Manufacturing of

Manufacturing of
Metals and
Metals and Metal
Metal
Products for
Products for
Construction
Construction
Topic 7
 Learning Points
Learning Points
One
One Two
Two Three
Three Four
Four
Metal Extraction and
Introduction to Metals Metal Forming and Application, Products,
Primary
in Construction Processing Techniques and Trends
Manufacturing
Introduction to
Introduction to
Metals in
Metals in
Construction
Construction
 What isis metals
What metals for
for construction?
construction?
Metals used in construction are strong, durable, and versatile materials that
provide stability, resist heavy loads, and ensure long service life in structures.

The importance of metals in construction

lies in their strength, durability, and ability
to withstand heavy loads and harsh
conditions. They provide structural stability,
Me
teM
tal
resist wear and corrosion when treated
properly, and allow for flexible designs in
lsa s buildings, bridges, and other
infrastructures. Metals also support safety
and longevity, making them essential in
modern construction.
Common types of
Common types of Metals
Metals
Used (Ferrous)
Used (Ferrous)

Carbon Steel Cast Iron Wrought Iron

Alloy Steel
 Carbon Steel
Carbon Steel
Widely used for structural frameworks due to its strength and affordability.

Properties
Properties
Strong, durable, and has good ductility,
making it ideal for beams, columns, and
reinforcement bars in buildings and
bridges. However, it needs protection
from rusting.
 Cast Iron
Cast Iron
Commonly used for pipes, manhole covers, and decorative elements because
of its hardness and wear resistance.

Properties
Properties
Excellent compressive strength and
wear resistance, but brittle under
tension. Commonly used for pipes,
manhole covers, and foundations where
compression dominates.
 Wrought Iron
Wrought Iron
Known for its malleability and toughness, often used in gates, railings, and
ornamental works.

Properties
Properties
Tough, malleable, and corrosion-
resistant, making it suitable for railings,
gates, decorative elements, and older
structural ties. It is easy to weld and
shape.
 Alloy Steel
Alloy Steel
Contains other elements like chromium, nickel, or vanadium to improve
strength, toughness, and resistance to corrosion, making it suitable for high-
stress structures.

Properties
Properties
With added elements like chromium or
nickel, it offers improved toughness,
hardness, and corrosion resistance. Often
used in high-strength structural parts,
bridges, and modern high-rise
construction.
Common types of
Common types of Metals
Metals
(Non-Ferrous)
(Non-Ferrous)

Aluminum Copper Zinc

Lead Brass Bronze

 Aluminum
Aluminum
Widely used in construction for roofing, window frames, curtain walls, and
cladding due to its lightweight nature and versatility.

Properties
Properties
Lightweight, corrosion-resistant,
malleable, and has good thermal and
electrical conductivity.
 Copper
Copper
Commonly applied in plumbing systems, electrical wiring, roofing, and
decorative finishes in buildings.

Properties
Properties
Excellent electrical and thermal
conductivity, corrosion-resistant, ductile,
and durable.
 Zinc
Zinc
Often used for galvanizing steel to prevent corrosion, as well as in roofing and
façade applications.

Properties
Properties
Highly corrosion-resistant, easily
workable, and has self-healing properties
when exposed to scratches.
 Lead
Lead
Traditionally used in roofing, cladding, and as a sealing material in
construction joints.

Properties
Properties
Dense, malleable, corrosion-resistant, and
provides good sound and radiation
shielding.
 Tin
Tin
Typically applied as a coating for other metals and in specialized construction
materials.

Properties
Properties
Soft, ductile, corrosion-resistant, and has
a low melting point.
 Nickel
Nickel
Used in alloys and coatings in construction to improve durability and finish of
building materials.

Properties
Properties
Strong, corrosion-resistant, tough, and
retains its properties at high
temperatures.
 Historical Development
Historical Development of
of Metal
Metal Use
Use
≈
Copper Age ( 5000 BCE)
First use of native copper for tools, ornaments, and simple weapons.
Marked the beginning of human reliance on metals.
≈
Bronze Age ( 3300–1200 BCE)
Discovery of alloying copper with tin to create bronze.
Bronze was harder and more durable than copper.
Enabled advanced tools, weapons, and societal growth in Mesopotamia, Egypt, and China.
≈
Iron Age ( 1200 BCE onward)
Development of iron smelting techniques.
Iron tools and weapons became stronger and more abundant than bronze.
Iron supported agriculture, construction, and warfare.
Industrial Revolution (18th–19th Century)
Advancement in steel production (iron + carbon).
Steel became the backbone of railways, bridges, ships, and buildings.
Marked a turning point in construction and manufacturing.
Modern Era (20th Century–Present)
Expansion of non-ferrous metals like aluminum, copper, zinc, and nickel for their lightweight, corrosion
resistance, and conductivity.
Development of specialty metals and alloys (titanium, stainless steel, superalloys).
Metals became essential in aviation, aerospace, electronics, and renewable energy systems.
Metal Extraction
Metal Extraction and
and
Primary
Primary
Manufacturing
Manufacturing
From Ore
From Ore to
to Useful
Useful Metal
Metal
Metals are important in construction (steel, aluminum,
copper).
Before we use metals, they must be extracted from ores.
After extraction, metals are shaped through primary
manufacturing.
 What isis Metal
What Metal Extraction?
Extraction?
Metal extraction is the process of separating a metal from the rock
(ore) in which it is naturally found.

Methods:
Methods:
Pyrometallurgy – using heat (iron).

Hydrometallurgy – using water/chemicals (copper).

Electrometallurgy – using electricity (aluminum).

 Steps in
Steps in Extraction
Extraction
STEP 1:
STEP 1:
Mining – digging ores from the ground.

STEP 2:
STEP 2:
Concentration – removing dirt and unwanted materials.

STEP 3:
STEP 3:
Reduction – turning ore into raw metal.

STEP 4:
STEP 4:
Refining – making the metal pure and ready for use.
 What isis Primary
What Primary Manufacturing?
Manufacturing?
The first stage of processing metals after extraction is where raw
metals are converted into basic shapes and forms such as sheets,
rods, beams, and wires.

Processes:
Processes:
Casting – molten metal is poured into a mold to take its shape.

Rolling – Metal is passed through rollers to flatten it into sheets, plates, or beams.

Forging – Metal is shaped by hammering or pressing under high pressure.

Extrusion – Metal is forced through a die to create long shapes like pipes or rods.

Drawing – Metal is pulled through a die to make thin wires or bars.

 Metals and
Metals and the
the Environment
Environment

Environmental
Environmental
Considerations in
Considerations in Metal manufacturing can impact air,
water, and soil.
Metal Manufacturing
Metal Manufacturing Emissions come from mining,
smelting, and processing.
Understanding these effects helps
reduce environmental damage.
 Metals and
Metals and the
the Environment
Environment

Air Pollution: Dust, CO₂, and toxic gases

from smelting.
Main Environmental
Main Environmental Water Pollution: Chemicals and heavy

Issues
Issues
metals can contaminate rivers and
groundwater.
Solid Waste: Slag, tailings, and scrap can
cause land pollution.
Energy Consumption: High energy use
contributes to greenhouse gas emissions.
 Metals and
Metals and the
the Environment
Environment

Use cleaner technologies – reduce

emissions from furnaces and machines.
Mitigation Strategies
Mitigation Strategies Recycle metals – minimizes the need for
new mining.
Treat wastewater and waste – prevent
contamination of soil and rivers.
Energy efficiency – use renewable energy
or optimize processes.
Metal Forming and
Metal Forming and
Processing
Processing
Techniques
Techniques
 Metal Forming
Metal Forming and
and Processing
Processing Techniques
Techniques

One
One Two
Two Three
Three Four
Four
Hot and Cold Surface
Casting Metals Joining Methods
Working Processes Treatments and
Coating
Hot and
Hot and Cold
Cold Working
Working
Processes
Processes
 Hot and
Hot and Cold
Cold Working
Working Processes
Processes
1. Rolling - The rolling process in metal forming is a
manufacturing method where metal is passed between rotating
rollers to reduce its thickness and shape it.
 Hot and
Hot and Cold
Cold Working
Working Processes
Processes
2. Forging - is a process that shapes metal by applying localized compressive
forces, typically through hammering, pressing, or rolling. This process deforms
the metal, refining its internal grain structure and enhancing its mechanical
properties like strength and durability. Forging is commonly categorized by
the temperature at which it's performed: cold, warm, or hot forging.
 Hot and
Hot and Cold
Cold Working
Working Processes
Processes

3. Metal Extrusion - is a metal forming

process where a metal billet is forced
through a die to create a desired
cross-sectional shape. It's a versatile
technique used to produce long,
continuous pieces with specific
profiles, like those found in window
frames, automotive parts, and
aerospace structures.
 Hot and
Hot and Cold
Cold Working
Working Processes
Processes

4. Drawing - in the context of metal

forming, is a process that elongates
metal by pulling it through a die to
reduce its cross-sectional area. This
process can be used for creating
various shapes, including wires, rods,
tubes, and even deep-drawn parts like
cups and other complex geometries.
Casting of
Casting of Metals
Metals
 Casting of
Casting of Metals
Metals
1. Sand Casting - is a metal casting
process where molten metal is
poured into a mold made of sand
to create a desired shape. It's a
versatile and widely used method,
particularly for creating complex
shapes and for metals with high
melting temperatures.
 Casting of
Casting of Metals
Metals
2. Die casting - is a metal casting
process that forces molten metal into
a mold cavity under high pressure.
The mold, typically made of hardened
steel, is designed to create the
desired part shape.
 Casting of
Casting of Metals
Metals
3. Investment casting - it is also
known as lost-wax casting, is a
precision metal casting process that
creates highly detailed and accurate
parts. It involves creating a wax
pattern, coating it with a ceramic
shell, melting out the wax, and then
pouring molten metal into the
resulting mold.
Joining Methods
Joining Methods
 Joining Methods
Joining Methods
1. Welding - is a process that joins materials, usually metals, by using heat,
pressure, or both to cause fusion. This creates a permanent bond called a
weldment, with the original pieces being joined referred to as the parent
materials.
 Joining Methods
Joining Methods

2. Bolting - a process involves joining

metal parts by passing a bolt
through aligned holes and securing it
with a nut.
 Joining Methods
Joining Methods
3. Riveting - is a metal joining process that uses a rivet, a mechanical fastener,
to bind two or more metal parts together. It involves inserting a rivet through
aligned holes in the materials and then deforming the rivet's tail end to create
a secure, permanent connection.
Surface Treatments
Surface Treatments
and Coatings
and Coatings
 Surface Treatments
Surface Treatments and
and Coatings
Coatings
1. Galvanizing - is a process of coating iron or steel with a layer of zinc
to prevent rust and corrosion.
 Surface Treatments
Surface Treatments and
and Coatings
Coatings
2. Painting - metal surfaces serves
both protective and aesthetic
purposes. It acts as a barrier against
corrosion, preventing rust and
extending the lifespan of the metal.
Additionally, paint allows for
customization of appearance,
enabling personal expression and
matching the metal object to its
surroundings.
 Surface Treatments
Surface Treatments and
and Coatings
Coatings
3. Powder Coating - for metal is a
finishing process that applies a dry,
free-flowing powder (typically a
mixture of pigment and resin) to a
metal surface using an electrostatic
charge. The coated object is then
heated, causing the powder to melt,
flow, and fuse into a durable,
protective layer. This process creates
a tough, attractive, and long-lasting
finish that is highly resistant to
scratches, corrosion, and fading.
PRODUCTS AND
PRODUCTS AND
APPLICATIONS
APPLICATIONS
 Products and
Products and Its
Its Application
Application
1. Steels - An alloy of iron and carbon,
often mixed with other elements for
strength and durability.

- Structural Frames
- Reinforcement Bars
- Bridges and High-rise Buildings
 Products and
Products and Its
Its Application
Application
2. Aluminum - A lightweight,
corrosion-resistant metal obtained
from bauxite ore.

- Windows and Door Frames

- Roofing Sheets and Panels
- Curtain walls and Cladding
- Ducting
 Products and
Products and Its
Its Application
Application
3. Copper - A reddish metal with
excellent electrical and thermal
conductivity.

- Electrical Wirings and Conductors

- Heating and Cooling systems
- Plumbing pipes and fittings
 Products and
Products and Its
Its Application
Application
4. Cast Iron - A hard, brittle form of
iron made by casting molten iron into
molds.

- Water and Sewer Pipes

- Manhole Covers and Drainage Grates
- Gates and Fences
- Columns for Heavy Structures
 Products and
Products and Its
Its Application
Application
5. Wrought Iron - A tough, malleable
form of iron that is easily welded and
shaped.

- Handrails and stair railings

- Gates, Fences, and Grills
- Window Guards
 Products and
Products and Its
Its Application
Application
6. Zinc - A bluish-white metal mainly
used for coating other metals to resist
corrosion.

- Protective Coatings
- Gutters and Downpipes
- Roofing Sheets
- Flashing and roof drainage systems
 Case Examples
Case Examples of
of Metal
Metal Structures
Structures

Skyscrapers Stadiums Bridges

 Innovations and Sustainability
Innovations and Sustainability in
in
Metal Manufacturing
Metal Manufacturing
Recycling of Metals - The process of
collecting, processing, and reusing
scrap metals to make new products
instead of extracting raw ores.

- Saves energy (e.g., recycling aluminum saves

up to 95% energy vs. making from ore).

- Reduces greenhouse gas emissions.

- Conserves natural resources (less mining).

- Cuts construction waste going to landfills.

 CONCLUSION
CONCLUSION
Metals are very important in construction because they provide
strength, last a long time, and can be used in many ways. Materials
like steel, aluminum, copper, cast iron, wrought iron, and zinc are
common in buildings, whether for structural supports, roofing,
plumbing, or even decorative parts. These metals are made by
extracting and processing ores into useful products that shape
modern infrastructures. But their production also affects the
environment through pollution, high energy use, and the depletion
of resources. That’s why recycling, green steel, and low-carbon
alternatives are now being developed to make construction more
sustainable.
Thank you for
Thank you for
listening!
listening!
Metals and Non-metals