From Molten Metal to Mighty Towers: How Steel Beams Are Made

If you have ever walked by a skyscraper or crossed a bridge, you have already seen the fantastic work of steel beams in action.

But how exactly are steel beams made to withstand large amounts of weight and maintain structural integrity?

In this brief guide, we will explore the process of making steel beams and address some common questions related to steel beam fabrication. By the end of this guide, you will have a better understanding of what to look for when it comes to steel beams, whether it is for a small structure or a large overpass.

Table of Contents

• How Are Steel Beams Made​?

• 5 Steps To Making Steel Beams

• Commonly Asked Questions About Steel Beam Fabrication

• Madden Fabrication: Bringing Steel Projects to Life for Over 30 Years

How Are Steel Beams Made​?

Steel beams are crucial components in construction due to their strength, durability, and versatility. They are critical for supporting heavy loads and ensuring the structural integrity of buildings, bridges, and skyscrapers. They are used in a wide range of industries and construction projects, making them reliable and versatile. They are commonly used for:

• Supporting floors and roofs

• Reinforcing concrete

• Structural steel frames

• Bridge design

• Industrial and utility structures

• Ship designs

Steel beams are made in a series of steps involving melting, molding, and treating. This is done by:

• Melting and refining 

• Casting

• Rolling

• Heat Treatment

• Testing and Inspection

After production, the steel beams can be welded together to create parts of a structure. Madden Fabrication has the experience and qualifications to modify steel beams for any project tailored to our clients' specific needs. We understand how steel beams need to be fabricated for safety and to the highest quality for any project you may have.

5 Steps To Making Steel Beams

#1: Melting and Refining

Making steel beams starts with melting and refining raw materials. Steel beams are made of iron and carbon. To melt the materials to make them the correct steel grade, the materials will be:

1. Loaded into a blast furnace

2. Heated to over 2000°C, making an iron pool

   
   

During the heating process:

3. Any impurities are removed due to the high heat

4. Alloying elements are added to create the correct steel grade of the steel beams

#2: Casting

After the steel has been melted and refined, the molten steel will be poured into castings to make the desired shape needed for the steel beam. These end up being semi-finished beams. There are two primary casting methods used for steel beam production:

1. Continuous Casting: The molten metal is continuously poured into a water-cooled mould, creating continuous production of the steel products.

2. Ingot Casting: The molten metal is poured into individual, rectangular molds to create ingots. These then need to be rolled to form the desired shape of the steel beam. 

 #3: Rolling

After the casts of the steel beams are made, the beams will need to be rolled into their final form. There are two types of rolling:

1. Hot rolling: Heat the metal to a high temperature (900 degrees Celsius) to pass through a rolling mill. 

2. Cold rolling: This is when rolling occurs at room temperature, but makes thinner and smoother steel products

Hot Rolling vs. Cold Rolling

There are different uses for steel beams made with hot rolling vs cold rolling. The choice between the two depends on the specific project needs.

Hot rolling makes versatile and affordable components for the construction industry. Products used for hot rolling need to be more malleable. I-beams, columns, and other structural elements are typically made with the hot rolling process. 

Cold rolling makes thinner and lighter metal products such as metal wall studs, roof trusses, and cladding systems. Cold-rolled products tend to require more precision and strength.

#4: Heat Treatment

After rolling the steel beams, they undergo a few heat treatments to achieve the material properties needed for their intended use. Heat treatments for steel beams include:

• Quenching: The process of rapidly cooling metal from a high temperature. Each quenching method depends on the purpose of the finished steel beam. To quench the steel beam, you can use:

  • Water: fastest cooling rate, but can cause cracking

  • Air: slower cooling rate, but may reduce the rate of cracking 

  • Oil: Slowest cooling rate, which is often used for metals prone to cracking

  
  

• Quenching steel beams can increase: 
  

  • Hardness

  • Strength

  • Water-resistance

• Annealing: Heating the steel again and then slowly cooling it to relieve internal stresses, which helps:
  

  • Soften the steel

  • Increase ductility

  • Relieve internal stresses
    

• Tempering: reheated to a lower temperature, usually 150 to 600° C. Then it is cooled at a controlled temperature, such as room temperature. This treatment is often the final step of treating a steel beam. This helps:
  

  • Reduce brittleness

  • Improve toughness

#5: Testing and Inspecting

Once the steel beam is complete, a series of tests is done to ensure it meets the safety and quality standards based on its use. Testing the product for compliance will ensure it is ready to be used right away. Some tests and inspections of steel beams include:

• Chemical analysis

• Visual inspections

• Mechanical testing

• Non-destructive tests

Commonly Asked Questions About Steel Beam Fabrication

What Is an RSJ (Rolled Steel Joist)?

A rolled steel joint, otherwise known as an I-beam or H-beam, is a type of steel beam used in construction. These beams are commonly used in construction to support and distribute loads, providing structural integrity in buildings. They are known for their strength, durability, and versatility. 

Need RSJs for an upcoming construction project? Madden Fabrication would be happy to customize them to fit your needs.

What Are Some of the Design Considerations for Steel Beams?

When making steel beams, it is essential to consider the intended use when selecting the best steel beam for each project. It is necessary to consider:

• The characteristic loads

• The load requirements

• The cross-section classifications

• The bending verification

• The shear verification

• The lateral torsional buckling verification

• The deflection verification of the beam requirements

Have questions about which steel beam would be best for your project? Contact us today to see how we can customize steel beams for your upcoming construction project.

How Are Curved Steel Beams Made?

Curved steel beams can be formed by rolling straight steel plates and then welding them together. They use hot rolling, cold rolling, or induction bending to get the desired shape of the steel beam. Curved steel beams are used to distribute loads, create open spaces, and increase the visual appearance of a structure.

Madden Fabrication: Bringing Steel Projects to Life for Over 30 Years

For over 30 years, Madden Fabrication has been working with steel beams to make finished fabricated products for our clients. Located in Portland, Oregon, our metal fabrication facility serves the industrial, commercial, and residential construction industries. 

Regardless of the modification for steel beams, our team of qualified craftsmen can produce a high-quality product tailored to your construction needs. From a blank slate to towering buildings, we are your reliable industrial fabricators.