Steel is one of the most essential building materials in the world, with 1.9 billion metric tons produced annually. It’s so integral to our daily lives that we often overlook its importance. But what exactly is steel, and how is it made?

Why Steel is Essential

Steel’s popularity stems from its impressive strength-to-weight ratio, making it ideal for structures that need to withstand high pressures and harsh weather conditions. For example, structural steel, commonly used in large construction projects, boasts a yield stress of 50,000 pounds per square inch. This strength, combined with its relatively low cost, makes steel an invaluable material for everything from skyscrapers to intricate gadgets.

Steel’s sustainability is another major advantage. Nearly all structural steel available today is made from recycled materials, and it’s fully recyclable itself. Many demolition companies even pay for scrap steel to be remade and resold, making steel not only a robust material but also an environmentally responsible choice.

What is Steel Made of?

At its core, steel is an alloy primarily composed of iron and carbon. The exact composition varies depending on the type of steel being produced. Carbon steels, which make up about 90% of steel production, consist almost entirely of iron and carbon, with minimal amounts of other metals. These steels are graded based on their carbon content, with higher carbon levels resulting in harder, stronger steel that is less ductile—ideal for tools and heavy-duty applications. Carbon steels are often galvanized to protect against rust.

The other main category is alloy steel, which includes stainless steel. These steels contain various other elements, such as chromium and vanadium, to meet specific needs. For example, stainless steel’s high resistance to corrosion makes it ideal for applications requiring cleanliness and precision.

The Steelmaking Process

Steelmaking has evolved over thousands of years. Today, the most common method starts with blasting taconite chunks into small pieces, which are then crushed into a fine powder. Magnetism is used to extract iron ore from this powder, which is subsequently smelted into “pig iron.” Pig iron has a high carbon content (around 3.5-4.5%) and needs further refining. Oxygen bubbles are introduced to remove excess carbon and impurities.

Once refined, the steel can be alloyed with other elements like chromium, depending on its intended use. The final product is then molded into various shapes and sizes in a foundry or mill, with heat treatment applied as needed. Once the steel has served its purpose, it can be recycled by melting it down, removing impurities, and reforging it into new ingots, continuing the cycle.

Butler’s Use of Steel in Construction

At Freeman Building Systems, many of our projects involve using Butler Manufacturing’s Building Solutions. We choose Butler because of its proven building quality and pioneer innovations. With a dedicated Research and Development Center, Butler Manufacturing ensures its products are tested for strength, efficiency, and longevity.

For over 30 years, Freeman Building Systems has been a trusted part of the community, delivering efficient and cost-effective design/build steel construction solutions. Our commitment to excellence is backed by a team with over 500 years of combined experience. As a proud partner of Butler Manufacturing™, a leader in innovative building solutions, we specialize in advanced steel building systems for Warehouses and Distribution Centers, Heavy Manufacturing, Aircraft Hangars, and Athletic Facilities, known for their design flexibility, durability, and efficiency. Together, Freeman Building Systems and Butler Manufacturing™ provide high-quality, customized steel construction that is built to last.