1. What is Pig Iron? How is it Manufactured from Iron Ore?
Pig Iron is the intermediate product obtained from smelting iron ore in a blast furnace.
Manufacturing Process:
Raw materials: Iron ore (hematite or magnetite), coke, and limestone.
Steps:
1. Iron ore is charged into a blast furnace.
2. Coke burns to produce heat and carbon monoxide.
3. Carbon monoxide reduces iron ore to molten iron.
4. Limestone removes impurities as slag.
5. Molten pig iron is tapped from the bottom.
2. Differences Between Mild Steel, Wrought Iron, Cast Iron, and Cast Steel
Carbon
Material Properties Applications
Content
Mild Steel 0.15–0.25% Ductile, weldable, malleable Structural works, pipes
Tough, fibrous, corrosion-
Wrought Iron <0.08% Gates, fences, railings
resistant
Hard, brittle, good in Engine blocks, manhole
Cast Iron 2–4%
compression covers
Cast Steel Varies Strong, tough, shock-resistant Gears, valves, crankshafts
3. Short Notes
i. Mild Steel: Low carbon, widely used, easy to fabricate and weld. Common in beams,
frames.
ii. Wrought Iron: Almost pure iron, very ductile, resistant to corrosion. Decorative uses.
iii. Cast Iron: High carbon, excellent casting ability but brittle. Used in compressive
members.
4. Properties & Uses
Steel Type Properties Uses
Stainless Steel Corrosion-resistant, strong, shiny Sinks, cladding, surgical tools
High Carbon Steel Hard, wear-resistant, less ductile Cutting tools, blades, springs
5. Factors Controlling Steel Composition and Quality
Type and percentage of alloying elements
Carbon content
Manufacturing method
Cooling rate
Impurity removal
Heat treatment
6. What is an Alloy? Properties & Uses of Steel Alloys
Alloy: A mixture of metals or a metal and another element.
Steel Alloys: Steel mixed with Cr, Ni, Mo, etc.
Properties: Improved strength, corrosion resistance, toughness.
Uses: Aerospace, bridges, tools, marine structures.
7. Type of Steel for Given Components
i. Pre-stressed/Concrete Reinforcement: High tensile steel (HTS)
ii. Hammer: High carbon steel
iii. Spring: Spring steel (alloy with silicon/manganese)
iv. Suspension bridge cables: Alloy steel or HTS wire
8. Carbon Contents & Uses
Metal Carbon % Common Uses
Pig Iron 3–4.5% Steel production
Wrought Iron <0.08% Decorative and historic structures
Cast Iron 2–4% Pipes, cookware, machine parts
Low Carbon Steel 0.05–0.25% Building frames, car bodies
High Carbon Steel 0.6–1.5% Tools, chisels, cutting equipment
9. Rolled Steel Sections
Used in structural construction.
Forms:
o I-beam (RSJ)
o Channel section (C-section)
o Angle section (L-section)
o T-section
o Flat bars
o Plates
Drawing Example:
(I-beam and C-channel with labeled flanges and webs)
Can be added as visual if needed.
10. Open Hearth Process of Steel Manufacture
1. Pig iron, scrap steel, and iron ore are heated in a regenerative open hearth furnace.
2. Oxygen reacts with carbon and impurities.
3. Slag forms and is removed.
4. Molten steel is tapped and cast.
11. Properties of Hard Steel vs Mild Steel
Property Hard Steel Mild Steel
Hardness High Low to medium
Ductility Low High
Property Hard Steel Mild Steel
Weldability Poor Excellent
Applications Tools, dies Structural, general works
12. High Tensile Steel
Properties: High yield strength, fatigue resistance, less ductile.
Uses: Bridges, towers, reinforced concrete, cranes.
13. Corrosion of Steel & Prevention
Cause: Reaction with oxygen and moisture.
Prevention Measures:
Galvanization
Paint coatings
Cathodic protection
Use of stainless steel
Adequate drainage and sealing
14. Notes
Bessemer Pig Iron: Produced by Bessemer converter; used for steelmaking.
Grey Cast Iron: Graphite in flaky form, good machinability.
Cast Iron: High carbon, used in machine beds, pipes.
15. Mild Steel Rods vs HYSD Bars
Property Mild Steel Rods HYSD Bars (High Yield Strength Deformed)
Yield Strength ~250 MPa 415–500 MPa
Surface Smooth Ribbed for better grip
Ductility More Less but stronger
16. Concept of Pre-Stressing in Concrete
Pre-stressing applies initial compressive stress to concrete to counteract tensile stresses during
service.
Benefits:
Longer spans
Crack-free sections
Material economy
High load-carrying capacity
17. Why Steel is Widely Used in Buildings
High strength-to-weight ratio
Ease of fabrication
Durability
Flexibility in design
Recyclability
Ductility for earthquake resistance
18. Steel Manufacturing Processes
1. Primary production: Blast furnace (pig iron)
2. Secondary steelmaking: Bessemer, Open Hearth, Electric Arc
3. Refining: Removal of phosphorus, sulfur, etc.
4. Casting & rolling
Factors Determining Quality:
Purity of raw materials
Temperature control
Refining process
Alloying technique
19. Classes of Steel in Civil Works
Mild Steel: General structural works
HYSD Bars: Reinforced concrete
High Tensile Steel: Bridges, heavy construction
Stainless Steel: Decorative, corrosion resistance
Tool Steel: Cutting/drilling tools
20. Steel Corrosion in Buildings & Prevention
Causes: Moisture, salt, acidic environments
Prevention:
Use of corrosion-resistant steel
Paint or coating
Epoxy-coated rebars
Proper drainage design
21. What is an Alloy? Steel Alloys
Repeated from Question 6 – Steel + other elements (Cr, Ni, Mn, etc.).
Properties: Enhanced strength, corrosion, heat resistance.
Uses: Structural, marine, automotive, aerospace, tools.
