Uncategorized | MELFAB Engineering

April 10, 2017

Used to provide buildings with a sleek exterior and to part clad buildings, perforated metal is in high demand nowadays. That’s because of its easy installation and the many other benefits it provides. We’re going to take a closer look at some of those benefits.

Customised Aesthetic

The best way to make a building have a unique presence and design it to use metal in interesting and original ways. Perforated metal allows you to create bespoke building designs with a huge wealth of options for shape, hole size, patterns and finishes. It is ideal for creating a unique appearance. It can make a building’s exterior look far more interesting and allow people inside the building to look out while enjoying a level of privacy. It can also bring in more natural daylight to reduce the need for artificial daylight.


The structural integrity of perforated metal is far greater than many other materials. It has an amazing strength-to-weight ratio, and that allows it to easily withstand inclement weather and extreme pressure. The perforated design of the metal also means that the building doesn’t have to support as much weight.


The way that perforated metal is constructed allows it to easily bend and shape to what you want. It can be used structurally or decoratively. As a structural material, it offers a lot of benefits. For instance, you can use it for railing infills, allowing it to serve structural purpose yet decrease the amount of mass. It can also filter out light and create a pleasing aesthetic as a cover for columns.

Environmentally Friendly

This metal is a very green material. It can be recycled and reused, thanks to its unique design. It’s also very sustainable, as it doesn’t use up as much energy to produce as standard metal. That also means that there isn’t as much fuel being used or as much stress on the building, saving precious resources over time.


Thanks to the way it can balance ventilation and light, it helps architects to control thermal build-up. It deflects the sun’s heat, meaning that air conditioning systems won’t have to work as hard. When used as a light screen, it can reduce the amount of indoor lighting needed.
Engineers, architects, contractors and designers can all enjoy the numerous benefits of using perforated metal. If you want to try out some new options for your next building or enhance your current structure, then contact us today.

March 24, 2017

Steel is incredibly versatile and can be used to make a large variety of products. It is widely used in the aerospace, transportation and construction industries. The term “steel” can refer to several different alloys, which can vary in strength and use, but it can be classified into two primary categories- stainless steel and carbon steel. What separates these two and when do you use one or the other?
Steel is made up primarily of iron and carbon. The more carbon steel contains the more brittle and harder it is likely to be. Steel with less carbon in it tends to be more pliable and can be made into a wide range of shapes while still retaining its strength.

What Is Carbon Steel?

Carbon steel, as you might have guessed, has more carbon than your average steel. It is most often used in knives and tools. So, when would you use this kind of steel? Well, it is very durable, and it is great at keeping its shape and withstanding abrasions. It takes lot of force to deform carbon steel. It will crack or bend when put under extreme pressure, however. You can incorporate other elements into the carbon steel to make it strong and give it a wide range of uses. These could include manganese, nickel chromium, silicone and molybdenum.

What Is Stainless Steel?

In general, stainless steel has both carbon and iron, but it contains less of them and more chromium. It tends to have about 10% chromium content. That’s important to note, because it is the chromium that reacts with oxygen to provide a layer of protection over the metal that hinders corrosion. This means that many types of stainless steel will be able to last longer and function better in wet environments. The more chromium the stainless steel contains, the more it will resist rusting. So, how much chromium content there is in the steel will determine the cost. Also, the more chromium there is, the longer the steel should last.

Which One to Use?

These two types of steel are quite different and they have different uses. You can’t say that one is better than the other because you can’t use them in the same capacity. You need to pick the right kind of steel for each job.
We sell a wide variety of steel and create bespoke metal products for clients to use in many different industries. If you aren’t sure which kind of steel to use in your project, then please contact us so we can help.

February 19, 2017

Sheet metal applications primarily use either stainless steel or aluminium. For many people, it’s easy to confuse these two, but there are a lot of differences between them. They have some very different uses, and we are going to look at the instances where you would use one over the other.

Natural vs Alloy

Aluminium is a completely natural element, and it is the most common metal located in the crust of the Earth. Most often, it will be found in bauxite ore, and in its purest form it is very soft. To use it commercially, it needs to combine with other alloys to create the metal we know that’s usable for construction and a variety of other implementations.
Stainless steel, on the other hand, does not exist naturally. It’s something that is manmade, and it comes from a combination of manganese, copper, nickel, iron ore and chromium oxide. A concentration of 10-30% chromium oxide is what allows the stainless steel to resist rust and corrosion.
Steel tends to be much stronger than aluminium sheet metal, but that aluminium is much lighter, which makes it useful for implementation in aircraft and a variety of other vehicles. The heavier and stronger stainless steel is ideal for construction, since it is far less likely to warp or deform under tremendous pressure. Stainless steel is durable enough to be used again and again while never losing its durability. That often makes it far more environmentally friendly than its aluminium counterpart.

Temperature and conductivity

Certain metals conduct thermal energy better than others. How well materials transfer heat is known as thermal conductivity. The materials that have a low heat conduction will transfer heat slowly, and those with a higher conduction rate transfer it faster. Aluminium has a very high thermal condition rate, and that’s why it is often used in HVAC systems and car radiators.
Steel, on the other hand, can be subjected to far greater temperatures without warping or bending, while aluminium may become soft at about 200 degrees centigrade. Stainless steel, then, is ideal for use in heat exchangers.

Time and Money

The steel industry ranks third in the world, falling in after gas and oil. There is about $900 billion going into the steel industry each year. There is huge global demand for this metal, and creating steel from the initial bauxite ore extraction to the rolling stage where it is finished entails tremendous expense. Making aluminium sheeting is a far less labour-intensive process and costs much less, which makes it the more cost-effective choice.
Each of these metals is used to carry out specific tasks. They are both every important, and if you are working on a project, you want to make sure you are using the correct metal. If you aren’t sure which to use, then just ask us. Our professional team has been producing aluminium metal and fabricating steel for years now, and we have the expertise to help make your ideas become reality. Contact us today to get started on your next project.

January 20, 2017

The process of turning raw product into finished stainless steel is a lengthy one, but it can be simplified into six steps. Let’s look at this incredible process.

Making the Iron

To create pure steel, the products that go into it- lime, coke and iron ore- must be made into iron. These are all put into a blast furnace and melted down to create what is called molten iron or hot metal. The iron still has many impurities at this point, and they will have to be removed to ensure the metal is not brittle.

Primary Steel Making

To get the impurities out, the molten metal is infused with scrap steel. Oxygen will be forced through the furnace as well, which gets out a lot of the carbon and other impurities. For electric furnaces, electricity will be forced through the furnace and the same results can be achieved. After this process has finished, we have raw steel.

Secondary Steel Making

The different grades of steel are used for different tasks. The grading is based on which elements are still in the metal, such as carbon dioxide. A lot of the carbon will be removed, but aluminium will take its place to create a Drawing Quality steel. To create structural steel, there is more carbon left inside, and this gives the steel more tensile strength. Certain techniques can be implemented to alter the level of impurities left, including:

  • Stirring
  • Raising or lowering the temperature
  • Removing the gasses
  • Ladle injection

When the process is over and the right grade has been achieved, the next step can begin.

Continual Casting

Next, the steel in its molten form is cast into cooling moulds. This allows the steel to become hard, and the steel is drawn out of there while it is still hot. Guided rollers are used to pull it out and then the steel is cut into the desired lengths. It may be used for beams, billets, slabs or other items, and when the parts are fully cooled they are sent elsewhere for primary forging.

Primary Forging

In this step, the rough cast items are formed into shapes through a process called hot rolling. This get rid of defects in the shape and creates the desired quality of steel. This process can be used to make seamless tubing, long and flat products and a variety of bespoke items.

Secondary Forming

To create the final shape of the steel there are a number of secondary techniques that can be used, including:

  • Coating
  • Thermal treating
  • Joining
  • Pressing
  • Drilling
  • Machining
  • Riveting

That is the entire process by which steel is formed. If you are creating project out of steel and would like some professional advice about what technique to use or what type of steel to implement then contact us. We can take your design plans and turn them into the products you want to ensure the success of your project. Call us today for a free quote.