Author: Emily

Efficient transport is essential for our modern way of life and steel plays a key role in providing strong, safe, and sustainable transport solutions. Steel facilitates the transport of goods and our mobility, whether it’s by bicycles, cars, buses, trains, etc or in the networks that support them, steel is crucial to every mode of transport. In this article, we’ll be looking at exactly how steel is used in the transport industry and the benefits of it. 

How steel is used in transport 

Steel is well-suited to the transport sector because it is strong, durable (meaning better safety in case of a collision), lightweight, affordable, UV-resistant, and fully recyclable. Additionally, regularly reinforced concrete roadways have a steel rebar to structurally support them and help to improve fuel efficiency for bigger vehicles. 

Design and development innovations in new high-strength steels have also played an important part in boosting the efficiency of a lot of these transport modes whilst significantly reducing the lifecycle of greenhouse gas (GHG) emissions. Including automotive, roughly 16% of steel produced around the world is used to meet society’s transport needs. Steel is also vital to relevant infrastructures such as roads, bridges, ports, stations, airports, and fuelling. Some of the most notable applications include: 

Ships and shipping containers 

Shipbuilding normally requires structural steel fabricators to make plates for the hulls. The modern steel plates of today have much higher tensile strengths than they did in the past, meaning they are a lot better placed to efficient construction of large container ships. A specific type of plate is available with a built-in resistance to corrosion, which is great for building oil tankers. 

Steel fabrication like this make it possible to create much lighter vessels than there has been before, or vessels with more capacity of the same weight, offering important opportunities to save on fuel consumption and CO2. To put this into context, steel ships transport 90% of the world’s cargo, and around 17 million containers of various types make up the global container fleet, most of which are made of steel.

Trains and rail cars 

Rail transport utilises steel in the trains and for rails and infrastructure. For short or medium-length journeys, rail minimises travel times and CO2 emissions per passenger kilometre in comparison to almost all other types of transport.  

Steel accounts for up to 15% of the mass of high-speed trains and is vital. The main steel parts of these trains are bogies (the structure underneath the trains like wheels, axels, bearings, and motors). Also, freight or goods wagons are made almost completely from steel. 

Aeroplanes 

Steel is an integral part of engines and landing gear. 

What are the benefits of structural steel? 

Structural steel has a wide range of benefits which make it lend so well to the transport industry. These are: 

• Contains recycled steel and can be recycled continuously 

• Strong and safe which is key to busy transport services 

• Durable and long-lasting, saving time and energy as it won’t need replacing on a regular basis 

• Cost efficient 

• Can be easily remanufactured if needed 

• Reusable rail tracks

Where can I find structural steel fabricators near me? 

At FEM, our family-run team of structural steel fabricators have extensive experience and skills to create bespoke metal products that fit the exact requirements our clients need. To discuss your steel fabrication project needs, contact us today. 

If you need to carry out a job that involves lifting or moving big, heavy objects or fragile loads, investing in a load spreader beam or a lifting beam can make difference to the efficiency and safety of the operation. Both types of beams share the same goal of distributing the weight of the load to make it more stable, but they do so in different ways. In this guide, we’ll be looking at the difference between the two beams and the circumstances in which each one would be used. 

What is a spreader beam and how is it used?

A spreader beam evenly spreads the weight of a load over two or more pick points with the support of two slings that rig the beam to the hook. These beams have two attachment points on the top, allowing for a 45–60-degree angle to the crane hook and two equally spaced lower pick points. 

The extra rigging at the top alters the forces that are applied to the spreader beam. Due to the lift forces travelling along the vertical bottom rigging, and then moving to the inward-angled top rigging, forces that are put on the beam are compressive instead of bending forces. 

Spreader beams are 3-4 times lighter and so cheaper than a lifting beam with the same capacity. Compressive forces are simpler for the beam to handle than bending forces applied to a lifting beam. This means they are often used to carry very wide or heavy loads. 

What is a lifting beam and how is it used? 

A lifting beam is a below-the-hook piece of lifting machinery that is designed to offer extra pick points for loads where one pick point won’t be enough for load stability. To balance the lift forces throughout the beam, they usually have one attachment point on the top of the beam and two or more evenly distributed pick points on the bottom. 

Lift beams attach directly to the hook, they don’t require any top rigging. This makes them especially useful in cases where there is limited headroom like inside a building or underneath a structure. 

On either end, lifting beams help to produce similar pulling forces between the top centre hook and the bottom hooks. Forces move upwards through the bottom slings then throughout the full length of the beam. This force results in a bending effect a lot like a stick when bent over a knee.  

To get past the bending forces, lifting beam manufacturers typically need to make sure the beams are bigger, stronger, and heavier than spreader beams. Therefore, they are more expensive per foot and per ton of capacity.

What are the similarities and differences between a spreader and lifting beam? 

Both these types of lifting devices are very similar as their main goals are still the same and it’s easy to get them confused for one another. Also, the LEEA definition of the beams states that a lot of designs are a hybrid of the two systems and the equipment as a whole, including spreaders and hybrids are collectively called lifting beams, which doesn’t help with the confusion. This is why the differences between spreader and lifting beams are so important. 

The design of each of these lifting solutions influences how force is generated and used to lift heavy loads. A lifting beam absorbs the majority of the stress from the load, whereas the spreader beam shares that stress with the slings. The lifting beam is easier to use as it doesn’t need as much overhand clearance or rigging, but it is much more costly and less stable than spreader beams. 

How do I choose between a spreader beam and lifting beam? 

When looking at lifting beams and spreaders for your project and deciding on the right one, you will want to ask yourself: 

• What am I lifting? 
• How am I lifting it? 
• What is the size and weight of the load? 

• Where is the load being lifted to? 

 

It is important to think about how heavy the object being lifted is and where the lifting points are situated. Spreader beams will be more effective for loads with wide spans. However, if the length of the load needs support throughout the lift, then a lifting beam would be the better choice as a spreader beam would not be able to support loads in the centre. 

No matter which type of beam you choose for your project it is important to go to a high-quality manufacturer to produce a bespoke lifting beam for you. Bespoke metal fabrication for load lifting beams is essential to ensure the project runs smoothly and there are no risks to the health and safety of workers. 

Where can I find steel fabricators near me?

If you’re looking for either a spreader beam or a lifting beam, or other types of steel fabrication in Sheffield, our team at FEM can help. We offer professional bespoke fabrication services as each project, business, and industry is unique and the requirements for your steel fabrication will be unique too. Contact us today to discuss your metal fabrication needs. 

Using steel is various projects has a lot of benefits. As well as being a key aesthetic elements in modern architecture and design, and its strength and versatility in the construction industry, working with steel has environmental advantages too. Easily sustainable and recyclable, steel is an important element of the cyclic economy that humanity needs – one that reuses rather than always producing from scratch. In this guide, we’ll be looking at the environmental benefits of steel and why steel fabrication is useful. 

 

Steel is recyclable 

One of the main reasons why steel is thought to be environmentally friendly is how easy it is to recycle. Steel is reported to be the most recycled material in the world and its metallurgic properties ensure that when it is recycled, its quality doesn’t deteriorate in any way. This means that it can be melted down and reused over and over without being negatively impacted at all. 

The recyclable nature of steel significantly reduces the environmental effect of making it new from raw materials. For example, producing steel cans from recycled steel uses 75% less energy than manufacturing them from raw materials. Recycling 1kg of steel prevents 2kg of greenhouse gases from getting into the atmosphere and stops products from being dumped in landfills. This allows the material to be reprocessed which in turn conserves precious and costly raw materials. 

 

Less waste 

A big factor that makes working with wood and other similar materials so damaging to the environment is the amount of waste that comes from unusable offcuts. Bespoke steel fabrications are custom-made by professional engineers like us, which means every project is made to order all the way down to the smallest of details. This ensures wastage is pretty much non-existent, while the waste that builds up with wood also needs removing in some capacity, (e.g., removing offcuts in a truck or using water) putting more strain on the environment. 

 

Saving energy 

Constructing a steel framed house, for example, is beneficial to your energy usage and bills all year round. Steel’s natural strength means it can hold thicker and more efficient insulation. Therefore, when winter comes around you will use a lot less energy trying to keep your home warm with heating and boilers. Equally during the summer, steel framed buildings offer better air quality and minimise humidity, so you won’t be relying on dehumidifiers and air purifiers, further lowering both your energy costs and your carbon footprint. Saving energy and reducing each building’s carbon footprint is an essential step in becoming more environmentally friendly and helping with the fight against climate change. 

 

Quick construction 

The highly efficient nature of building with structural steel means the construction process as a whole is simplified. A quicker construction rate and less manpower minimises overall resource consumption on each project. Pre-engineered steel buildings are lighter in weight compared to concrete or wood, so the product is easier to handle. Also, steel structures don’t need as much space as ones comprised of masonry, concrete, or wood. It might not seem like it will make a big difference but when it comes to conserving the environment, every little bit helps. 

 

Durable and long-lasting 

Once you build with steel, you won’t have to worry about damage or having to build the structure again after a few years. Steel is designed to last and can withstand whatever the weather throws at it. It won’t crack, warp, twist, split, or rot, and it will resist rust and corrosion too. It’s ability to last a long time reduces the impact of raw material consumption and the widespread felling on trees which is extremely damaging to the environment. 

 

Why should steel be used in fabrication? 

The environmental benefits alone are enough of a reason as to why steel should be used in fabrication, but there are also a lot of other advantages too like low cost, flexibility in customisation, visual aesthetic and more. 

If you need steel fabrication in Sheffield, FEM can help. Contact our team of experienced engineers to discuss your project needs today and experiences our cutting-edge steel fabrication services first hand.

Aluminium and the aerospace industry have a close relationship that goes way back. From engines to propellers, fuselage frames to fuel tanks, where there’s aviation you will find aluminium fabrication. The industry benefits greatly from the many advantages the metal provides to ensure aircrafts, helicopters, and spacecrafts can all operate safely and efficiently.  

It has become so integral in fact, that around 75-80% of a modern aircraft is made up of aluminium. In this article, we’ll be exploring the history of aluminium in the aerospace industry as well as the useful benefits the metal brings to the table. 

History of aluminium in aerospace

The Wright brothers

On 17th December 1903, the Wright brothers made history with the first human flight using their airplane, the Wright Flyer. During this time, automobile engines were very heavy and didn’t have enough power to achieve take off. So, the Wright brothers created their own special engine in which the cylinder and other elements were constructed from aluminium. 

Given that aluminium was not easily available and incredibly expensive, the plane itself was made from Sitka spruce and bamboo frame covered with canvas. It would take more than a decade for aluminium to become more widely used in the industry. 

World War 1

Wooden aircrafts got the ball rolling in the early days of aviation, but during World War 1, lightweight aluminium started to replace wood as the key part of aerospace manufacture. In 1915, German aircraft designer Hugo Junkers built the first ever full metal aircraft; the Junkers J1 monoplane. Its fuselage was made up of an aluminium alloy that utilised copper, magnesium, and manganese. 

The golden age of aviation 

The years between WW1 and WW2 were known as the golden age of aviation. Throughout the 1920s, Americans and Europeans were competing in airplane racing, which resulted in innovations in aircraft design and performance. Streamlined monoplanes replaced clunky biplanes and there was shift towards all-metal frames using aluminium alloys.

In 1925, the Ford Motor Company branched out into the airline industry with Henry Ford designing the 4-AT, three-engine, fully metal plane using corrugated aluminium. The plane was nickname “The Tin Goose” and became very popular with passengers and airline operators. By the mid-1930s, a new streamlined aircraft shape came to the forefront. Planes built during this time had tightly cowled multiple engines, a retracting landing gear, variable-pitch propellers, and stressed-skin aluminium sheet fabrication. 

World War 2

During WW2, aluminium was required for multiple military applications, especially construction of aircraft frames which led to a huge increase in aluminium production. The demand for aluminium was so high that in 1942, WOR-NYC broadcast a radio show called “Aluminium for Defence” which aimed to encourage Americans to contribute any scrap aluminium for the war effort. Aluminium recycling was pushed, and “Tinfoil Drives” offered free movie tickets in exchange for balls of aluminium foil. 

From July 1940 to August 1945, the US produced an impressive 296,000 aircrafts and over half of these were made mostly from aluminium. The American aerospace industry could meet the needs of not only their own military but also their allies, including Britain. At the height of production in 1944, American aircraft plants were building 11 planes an hour. By the end of WW2, the US had the most powerful air force in the world. 

The modern day 

Since the end of the war, aluminium has become an essential part of aircraft production. Whilst the composition of aluminium alloys has got better with time, the benefits of the metal have always been the same. As a result, aluminium is used extensively in modern aircraft manufacture. 

The Concorde, which flew passengers at more than twice the speed of sound for 27 years, was made with an aluminium skin. The Boeing 737, the best-selling jet commercial airliner is made up of 80% aluminium. Modern day planes use aluminium in the fuselage, wing panes, the rudder, exhaust pipes, the door and floors, seats, engine turbines, and cockpit instrumentation. 

Space exploration

Aluminium is not just crucial to airplanes but also to spacecraft as well where low weight combined with maximum strength is even more important. In 1957, the Soviet Union launched the first satellite, Sputnik 1, which was constructed using an aluminium alloy. 

All modern spacecrafts are made up of 50-90% aluminium alloy. These alloys have been used heavily on the Apollo spacecraft, the Skylab space station, and the International Space Station. Aluminium continues to be essential for the Orion spacecraft which is currently under development. The craft aims to enable human exploration of asteroids and Mars and the manufacturer, Lockheed Martin, is using an aluminium-lithium alloy for Orion’s main structural elements. 

The benefits of aluminium

With many beneficial features, aluminium was an obvious choice for aircraft manufacturing. Wood was originally used but it tends to rot and splinter without extensive maintenance. Similarly, steel is stronger than aluminium, but it is also much heavier. Therefore, steel is only used in cases when extremely high strength is required like on landing gears or particularly high-speed planes. Some examples of the benefits of aluminium include: 

• Lightweight- using aluminium significantly reduces the weight of an aircraft. Weighing about a third less than steel, it enables an aircraft to either carry more weight or have better fuel efficiency. 
• High strength- the high level of strength aluminium has means it can replace heavier metals without losing any strength from the other metals, while benefitting from its lighter weight too. Also, load-bearing structures can maximise aluminium’s strength to make aircraft manufacturing more reliable and cost-efficient. 
• Corrosion resistance- corrosion can be very dangerous for an aircraft and its passengers. Aluminium is naturally highly resistant to corrosion and chemical environments, meaning it is even more valuable for aircrafts operating in corrosive maritime environments. 

 

Using aluminium in fabrication 

It is thanks to these impressive benefits that aluminium is so sought-after, not just for use in the aerospace industry but many other industries, making aluminium fabrication an essential service. Bespoke fabrication using aluminium allows products to be made for clients that will be strong, lightweight, durable, resistant to anything, and long-lasting, whilst also meeting the requirements of the project. 

If you’re looking for high-quality, professional, and experienced aluminium fabrication in Sheffield, contact our team at FEM today and we can make your bespoke metal product needs a reality. 

Metal finishing is the last, but very important step in the metal fabrication process, preparing the products to be used. On their own, a lot of metals can’t perform long term the way we would want them to. This is where finishes come in.  

The process allows new properties to be added to the metals, for example, electrical, chemical, heat, and corrosion resistance. Additionally, metal finishing improves visual aesthetics and offers an extra level of durability. The type of metal finish needed, depends on the intended use for the product. 

Choosing the right metal finish  

There are a number of factors to consider when selecting a finishing method for your metal work. The term metal finishing includes more than one execution process. This means there are multiple ways to achieve the metal finish required. Some key questions to think about when choosing the right finish include: 

• Which finishing process works best with your products intended use? 
• Is the metal finishing service right for the materials used in your project? 
• Can the finishing technique keep up with the demands of your production speed? 
• Is the metal finish the most cost-effective solution without affecting the quality of the end product? 

What are some examples of metal finishings? 

Electroplating 

Also referred to as metal plating, electroplating is one of the most common metal finishing services available. Electroplating involves a thin layer of metal being coated onto a substrate. This is normally because the original part doesn’t have the properties to work on its own.  

So, a suitable metal coating is applied to improve the performance of the product. The electroplating technique offers several benefits that will vary depending on the type of metal coating used. Some examples include, added strength, durability, corrosion resistance, and visual appeal, to name a few. 

Galvanising 

Galvanising is the process of adding a protective zinc coating to a metal. The layer of zinc is applied by dipping the product into a bath of zinc solution. It is a process that is best suited to products made of steel and therefore popular with steel fabricators.  

This is because when molten, zinc reacts with steel and sticks to it to create a protective seal. Even if some of the metal is damaged, the seal is strong enough to protect the other areas. Zinc coating is a very cost-effective solution that extends the life expectancy of steel products. 

Powder coating 

Powder coating is a great option for products that require the best visual aesthetic. It is double the thickness of paint which is why it is considered to be a much more durable solution for finishing metals. The process involves melting the powder and applying it to surfaces in a range of colours and textures.  

Powder coating is the best choice for parts that have regular movement as it effortlessly yields when added to the material. Products that have powder coating are less likely to chip but unlike paint, they are more difficult to touch up. 

Anodising 

Even though the process of anodising is similar to electroplating, it is actually the opposite. Electroplating can be carried out on several different metals, whereas anodising is specifically suited to aluminium. Also, anodising changes the molecular composition of the product’s surface and offers key benefits.  

These include reducing wear and tear, boosting resistance to corrosion, and forming a stronger finish. This metal finish is colourless, but dyes can be added if a visual appeal is needed for the product. 

Conclusion 

There are many different metal finishes that will be better suited to different projects than others. If you’re looking for metal fabrication in Sheffield, contact our friendly team at FEM today to discuss your requirements. 

 

Contact Us

  

Cutting is one of the most basic and widely used processes in the metal fabrication industry. Over time as technology has advanced, laser cutting has become the go-to technology to carry out cutting tasks because it has a number of advantages over other methods. However, it does have a few disadvantages too. In this article, we’ll be discussing both the pros and the cons of laser cutting so you can get a balanced understanding of the process if you need fabrication in Sheffield. 

The pros of laser cutting 

Engineers often prefer to use laser cutting due to the long list of pros it offers. Let’s look at some of the most important ones below: 

Flexibility 

Laser cutting doesn’t need tools to be exchanged for each separate cut. The same setting can cut multiple different shapes within the same material thickness, saving a lot of time and energy as well as allowing you to be flexible. Also, the intricate cuts don’t cause any issues. 

Precision 

Accuracy and precision are two of the main advantages of laser cutting in comparison to other thermal cutting processes. An accuracy of +/-0.1mm gives you the chance to achieve a high level of precision without requiring any after treatment. In a lot of cases, working to such a high standard means no extra tolerances are necessary. 

Easy repeatability 

+/-0.05mm means parts can be cut accurately that need to be pretty much exact copies of each other. 

Quick process 

Laser cutting is much faster than traditional methods of mechanical cutting, especially when it comes to completing more complicated cuts and projects. In comparison to other thermal cutting methods such as plasma or flame cutting, laser is the front runner in terms of speed, but only up to a certain thickness, which is about 10mm. Although, the exact advantage point will come down to the power of the laser cutter. 

Automation 

The process requires little manpower because modern laser cutting machinery is designed to be easily automated. Experienced machine operators like our expert team of local metal fabricators still play a key role in the overall quality.  

However, the speed of the cutter and little demand for manual labour ensure lower costs in comparison to other cutting methods. Some machines even have feeding systems alongside follow-up conveyors. Naturally, these setups mean a higher priced laser cutting machine. 

Quality 

With the correct setup, laser cutters will only leave a small burr and most of the time it doesn’t need removing. However, this will depend on the material, its thickness, and a few other factors. Another benefit is having a small heat affected zone. This means that as the microstructure along the HAZ changes, a smaller HAZ area leads to more predictable and dependable parts. 

Contactless cutting 

During the laser cutting process, only the beam touches the material. So, there is no friction from the machinery that could damage the tools, which will save you a lot of time and money on replacing tools further down the line.

Versatility 

This is one of the most important pros of laser cutting, its versatility can be demonstrated in two key ways. Firstly, laser cutting can be used for a wide range of different materials. Examples include various metals, MDF, acrylic, wood, paper, etc. One machine can be programmed to carry out different jobs, but the ability of cutting some of the materials will come down to the power of your machine. 

A lot of laser cutters aren’t just used for cutting. They can also be used for laser marking which has many applications when creating everyday products. Finally, the technology is appropriate for use in a variety of profiles. Tube laser cutting for example, can carry out the process on anything from box sections to open channels. 

The cons of laser cutting 

Despite it being used to make parts for almost every industry, laser cutting does have some drawbacks that need to be considered. 

High level of expertise needed 

As previously mentioned, a specialist operator is needed to ensure the most is made of the laser cutter’s potential. The right configuration will guarantee the cutting quality is always up to the high standard that is expected from this modern technology. 

Metal thickness limitations 

When looking at laser cutting in relation to other thermal cutting methods, it’s not the best option for cutting very thick plates. The largest thickness that will be suitable depends on the machinery available and the skills on hand. As a rough guide, metal is often laser cut up to 15 or 20mm. 

Upfront costs 

Laser cutting machines are extremely expensive to purchase, they can be double the cost of waterjet or plasma cutters. Even though the running costs and high efficiency do make up for it in the long run, the initial investment in laser cutting machinery is very big. 

Emission of fumes 

As we’ve seen, one of the benefits of laser cutting is its versatility in being able to cut different materials. However, the thermal cutting method often leads to emitted gases and dangerous fumes being dispersed. This is especially relevant when cutting plastic. Therefore, a high quality but normally expensive ventilation system will be needed in order to have a safe working environment.

Metal Fabrication in Sheffield

Despite a few minor downsides, it’s clear to see that laser cutting has more pros and is highly beneficial to the metal fabrication industry. If you’re looking for metal fabrication in Sheffield, contact the team at FEM today.

Contact Us

 

 

The construction industry has significantly evolved over the years, and with it, several new and improved methods that make the industry safer and more efficient, one of which is steel fabrication. If you consider different types of large buildings like skyscrapers, warehouses, and shopping centres for instance, almost all elements of their construction involve structural steel. Steel-framed structures are also used extensively across a number of different types of construction projects such as garages, residential buildings, and short-term temporary structures. 

Steel fabrication is integral to creating various parts and products with different qualities for different applications. There can be no denying that structural steelwork has been the top choice for the majority of engineers, builders, contractors, and structural steel fabricators. A lot of industries depend on bespoke steel fabrication in one way or another because of its reliability, quality, flexibility, cost-effectiveness, and sustainability.

Structural steelwork and fabrication 

Two of the hardest industries in the world today are architectural engineering and construction. This is largely down to complex and demanding designs where the finished product needs to have the highest integrity and withstand any type of conditions. Due to the nature of these sectors, there is high demand for materials that are exceptionally strong and durable. 

A large amount of steel fabrication is done in cold, rolled, mild, and stainless steel. Of these, stainless steel is the most commonly used thanks to its strength, high level of weather resistance, and aesthetic appearance, particularly brushed stainless steel. Modern advancements in technology, machinery, and computer-aided design (CAD) software have taken the steel fabrication process to the next level. It now includes using other manufacturing practices such as bending, cutting, brazing, grinding, and welding. 

Where is steel fabrication most commonly used in construction?

Steel fabrication can be found in multiple different parts of the construction industry. Some examples of these include: 

• High-rise buildings- thanks to its light weight, strength, and quicker construction 

• Industrial buildings- due to its ability to manufacture large spaces at a low price 
• Warehouse buildings- again because of making big areas at lower costs 
• Residential buildings- with a technique known as light gauge steel construction 
• Temporary structures- because they can be set up and taken away quickly and easily 

What are the benefits of steel fabrication in construction? 

• Ensures structurally sound products that are made to strict specifications and tolerances. 
• Energy efficient and additional material leftover from the process is fully recyclable. 
• The strength of steel means it won’t warp, twist, buckle, or bend, so it will be long-lasting, and any modifications can easily be made if needed. 
• It’s cost effective and pricing stays fairly consistent. 

• It allows for better quality construction and less maintenance and repairs will be needed on the finished product. 

 As well as safety and economic benefits, steel fabrication in construction also provides important environmental and social benefits. This is because steel lasts a very long time, it is reusable, and it can be repeatedly recycled without compromising its properties. Steel framed buildings, as mentioned briefly above, can also be impressively energy efficient when used in conjunction with other enhancements. 

Steel fabrication in construction needs industry experts 

Bespoke steel fabrication is a skilled, specialist process that requires cutting, shaping, or moulding metals to create the final product. Therefore, it’s important that anyone needing steel fabrication in the construction industry goes to an engineering company with extensive industry experience, professionally trained staff, and cutting-edge machinery. 

With that in mind, if you’re looking for high quality steel fabrication in Sheffield, contact our team at FEM today. Our family-run bespoke fabrication service ensures your exact specifications are met to the highest possible standard, quickly and efficiently and competitively priced. 

  Contact Us

Sheet metal is metal that is manufactured into thin, flat pieces of various thicknesses. It is often used in sheet metal fabrication processes to create products for a number of different sectors. Sheet metal can be made from several metals and metal alloys, which we will be exploring in this article as well as how they’re used. 

The different types of sheet metal 

Aluminium 

Due to its many benefits, such as large supply, low cost, ease of fabrication, good strength-to-weight ratio, good electrical and thermal conductivity, corrosion resistance, and high recyclability, aluminium is a popular choice for various applications. Some of the ways aluminium sheet fabrication is used includes for automotive parts, electrical devices, and cooking vessels. 

Aluminised steel

Aluminised steel is created by coating carbon steel with an aluminium-silicon alloy, which forms a material that blends the strength of carbon steel with the impressive corrosion resistance of aluminium. Sheets of aluminised steel are used for products designed to withstand high temperature or corrosive environments including cooking implements and kitchen appliances. 

Carbon steel

Carbon steel is a steel alloy that is partly made up of carbon (up to 2.1%). As the carbon content is increased, the material becomes stronger and harder after heat treatment, but less ductile. Carbon steel is often used in architectural sheet metal fabrication and creates a lot of products in both the industrial and consumer markets. 

Copper 

When compared to aluminium which has good electrical and thermal conductivity, copper is even better. However, it is also typically more expensive. The most common items made from copper include rain gutters, doors, roofs, and heat sinks.

Galvanised steel 

Like with aluminised steel, galvanised steel is produced by costing steel with zinc to make it more resistant to corrosion (this is done by hot dipping). Sheets of galvanised steel are often used to make the bodies of automobiles, water pipes, and several construction elements such as staircases, roofs, and fences.

Galvalume 

Galvalume is a process of coating steel with an alloy of aluminium, zinc, and silicon, which makes the steel more durable and resistant to corrosion than galvanised steel. As a result of the significantly improved corrosion resistance, galvalume sheets are heavily used in outdoor applications like on roofs that are consistently exposed to different weather elements.

High strength steel 

You will usually find high strength steel being used for military armour plates. The material is created by alloying steel with a range of elements such as carbon, manganese, and copper to increase its hardness.

Hot rolled steel 

In comparison to cold rolled steel, hot rolled steel is a lot cheaper to make. It is usually used in structural applications like automotive body parts.

Stainless steel 

Stainless steel is an alloy of steel with a minimum of 11% chromium and less than 1.2% carbon. The material has many benefits to offer like a high level of corrosion resistance, fire and heat resistance, strength-to-weight ratio, and easy manufacturability. Stainless steel sheet fabrication often produces kitchen vessels, storage tanks for chemicals, and components for food processing machinery.

Titanium 

Titanium has multiple beneficial metallurgical traits that make it appropriate for a broad range of industrial applications. Even though it is mostly used for its high strength-to-weight ratio and resistance to corrosion, it also has the added advantages of durability, being easily recyclable, and biocompatibility. Common uses for titanium include aviation parts, construction elements, and medical equipment.

Custom sheet metal fabrication at FEM 

If you find yourself searching for ‘sheet metal fabrication near me’ you’ve landed in the right place. At FEM we have over 45 years of working in fabrication with our team being specialists in mild steel, steel, aluminium, and stainless steel fabrication. We pride ourselves on always providing the highest standard of fabrication services and products for our clients. Contact us today to discuss your project needs and see how we can help you with our sheet metal fabrication service. 

Contact Us

Manufacturing and fabrication are industrial terms relating to the process of production or construction. People often compare manufacturing vs fabrication like they need to choose between them, but in a lot of cases they work together. In this guide we’ll be looking at the meaning of both manufacturing and fabrication within industrial processes. 

What is involved in fabrication? 

Fabrication is a method of constructing products by mixing typically standardised parts using one or more individual procedures. For example, steel fabrication is the creation of metal structures using multiple different processes like cutting, bending, and assembling. 

Metal fabrication will mostly form a complete assembly made from smaller sub-assemblies to use with readily available standard sections. This is done with CAD (computer-aided designs) that are programmed with CNC (computer numerical control) technology which directly communicates with the machinery is on the factory floor. 

By using these technologies, production quality standards are increased, and better-quality assemblies are made. This makes for a more accurate and quicker steel erection time on site, which is essential in high volume production, lowering the cost for customers though maximised material utilisation and faster assembly times. 

Our team at FEM have extensive experience of fabrication in Sheffield which ensures the highest quality within all our projects, giving our customers products that are durable and have longevity. 

What is manufacturing? 

A manufacturing process involves converting raw materials into a finished product. Basically, it’s making something from start to finish. The manufacturing sector includes large scale production using machines, tools, and chemical/biological processing.  

It is the stages that raw materials need to undergo before being deemed a final product. There are a range of different industries that fall into this category such as: 

• Apparel 
• Chemicals 
• Electronics and electrical equipment 
• Fabricated metal 
• Food and kindred 
• Leather 
• Lumber and wood 
• Petroleum refining 
• Printing and publishing 

Comparing manufacturing and fabrication 

Manufacturing is about making a complete product to be sold to consumers using either prefabricated parts or raw materials. Normally, the production process uses machinery, assembly lines, and skilled labour. There are five general categories when it comes to manufacturing: 

• Repetitive- the same product is created all the time 
• Job shop- an open system without assembly lines, this strategy is useful for specialised or custom-made products 
• Discrete- this might follow the assembly or production line method, but the processes for making them vary significantly 
• Continuous- the nature of the product being made is regularly in demand and needs continuous movement 
• Batch- products are manufactured in specific groups within a restricted timeframe. Contract manufacturing can be part of this method because typically the contractor is producing quantities of unique products for various companies 

Fabrication involves building a product to be used by manufacturers, not consumers. Fabricators work to process raw materials or refine parts of them, so they are suitable for assembly. The options are practically limitless, but some of the most common methods of fabrication include: 

• Cutting/punching 
• Welding 
• Folding 
• Machining 
• Shearing 
• Stamping 

The main difference between manufacturing and fabrication is how much of the process a job involves. Fabrication entails assembling standard or specialised parts to create parts of a product to be used in the manufacture of the completed piece. 

Manufacturing on the other hand, is a start to finish method, from creating parts to the final assembly to form the finished product, often using areas of fabrication within the manufacturing journey. 

If you’re looking for metal fabrication Sheffield, check out our range of fabrication services and if you have any questions or want to discuss a specific project, contact our family run team at FEM today. 

 

The overall term steel covers a wide variety of different metals, two of the main examples being mild steel and stainless steel. Even though both stainless and mild steel include a whole sub-group of different metals, there are a few important characteristics that differentiate the two. 

What is mild steel? 

Mild steel is a type of steel made up of iron and carbon as its main components. This type of steel differs from normal steel in the sense that it contains a much lower percentage of carbon compared to standard steel. 

The carbon content of mild steel can vary from 0.05% to 0.25%, with its properties being mostly dependent on this little amount of carbon. There are several grades of mild steel, and it is often used as a building material with a number of famous skyscrapers and bridges being made from it. 

What is stainless steel? 

Stainless steel is comprised of iron and chromium and is categorised as a metal alloy. It has around 10% of chromium mixed in with the iron, with the other metal elements involved being nickel, molybdenum, titanium, and copper. Non-metal components in stainless mainly have carbon present. 

This type of steel can naturally cope with very high temperatures. For this reason, stainless steel is often used to make kitchen equipment. Unlike normal steel, it has a clean and shiny appearance which makes it attractive and appealing for consumers. 

Comparing mild steel and stainless steel 

The most prominent factor that distinguishes mild steel from stainless steel is their alloying element. As previously mentioned, mild steel is alloyed with carbon whilst the alloying element in stainless steel is chromium. These alloys produce vastly different outcomes in terms of corrosion resistance, malleability, ease of fabrication, and cost. 

Corrosion 

Due to stainless steel being alloyed with chromium, it has a significantly higher level of corrosion resistance than mild steel. The chrome within the stainless steel reacts with oxygen in the air and creates a natural ‘chromium oxide’ protective layer on the surface of the metal. This means that as long as the layer doesn’t become damaged, the metal will be resistant to corrosion. 

Different grades of stainless steel will contain different elements that make them more suitable for various environments, for example a marine environment which includes the presence of water and salt. 

By contrast, mild steel does not have a chromium oxide protective layer, meaning the iron that is present will react with the moisture to form iron oxide or rust. Therefore, additional processing will be needed during mild steel fabrication such as galvanising in order to ensure the metal is protected. 

Fabrication 

Chrome is a hard alloy, which means stainless steels are a lot stronger and resistant to impact in comparison to mild steel. However, despite stainless steel fabrication being relatively easy, it’s not as easy as mild steel metal fabrication. Mild steel is much more malleable than stainless steel, and so it is commonly used in general fabrication engineering.  

Cost 

When deciding between mild or stainless steel, cost can be an influential factor. Despite stainless steel offering a far better life span and corrosion resistance than its mild counterpart, the different alloying elements it contains (especially chromium) make it more expensive.  

If you combine that with the extra work that goes into fabricating it, stainless steel comes with a much higher price tag than mild steel. However, the benefits you get in return with stainless steel, particularly the aesthetic look, impressive rust resistance, and low maintenance, you will find that it’s very much value for money.   

At FEM, our team are experts in the field of steel fabrication in Sheffield with skills covering both mild steel fabrication and stainless steel fabrication and welding. So, no matter your project requirements we will carry out the work to the highest standard. Contact us today to find out more about how we can help you with our steel fabrication service.