Strength of metal structures in industry: factors and solutions

The strength of metal structures is a key element in industrial environments, where infrastructure is exposed to continuous stress, heavy loads and often extreme environmental conditions. Metal structures used in industry must be designed to withstand a variety of factors that test their integrity and durability. These structures are found in industries such as brickmaking, construction, and engineering, where they operate in harsh conditions and need high strength to ensure safety and efficiency.

The maintenance and design of resilient structures, such as those built by Mantiero Angelo S.r.l., are essential to ensure that industrial infrastructure maintains its integrity over the long term. Mantiero, with its long experience in heavy steelwork and ability to make steel components to design, is a reliable partner for companies that require structures capable of withstanding extreme loads and resisting weathering and chemicals.

Main factors affecting the strength of metal structures in industrial settings

Industrial metal structures are exposed to a variety of environmental and mechanical factors that affect their strength and durability. The main factors include:

• Mechanical stresses and heavy loads: metal structures in industrial environments often have to support static and dynamic loads. For example, facilities such as overhead cranes and fire ladders must be able to withstand heavy use and support the weight of equipment, materials and, in some cases, even operators. Resistance to heavy loads is a critical factor in ensuring the stability and safety of structures.
• Exposure to chemicals and corrosive environments: in many industrial settings, metal structures are exposed to chemicals, moisture and corrosives that can rapidly deteriorate metal. Environments such as brick factories, where chemicals are used in the production and processing of materials, require structures with specific coatings to prevent corrosion with materials and treatments that ensure durability even in harsh environmental conditions.
• Temperature variations and fire resistance: metal structures used in high-temperature environments must be resistant to temperature variations and fire. In particular, there is a risk of fire in some industrial environments, and structures must be able to withstand intense heat without losing their structural properties.

Types of stresses in industrial metal structures

Industrial metal structures are subject to different types of stresses that can affect their strength and durability. These stresses mainly include static and dynamic loads, which affect the mechanical properties of the material.

• Static loads: static loads represent the constant stresses to which a structure is subjected, such as the weight of equipment or materials stored on it. Building supporting structures and mezzanines must be capable of supporting these loads without significant deformation. This type of stress is common in support structures that must remain stable and unchanged over time.
• Ddynamic Loads: dynamic loads are those that vary over time, such as the passage of heavy vehicles or operators. In industrial environments, rails, overhead cranes and other metal structures are exposed to continuous movement and vibration that test their strength. This type of stress requires that the materials used have high fatigue properties, that is, the ability to withstand repeated loading and unloading cycles without being damaged.
• Fatigue and mechanical stress: fatigue is a major cause of degradation in metal structures subjected to repeated cycles of loading. Over time, even relatively low loads can lead to cracks and permanent deformation. Metal structures must therefore be made of materials designed to withstand continuous mechanical stress, reducing the risk of structural damage and increasing the safety of facilities.

Fire resistance of metal structures

In many industries, fire resistance of metal structures is a priority. In the event of fire, high temperatures can impair the mechanical properties of the metal, leading to structural failure. Fire resistance can be improved through the use of specific treatments and protective coatings that help maintain the stability of the structure even in extreme heat.

• • Passive fire protection: one of the most widely used techniques for increasing the fire resistance of metal structures is passive protection, which involves theapplication of fire-resistant coatings, special plasters and insulating panels. These materials retard the heating of metal, allowing the structure to maintain its mechanical properties for a longer period in case of fire. Mantiero Angelo S.r.l. can provide roof structures and prefabricated sheds with fire retardant protection, meeting the specific needs of industry.
  • Treatments to increase structural heat resistance: there are also specific treatments that increase the metal’s resistance to heat, such assurface hardening and theuse of fire-resistant alloys. In particularly critical environments, special steels and fire retardant coatings are used to retard the deformation of the structure during exposure to flame and heat. Mantiero can offer advice on the selection of the most appropriate materials and techniques to ensure maximum safety and durability of structures.

Let us now look at a table showing some of the most common materials used in industrial metal structures, highlighting their main properties and specific applications. Choosing the right material is critical to ensuring fire resistance and durability of infrastructure in high thermal stress environments.

Materials and coatings to increase the durability of metal structures

The choice of materials and coatings plays an essential role in determining the strength and durability of metal structures in industrial environments. In particular, materials such as high-strength steel, stainless steel, and steels treated to resist corrosion are used to meet the challenges of aggressive environments. Stainless steel, for example, is highly valued for its corrosion resistance and is used in environments exposed to chemicals, such as factories and manufacturing plants. To further extend the life of structures, many industries also use anticorrosive paints and galvanic treatments that protect the metal surface from the effects of weathering.

A common galvanic treatment is zinc plating, which applies a thin layer of zinc to the surface of the steel to prevent rusting. This coating creates a protective barrier that insulates the metal from moisture and corrosive compounds, increasing the longevity of the structure.

Effects of corrosive agents on metal structures in industry

In the industrial environment, metal structures are frequently exposed to a variety of corrosive agents that accelerate their deterioration. These agents include moisture, aggressive chemicals, exposure to salts, and temperature changes that cause corrosion and reduce the metal’s strength. Corrosion is a natural chemical process that causes oxidation of metal, leading to rust formation and loss of mechanical properties.

The risk of corrosion is particularly high in environments that use acidic or alkaline compounds, such as the chemical and brick industries, where metal structures can experience accelerated deterioration. In these situations, it is essential to take preventive measures that protect metal surfaces from aggressive agents. The application of protective coatings, such as anticorrosive paints and special plasters, is one of the most effective solutions to prevent degradation.

Preventive maintenance techniques to ensure structural strength

Preventive maintenance is one of the most effective tools for ensuring the structural strength of metal infrastructure over time. By planning periodic inspections and scheduled interventions, metal structures can be kept in good condition and costly damage can be prevented. Preventive maintenance involves a series of inspections and checks to monitor the condition of structures and identify any signs of deterioration or corrosion at an early stage.

Proper preventive maintenance can greatly reduce long-term operating costs because it allows early action on problems before they escalate. Through techniques such as the use of laser monitoring and ultrasonic testing, it is possible to detect deformations and microcracks that, if overlooked, can compromise the stability of the structure.

Innovations in the design of metal structures for industry

In recent years, the metal structure design industry has seen the introduction of numerous innovations aimed at improving the strength of infrastructure in industrial environments. These innovations include the development of stronger materials, such as advanced metal alloys, and the application of manufacturing techniques that optimize the metal’s resistance to mechanical stresses and corrosive agents. Among modern alloys, the use of high-strength light steels and flame-retardant alloys has improved the performance of structures in terms of durability and load-bearing capacity.

An innovative aspect of design also involves the use of advanced analysis techniques, such as computer simulation, to predict the behavior of structures under extreme conditions. The ability to virtually test materials enables the identification of critical areas and the design of structures that better meet the needs of industrial environments.

Industry needs strong metal structures

The strength of metal structures in industrial environments is a crucial factor in ensuring the safety, efficiency and longevity of infrastructure. Adopting resistant materials, protecting against corrosive agents, and improving fire resistance are just some of the measures that can be taken to preserve the integrity of structures. Preventive maintenance and the use of advanced monitoring technologies allow problems to be identified at an early stage, limiting damage and reducing long-term operating costs.

Mantiero Angelo S.r.l., with its experience in heavy metal carpentry and quality certifications, offers tailor-made solutions for the needs of industrial companies, ensuring structures designed to withstand mechanical stresses and the most demanding environments. Investing in the quality and maintenance of metal structures not only increases the safety of facilities, but is also a strategic choice that will optimize resources and improve operational performance for many years to come.