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Varlowe Industrial Services

Varlowe Industrial Services

Welding, Fabrication, CNC, Gas And Pipework Specialists

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Information

What Is Mild Steel?

Mild Steel

Mild Steel is a low carbon steel variant which is also known as low carbon steel. 

Due to its low carbon, mild Steel is typically more malleable, machinable, and weldable than other steels. However, it also means it is almost impossible to harden through heat treatment. 

Mild Steel is also magnetic due to its high iron and ferrite, which means it’s not an alloy metal.

Unlike Stainless steel, the lack of alloying elements means that mild steel iron is subject to rust if not surface treated. Because of this, it means mild steel is more affordable compared with other steel. 

The affordability, weldability, and machinability make it such a popular choice of Steel for consumers.

Carbon steels are typically classified based on the amount of carbon that they contain. Each category has different purposes.

  • Low carbon steel has up to 0.30% plain carbon. It is mainly used for flat-rolled steel products such as sheets, strips or light and rolled sections.
  • Medium carbon steel has between 0.30%-0.60% carbon content and is used for wheels, rails, gears and vehicle components.
  • High carbon steel has between 0.60% to 1% carbon. It is the strongest of the three and is used to make milling machines, cutting tools and high strength wires.

How is Mild Steel Made?

It is made very similarly to other carbon steels. It involves a combination of iron ore and coal melting together in a blast furnace. 

The mixture is then moved to another furnace to burn off any impurities. At this stage, adjustments can also be made to the steel composition if needed.

Following that, the casting process involves being poured into a mould and allowed to solidify. This is then brought down to the desired size using hot rolling or cold drawing processes.

Physical Properties of Mild Steel

The properties of mild steel is why it is growing in popularity across several industries. Some mild steel’s physical properties are as follows:

  • High tensile and impact strength
  • Good malleability (Cold forming possibilities)
  • Not suitable for heat treatment
  • Magnetic
  • Ductile 
  • Weldable 
  • Affordable

What Is Mild Steel Used For?

Mild steel has many uses due to its nature. Here are some examples of where it is used:

  • Machinery parts
  • Pipelines
  • Steel frame buildings
  • Gates and fencing
  • Structural Steel
  • Signs
  • Automobiles
  • Furniture
  • Decorations
  • Wire
  • Fencing
  • Nails

Steel Fabrications At Varlowe

Our team of steel fabricators can fabricate and weld most modern day metals. We employ highly experience fabricators that can work to coded specifications.

We can provide up to 3,500 person hours a week, constantly working to a high standard.

For more information, please visit our Steel Fabrication page. For more on our welding methods, please visit our Welding Services page.

You can also call us on 01902 861042 and email info@varlowe.co.uk.

Filed Under: Information

Welding Positions

What are the different types of Welding Positions? 

If you don’t work in the industry, you might think items being welded are flat on a table. You may think the engineer has the freedom to move around the object in front of them. But 90% of the time, that’s not the case. 

Items may be fixed overhead, vertically along a wall, buried underground or horizontally on the floor. Some of these items may not have the ability to be moved, so welding cannot always be completed in the same position.  

Over the years, engineers have tested and created positions to allow for these challenges. As a result, they are the most reliable welding positions for the welder to perform the task.

The four main welding positions are: 

  • Flat Position 
  • Horizontal Position 
  • Vertical Position 
  • Overhead Position 

Some Welding processes can use all four welding positions. Some can only use one or two. So choosing the correct method and welding type is critical to the job.

Welding Symbol ISOWelding Symbol ASMEWelding Position
PA1FFlat Position
PA1GFlat Position
PB2FHorizontal Position
PC2GHorizontal Position
PF3G DownhillVertical Position
PG3G DownhillVertical Position
PD4FOverhead Position
PE4GOverhead Position
PH5G UphillHorizontal Position
PJ5G DownhillHorizontal Position
H-L0456G Uphill45 Degree Position
J-L0456G Downhill45 Degree Position

Positions Of Welding

Flat Position (PA ISO, 1F/1G ASME) 

The flat position is the easiest and most sought after method. It’s the first one that people new to welding learn. As the name suggests, the metals joined are placed flat, and the weld follows a horizontal direction. The weld performed is on the upper side of the joint. This position is also known as Downhand. 

The following three welding positions are referred to as “Out Of Position” because they require many more skills to complete. These are the Horizontal, Vertical and Overhead.

Horizontal Position (PB/PC ISO, 2F/2G ASME) 

Like the Vertical and Overhead positions, the Horizontal requires a lot of skill to perform correctly. The weld axis is horizontal, but depending on the position determines the type of weld.  

If the vertical and horizontal piece of metal meets at a 90-degree angle, you require a Fillet Weld. 

If the weld face is along a vertical plane, then you’ll need a Groove Weld.

Overhead Position (PD or PE ISO, 4F or 4G ASME) 

The overhead position weld is the most challenging position to work as It’s performed above the welder. The welder will have to angle themselves and the equipment to reach the joints. 

In the overhead position, the metal can drop or sag from the plate. To avoid this, you can keep the puddle of molten metal small. When the metal sags, it creates a crown. 

Uphill and Downhill Positions

The Uphill and Downhill positions pertain to the direction of weld travel. 

The Uphill position starts and the bottom and goes up. Uphill progression is typically considered to make a more sturdy joint but has a higher potential for burn through.

Downhill starts at the top and goes down. It produces less penetration (thinner material or root passes) because gravity pulls the molten pool down, so you have to move quickly.

PF ISO, 3G Uphill ASME – Vertical Position 

It is a vertical-up position used for both butt and fillet welds. While welding, the angle of the torch is set at a 45° angle. The welder uses the metal from the lower part.

PG ISO, 3G Downhill ASME – Vertical Position 

It is a vertical-down position used for fillet and butt welds. Welders used the metal from the upper part. This position is considered good in terms of productivity.

PH ISO, 5G Uphill ASME

5G Uphill is a widespread way of welding pipes manually. In this position, the pipe is unable to be turned or rotated. The welder will be welding in three different positions—Overhead, horizontal, and finishing on the flat position.

PJ ISO, 5G Downhill ASME 

The engineer should do the weld with specific equipment to combat the force of gravity. Like uphill, the welder will be welding in three different positions but reversed. First, starting in a flat position to horizontal, and finishing on the overhead.

H-L045 ISO, 6G Uphill ASME and J-L045 ISO, 6G Downhill ASME 

The 6G is the most challenging position for a welder to perform. It is performed on weld tests to qualify a welder for all other positions. 6G is essentially the same as 5G but with the pipe at a 45º angle.

For more info on 6G welding, visit our post, “What Is 6G Welding?”

What Are the Main Types of Welds? 

There are two main weld types, Fillet and (depending on which side of the pond you sit) Butt or Groove welds. Groove and butt welds are the same weld types, so the only difference is the name.

Butt weld is the International Organization for Standardization (ISO) term. Groove weld is the American National Standards Institute (ANSI) term.

In ASME, you will find that a number can identify the weld position and a letter to identify the weld type. The letter F is for Fillet and G for Groove.

Fillet Weld

Fillet welds are the most used type in the industry. A fillet weld joins two pieces of metal at a right angle to each other. It requires less joint preparation making it very cost-effective. There are three types of fillet joints. These are: 

  • Corner Joint  
  • Tee Joint 
  • Lap Joints 

For more information about Fillet Welds, please click here.

Butt Weld

Butt welds (Groove Weld in the USA) are the second most used type of weld. A butt weld is referring to the beads that deposit between two pieces of metal. There are several types of Butt joints, which can be single or double. These are: 

  • Single V 
  • Double V 
  • Single And Double Bevel
  • Single And Double U 
  • Single And Double J Joints 
  • Square Butt Joints  

For more information about Butt Joints, please click here.

Welding at Varlowe

For over 17 years, we have been offering our services to the industry. We provide a class 1 coded welding service nationwide. Our Codings give us the ability to cover most applications, positions and techniques.  You can also read our article “What is the meaning of coded welding“.

If you want more information on welding, visit our blog post “What Is Welding“. More information on Welding Positions can be found here.

For more information on what we can offer, please visit our welding services page. You call us on 01902 861042 or email info@varlowe.co.uk.

Filed Under: Information

What Is A Mechanical Contractor?

A Mechanical Contractor manages the mechanical projects for many different companies. They are skilled professionals who can keep essential mechanical systems running optimally.

Serving in nearly every industry, they have a wide range of expertise across all trades.

Generally, a mechanical contractor is in charge of the following:

  • Plumbing
  • Refrigeration
  • HVAC
  • Electrical Systems
  • Pipework Fabrication
  • Ductwork
  • Gas Work

They problem-solve to find the faults that cause a system to fail. Then they will provide vital fixes by careful and calculated changes.

Part of the problem solving is taking into account the practical installation. They have to monitor a system’s costs and energy efficiency closely.

Some contractors will work on a project during inception and installation. Others will be involved and manage the ongoing maintenance and repair.

Duties of a Mechanical Contractor

A mechanical contractor is a jack-of-all-trades. They can work on a variety of different projects in many other trades. As long as there are mechanical parts, they ensure that everything is installed and working correctly.

Typically, their duties involve organising with other trades to complete the project. Any delays can cause a knock-on effect and impact the completion of a project. Therefore, Coordination between trades is vital as they work to strict time and budget scales.

Mechanical contractors will often design and manufacture parts ahead of time. Because of this, they are saving time and any disruption on site.

The other primary duty of a contracting company is to carry out maintenance on existing systems.

A regular maintenance process keeps all parts of these complex mechanical systems are in good working order. They allow you to continue your work without suffering losses from downtime.

Even though issues can still occur even under regular maintenance, most are addressed in a few hours.

In other words, regular maintenance reduces the likelihood of catastrophic problems that can cripple a business.

Varlowe’s Contracting Services

Varlowe is a mechanical contractor specialising in high-pressure pipework systems. We have been effective for making real benefits through careful planning.

The team of trained engineers can provide practical solutions on site. Our contract managers offer the knowledge to see you through the project. Above all, from start to finish, you will receive a high-quality service.

For more information on our services, please visit our services page.

Give us a call on 01902 861042 to chat with one of our team. You can also email info@varlowe.co.uk or visit our contact page to fill out a form.

Filed Under: Information Tagged With: information, welding

What Is The Difference Between Welding And Fabrication?

What Is Welding And Fabrication?

You may think Fabrication and Welding are the same things. You may even hear the two words used interchangeably.

Fabrication and Welding are two essential processes in metalworking. But if you are in the industry, you’ll know there is a difference between the two.

To put it simply, Fabrication is the whole cycle in which a component or structure goes through. Welding is part of that cycle. Although, you can produce the final product without the need for Welding altogether.

Welding and Fabrication use different processes. As a result, they need different skill sets, but they can share many of the same activities.

Different Techniques

Welding is the art of fusing metal using heat or pressure.

There are a lot of different welding types used today. The four common ones we use at Varlowe are: 

  • MIG (Metal Inert Gas) or GMAW (Gas Metal Arc Welding)
  • TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding)
  • Stick Welding or SMAW (Shielded Metal Arc Welding)
  • Electrofusion Welding

Fabricators share a few of the same techniques as Welders. They usually have their own set of methods to get the job done. These can be:

  • Die-cutting
  • Finishing
  • Hydroforming
  • Roll forming
  • Shrinking
  • Spinning
  • Stamping
  • Stretching 

Different Tools

The fabrication process usually starts with cutting metal down to size. Metals can be cut and shaped using various tools, for example:

  • Saws
  • Hammers
  • Grinders
  • Cutters
  • Plasma Torch

Tools such as lathes and presses help shape and remove parts of the metal. These can be manual machines or using CNC. Also, tubing and pipe benders help shape pipework fabrications.

Welding tools are very different in comparison. For example, they can use:

  • Welding Clamps
  • Magnets
  • Gauges 
  • Vices 
  • Electrodes

More safety equipment for Welding is needed—items such as heat resistant gloves, helmets, masks and safety glasses, to name but a few.

Welding helmets are required to have auto-darkening glass to protect the eyes. Also, they need to have built-in respirators to protect against welding fumes.

Both trades will use the same cleaning supplies to prepare the metal for work. Wire brushes, sandpaper and solvents such as acetone help wipe away any greasy deposits.

Different Skill Sets

Fabrication and welding both require a set of unique skills and tools.

Fabrication typically involves the use of portable hand and electrical tools, with equipment such as folders, rollers, shearing tools being used to manipulate the metal.

Welding, on the other hand, is conducted using stationary tools and largely done by hand.

Basic welds can usually be completed without requiring a specialist welder however more complex joins may need to be undertaken by experienced welders certified according to specific standards, e.g. Coded Welding.

Welding & Fabrication Safety Precautions

Both manufacturing forms need the same degree of safety precautions. They both work with hot metal and heavy machinery, each carrying its guidelines.

Each tradesperson should own or have provided the following:

  • Protective Trousers
  • Flame-Resistant Jacket
  • Overalls
  • Steel Toe Boots
  • Gloves
  • An Auto-Darkening Helmet
  • Safety Goggles
  • Hearing Protection
  • Respirator

You should also have a safe workshop to work in to prevent injury. The workshop should have these in place at all times-

  • Highlighted Walkways
  • Fume Extraction
  • Adequate Lighting
  • Welding Screens
  • First Aid Stations

To sum up

Fabrication and Welding are crucial professions. Both trades provides for almost every industry. From construction to transportation, you will find something that has been fabricated in some shape or form.

Varlowe has experienced metal fabricators and class 1 coded welders. We provide bespoke solutions for all industries. 

You can find more on our Welding Services page and Steel Fabrication page. You can also find what we offer on our services page. 

If you wish to speak to a member of the team, please call us on 01902 861042.

FAQ’s

What type of welding do fabricators use?

Fabricators can use various kinds of welding, depending on the materials being joined, the strength required, and the application. Some typical types of welding used by fabricators include MIG, TIG, Stick and Flux-Cored.

Is a welder and fabricator the same?

While welders may also have some fabrication skills, such as reading blueprints and using metalworking tools, their primary focus is welding. Fabricators, on the other hand, may have some welding skills, but their primary focus is on the broader process of creating metal structures and products from start to finish.

What is Steel Fabrication?

Steel fabrication creates metal structures and products from raw materials, primarily steel. This process involves cutting, bending, shaping, and welding steel components to make a final product that meets the intended design and engineering requirements.

Take a read of our comprehensive article here – “What Is Steel Fabrication?“

What is welding?

Welding is the metalworking process of combining two or more metal components using heat and pressure. The process involves melting the base metal and adding a filler material to create a solid and permanent joint between the components.

Take a read of our comprehensive article here – “What Is Welding?“

Filed Under: Information Tagged With: welding

What Is Welding?

Welding Explained

In a nutshell, welding is the process of uniting two or more materials together. 

From hobbyists to large industrial environments, welding is one of the most critical steps in modern fabrication.

In this article, we will go over the basics, but let’s start at the very beginning.

Welding History

Welding dates back to 500BC, the Iron Age (perhaps even before that).

Scientists have discovered a two thousand year old tiny box of gold with pressure welded joints. Furthermore, there is data pointing to Ancient Egyptians knowing how to weld iron together.

However, the welding performed in those times was very simple. It was nothing but hammering together two metal pieces under heat.

Archivists believe the Egyptians began to manage fire to join copper. They think they moved on to other alloys like gold, silver, iron and bronze.

Welding developed over the decades, and in the 16th Century era, they began using the term “Weld”.

The form of welding that we use today dates back to the 19th Century, albeit with more modern equipment and techniques.

After the development of electrical power, welding torches were created for cleaner and more controlled welds. Then came along –

  • Early 1900 – Gas Shielding and Flux
  • 1940 – GMAW, MIG, and TIG 
  • 1950 – Flux-Cored Arc Welding

Since their invention and as technology has advanced, these techniques have been improved. Today, engineers can weld Metals, plastics and even wood. 

In this article, we will be focusing on metal and the techniques we use here at Varlowe Industrial Services.

You can read more about the history on Wikipedia.

Joining Metal

Metal welding starts by heating at a high temperature using electricity or gas.

The high heat causes a weld pool of molten material that cools to form the joint.

Usually, this joint is stronger than the parent metal.

Pressure can also produce a weld and work either alongside the heat or by itself.

Shielding gas can protect the melted/filler metals from becoming contaminated or oxidised.

Welding requires lots of work and practice. Best learned under the guidance of professional metal fabricators.

Once competent, you can progress your skills by going coded. Have a look at our “What is the meaning of “Coded Welding” blog post or our Coded Welding page.

Fabrication Welding

Steel fabricators can transform some of the world’s most robust materials into different shapes and sizes.

They produce products ranging from pipework to staircases. Or, in our case, a pipework-based staircase which you can view here “Our signature staircase”.

Drilling, cutting, bending and grinding metals are techniques used to create the basic shapes.

Once finished, you should have something that resembles Ikea’s flat-pack furniture.

Then comes the time to apply your chosen welding technique to fuse these pieces.

There are several types of techniques, manual and automated. Each offers different ways of uniting materials together.

The term “fabrication” and “welding” however are two separate methods of manufacturing. Check out our blog post “What Is The Difference Between Welding And Fabrication” to learn the difference between the two.

We will go over four types of welding techniques. These four are the most used methods we use here at Varlowe.

Welding Types

There are many types of welding processes, each serving its strengths and weaknesses.

Choosing the correct technique is dependent on the project. For example, you may need specific materials and welding positions factoring in.

The correct method is essential, so it’s necessary to understand the differences between them.

Today, processes have an automated option. Equipment such as robotic welding can, within a controlled environment, deliver high quality and repeatability with ease.

Yet, some projects need expert metal fabricators to produce a type of weld in a position not compliant with automated processes.

MIG (Metal Inert Gas) or GMAW (Gas Metal Arc Welding)

To Mig, or not to Mig, that is the question, which is usually yes.

This style is the most common industrial welding process.

A solid steel wire passes through the Mig Gun. The gun is electronically charged at the pull of the trigger, creating an arc, heating the two metals together.

It requires a constant voltage and direct-current power source.

Pros – MIG can weld in all positions – You do not have to chip off slag build-up – Its relatively easy to learn.

Cons – Large tank of shielding gas – the expensive cost of consumables.

TIG (Tungsten Inert Gas) or GTAW (Gas Tungsten Arc Welding)

A non-consumable tungsten electrode is used in this type of welding process.

This tungsten electrode, along with shielding gas, directs the arc in a controlled manner to heat the base metal. The heat created produces a molten weld puddle.

When you need a higher standard finish, TIG is usually the go-to method. It creates a very clean weld with little to no clean up required externally or internally.

Pros – Used in a wider variety of materials in all positions – Provides very high-quality welds – Does not produce toxic smoke – Minimal fumes – No slag produced.

Cons – TIG welding is a complex process – The torch held at the right angle – More complicated to master.

Stick Welding or SMAW (Shielded Metal Arc Welding)

Stick Welding is one of the easiest to learn and most common types of metal joining.

The electrode, or “stick”, covered with a flux coating that melts to form a gas shield as the heat rises.

Slag gets created when the molten flux solidifies on the surface of the weld.

Pros – No other consumables needed than rods – Achievable in all positions – Equipment is simple to use and inexpensive.

Cons – Stick Welding has a very rough appearance – Requires extra cleaning work – Difficult to weld thinner metals.

Electrofusion

Electrofusion welding is a form of resistive implant welding used to join pipes.

A fitting with embedded metal coils is placed around two ends of the pipes. A current passes through the coils, which creates the heat required.

The heating of the coils melts small amounts of the pipe and fitting. When the joint cools, the line will be fused and ready for commissioning.

Pros – A simple process capable of producing consistent joints – The contained process eliminates the risk of contamination – The process allows repair without the need to remove pipes.

Cons – More expensive method – extra parts required.

If you want more information on the different welding types, take a look at our blogpost “Welding Types“.

Welding Positions

You might assume a welder sits at a workstation and fuses the metal components on a table in front of them.

But in everyday work environments, joining metal can be much trickier.

Unremovable structures attached to the ceiling, the wall or embedded into the floor offer different challenges.

They need a different method, which is why welders need techniques to weld in any position.

There are four common positions are:

  • Flat – As the name suggests, the welder passes over a flat placed piece of metal. The welder will move across the workpiece in a horizontal direction.
  • Horizontal – The weld axis is horizontal, which requires a higher level of skill. How the position passes depends on the type of weld need.
  • Vertical – Both the weld and plate will lie vertically. One of the problems performing this weld is the molten metal flowing downward and piling up.
  • Overhead – The overhead position weld is the most challenging position to work on. Fighting against gravity is the main issue in this position. The welder will also have to angle themselves to reach the joints.

If you want to learn more about positions, take a look at our Welding Positions blog post.

Fabrication Services At Varlowe

Here at Varlowe, we have been providing metal fabrication services for over 17 years.

Our specialist area is in Pipework Fabrication, specifically high pressure pipework systems.

We also offer a class 1 coded service for a range of applications, nationwide.

Please visit our Welding Services and our Steel Fabrication page for more details.

You can call us on 01902 861042 or email info@varlowe.co.uk.

Filed Under: Information Tagged With: welding

Signature Staircase Fabrication

Way back at the start of 2020, we brought a new unit to become our new headquarters.

It needed a complete renovation as the existing layout wasn’t fit for purpose. Click here to see the post about the renovation of the building.

We wanted an open plan reception area on the ground floor with open office space on the first floor. Where the current staircase was sat, it wouldn’t work with the proposed new layout.

So they had to go.

The staircase will be the primary architectural steel fabrication in the building and the first thing you’ll see when you walk in.

As a fabrication company, it was our chance to showcase what we could achieve.

Attention To Detail

We have years of experience designing, fabricating and installing staircases for different purposes. Yet, we knew it had to be different.

We believe that first impressions are everything.

Therefore, it demanded attention to the aesthetics to create an eye-catching feature, but they also need to be functional and safe.

We specialise in pipework fabrication, so we had an idea of the staircase incorporating pipework somehow.

The Final Design

After many sketches, brainstorms and prototypes, we finally had a design that we were happy with.

The stairs will feature an open design to showcase the pipework base. The steps and supporting brackets will be welded onto the pipe. These are then finished in black with a stainless steel finish on top of the step and railings. Frosted glass will finish it all off for a modern look.

With the completed design and Cad drawings in hand, it was over to our talented fabricators for manufacturing and installation.

After hours of hard work, they were in, tested, signed off and ready for use.

With the new staircase in, we couldn’t be happier. Our signature staircase for the new headquarters is in operation.

Filed Under: Information, Projects

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Head Office

Varlowe Industrial Services Limited,
Patrick Gregory Road, Wednesfield, Wolverhampton, Wv11 3du

Phone: 01902 861042
Email: info@varlowe.co.uk

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