durable if
protected.
5. They are good insulators.
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 . They are easy to be used for fabrication.

7. They can take good finishes.

8. They are light in weight.

9. Easy to maintain.

10. Stable under low temperatures.

Uses of plastics
The typical uses of plastics in building are as follows:
1. Bath and sink units

2. Cistern ball floats

3. Corrugated and plain sheet:s

. ianates and moulding:
5. trial conduits and insulators
6. Lhting, fixtures

7. Water tanks

8. Pipes to carry water

9. Paints and varnishes

10. Floor tiles etc.

2.4.9 TYPES OF PLASTICS(1

ne following are the plastics which are used everyday and in
Construction works.
4.9.1 Thermoplastics
1.
Polyvinyl chloride (PVC)
2. Acrylics (Perspex)

3. Polycarbonate
4. Polyethane (Polythene)

5. Nylon

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 2.4.9.2 Thermosetting Plastics

6. Polyester (terylene)

7. Formnal

8. Casein

2.4.9.3 Thermoplastics
The above mentioned the sub-divisions under this
are

group of plastics. These plastic become soft when heated and

hard when cooled. Thus it is possible to shape and reshape
these plastics by heat and pressure as the process of softenine
and hardening may be repeated for an indefinite time unless
the heat is not so high causing chemical decomposition. The
main advantage is old scrap materials can be used again and
again.

2.4.9.4 Thermosetting Plastics

The above mentioned are the sub divisions under this

group of plastics. These plastics become rigid when moulded at
suitable pressure and temperature. This type of pla_tic passes
originally through thermo-plastic stage. When they are heated
in temperature range of 127°C to 177°C they set permanently
and further application of heat does not alter their form or

soften them. But at temperature of about 343°C, charring

Occurs.

The thermo setting plastics are soluble in alcohol anu

certain organic solvents, when they are in thermo plastic stage

This property is utilised for making paints and varnishes rom

these plastics.
re
These plastics are strong, durable and hard and a
in
available in various colours. They are mainly
m a i n l y used
us

engineering applications of plastics.

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 4.10 VARIOUS PRODU:TS

here are many viarietje8 o1 plastics and sorne

are

2.4.10.14lastie Pipes

Dalvt.hene and P.V,. pipes are

plastic pipes. They are
iahle from 15 to l5 mn. d1a meter and 6m long. They are
a
ointed by applying adhesive and Blupping one over the other.
The end of the pipes are o proportjoned that the end of one
nine can be slipped into the other. Polypropylen: 3nd

polyethylene are some of the plastic for pipe manufacture.

Advantages

1. Free from corrosion.

2. 1t is cheaper.
3. Free from damage due to freezing and thawing of
water in closed pipes.
4. Highly resistant to acidic waters.
5. Light in weight, easy to handle and transport.
6. Painting, bending and installation are easy.
7. Good electric insulators.
8. Durable and unaffected by age, sunlight or weather.

9. Have adequate strength and are resistant to shock.

10. Small size pipes are available and hence easy to

transport.
Disadvantages
.
Have low resistance to heat.
2.
Co-efficient of expansion 1s hig.
3. Some type ofplastics impart taste and smell to water
4.
Difficult to obtain plastic pipes of uniform composito
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Uses
1. Plastic pipes are extensively used in water suhnl.y

caring 1ater.
schemes for

used for sewers to carry sewap

2. Now-a-days they a r e age
replacing clay pipes.

8. Used for the insulation

of electric cables.

4. Acid resistant plastic tubes are used in chemical

industries.
5. They are used as drainage pipes replacing cemeent

concrete pipes.

2.4.10.2 Plastic Doors and Windows

One of the materials used for doors and windows are

plastics.Plastic doors and windows are made of P.V.C. (Poly

Vinyl chloride)
P.V.C. doors and windows are maintenance free and they
will not rust, corrode, or not contrary to other windows made

with traditional frame. Some of the specially designed P.V.C.

doors and windows will never be affected by ultra-violet rays
or acid main. They are available in standard sizes as that o
wooden doors and also in non-standard dimensions as per tne

o
user's requirement. They can be easily swan and cut in
as
required dimension. They available for purposes such
are

sliders, casement, architectural works etc.

Advantages
e to
1. PVC doors and windows have a high resistanc
impact, weathering and fire.
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 aTheyprovide highest standard for quality, durabiiit

and efficiency.

8. Since they are fungal resistant, they require neither

painting nor varnishing.

to moisture.
4. They are impervious
The "cell design" of P.V.C. doors and windows reduce
heat loss and conductivity, making them a great
insulators.

6. They can meet all demands. All desires shapes are

available in a variety of colours and with different
finishes.
7. Their smooth surface does not need any special care
or maintenance.

8. They are so flexible so that we can produce doors and

windows in a large variety of type and size with
different opening ability.
9. They are light in weight and hence easy to transport.

10. Installation of plastic doors and windows is much

simple.
Disadvantages
.P.V.C. doors and windows can be used for only

unimportant purpose.
2. They not safe.
are

3 There is a possibility of cracks while driving screws

during installation.
15 not
he
appearance of plastic doors and windows
Pca$ant or decorative as wooden ones.

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Uses
1. P.V.C. doors and windows are used in gardens.

2. They are used in wardrobes.

3. They are ideal for bathrooms and toilets.

4. The ornamental PVC doors and windows are us

in guest houses, garages etC.

5. Plastic foldings doors and sliding doors finds it

application in offices, garages, etc.
6. Plastic doors and windows are recommended fr
regions subjected to heavy rain and humid climate.
7. They are used in low cost buildings.

2.4.10.3 Plastic Water Tanks

Plastic water tanks has now completely replaced the RCC

water tanks. Steel tanks have a problem of rusting and
corrosion plastic water tanks will not rust and corrode
polyethylene and PC tanks find their extensive applications
in water storage. They are available in various shape viz
cylindrical vertical tanks, loft tanks, cylindrical and horizontal
tanks (open top and closed top) rectangular tanks and square
tanks. All the above shape of plastie water tanks are available
in various sizes as per the demand. They are available in
various colours white, black and blue. Generally the capacity
of plastic water tanks are 500 liters, 750 liters, 1000 liters and
2000 liters.

Advantages
1. Plastic water tanks are unbreakable and 10nE

lasting.
2. They provide complete leak proof and 10
maintenance frce.

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 . They are available in single layer (inside and outside
black) and double layer (inside white and outside
black.)
4. They are available in various sizes and shapes.

5. They are light in weight and hence easy to transport.

6. They are finished smooth inside and outside.

7. They are provided with covers to prevent pollution.

8. The tank material is translucent for visualizing

content level.

9. They are resistant to chemical.

Disadvantages
1. More space is needed for tanks storing more water.

2. Some types of plastic tanks impart taste and smell

to water.

3. Not available in variety of colours.

4. The water inside the tank gets heated up during

summer seasons.

Uses

1. Plastic tanks are used to store water-petroleum oils

and chemicals.

2. Plastic tanks are used for garbage disposal.

3. Now-a-days plastic tanks are used as septic tanks.

4. Plastic tanks are used in dewatering, digester units

and distiiling purpose.

. Plastic water tanks are used in all types of building

ike houses, apartments, office building, industries,

schools, halls etc.

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2.4.11 ADVANTAGE OF PLASTICS

1. They are very light in weight and therefor.

handling is easy.
erefore,
2. Vermins, rot and fungus do not attack plasties.
3. They have high resistance to corrosion

4. They do not require painting and polishing.

5. Some plastics are very hard like steels.

6. All operations like sawing, drilling. punching

welding etc, can be easily done on plastics.
7. They have good electrical and thermal
insulation
properties.

8. Some plastics are highly transparent and can be

used as optical lenses.

9. They can be manufactured in a wide range of

plastering colours.
10. Some plastics absorb shocks better than steel.
2.4.12 DISADVANTAGES OF PLASTICS
1. High cost

2. High co-efficient of expansion

3. Combustibility

UPVC pipes and fittings

When PVC is iser
compounded with rubber stabilise
filters etc.
*It becomes
less brittle and more
temperature resist
tant.

2.38
 called plasticizing of pipes,
This p r o c e s s
is

A Dlasticisers are called pipes with less

unplasticized PVC ni
or UPVC or rigid plastic pipes.

11PVC pipes can be used in all cases where we have to

carry at ordinary temperatures.

Ror hot water systems we need special pipes.

2.4.13 ASBESTOS

The cement is mixed with about 15

percent of asbestos
hres and the paste so formed 1s
pressed under rollers with
ronves on teeth. Thus the sheets are
commonly known as the
asbestos cement (A.C.) sheets, with a series of waves or
corrugation are formed. The corrugation help to increase
strength and rigidity and they permit the easy flow of rain
water.

2.4.14 USES OF ASBESTOs

1. They cheap, fire-resisting, light in
are
weight,
strong, tough, sound proof,
impervious and durable.
2. They do not
require any protective paint and canuot
be eaten away
by the vermins.
3. These sheets can be sawn and
4.
scren.
Maintenance cost is practically nil if not
.
damaged.
Neat and
pleasing appearance can be achievecd.
6. Not affected
by acids and fumes.
1. Not
much affected by
8. It is temperature.
sound
proof
9. It
does not
10. They are
corrode
e
mainly used for factories, workshops
garages, big halls etc.
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