Introduction
The construction industry is a vital component of modern society, responsible for creating the infrastructure and buildings that shape our world. However, the industry is not without its challenges. Corrosion, quality, and labour issues are just a few of the hurdles that construction companies face daily. These issues not only impact project timelines and budgets, but also the safety and durability of the structures being built. In this blog, we will explore strategies and innovative solutions for overcoming corrosion, quality, and labour hurdles in the construction industry.
Corrosion Resistance
Sitting at US $2.2 trillion in 2016, over 3% of global GDP was spent on corrosion. With growing concerns over corrosion within steel products particularly, understanding the potential risks and costs involved in installing low quality components is a vital factor in ensuring that what we build now, is built to last.
Essentially the backbone of modern industrialisation, steel is the material of highest concern. Prone to rusting at varying speeds, dependent on the grade, steel is an incredibly strong metal that requires our undivided attention. Consider a commercial building or warehouse; invariably, the framework of both will consists of steel beams and connecting products. Without the correct anti-corrosion protection, such as hot dip galvanising, it is inevitable that rust will set in. From here it is simply a matter of time until these supporting components can no longer carry out their task and fail.
It is worth noting that this is a very uncommon occurrence. Following the construction of a building, maintenance companies are appointed to monitor and ensure its continued structural health. However, it is here where, should sub-par product have been installed, the most common of consequences is realised: cost.
According to the Galvanisers Association, the cost of a ‘cheaper’ paint job (alternative finishes) is nearly 70% more expensive across a 25-year project life when compared with hot dip galvanising.
Sticking with this finish, while it is not as aesthetically pleasing as paint, it is purposely designed to protect the material it covers. Being ‘sacrificial,’ galvanising oxidises quicker than the base material, essentially allowing itself to be consumed in defence of the more rust-prone metal beneath. Further to this, galvanising also repairs itself when damaged, proving itself over many years and decades as the primary coating for use on external metal applications.
With steel conduit systems in particular, a minimum coating thickness of 55 microns is recommended. When used for inland installations in the UK, the typical rate of loss to this coating is approximately one micron per year, moving up to two microns around more coastal areas. Overall, this superior finish is designed to protect critical cable management or load-bearing systems for 20 years or more.
Structures are built to last. But that does not mean that once construction has finished it is all over. Repairs and retrofits however can be postponed.
When it comes to external environments in particular, the reality is that there is no method of 100% protecting products from the effects of corrosion, even those with the most robust of finishes. It makes sense therefore to build and install using only the highest quality products which meet the latest standards. Without this mindset, the cost of corrosion is only going to continue to grow.
Product Quality
Tying directly into the challenge around corrosion resistance, general product quality is just as important during the lifetime of a construction, from procurement to maintenance.
Cost has commonly been the deciding factor for many, and with the price rises seen over the past couple of years, it has only exacerbated the trend of undermining quality for price. There is however a clear and decisive shift currently moving clearly away from this mindset.
Low quality product tends to be indicative of a low-quality operation, manufacturing, logistics, customer service etc. Whilst there tends to be a positive feeling linked with ‘getting a good deal,’ when it comes to construction products, the adage of ‘you get what you pay for’ is at its most potent.
Contractors are becoming less and less accepting of inferior quality, and it is easy to understand why. Not only can it mean delays on-site, but it can also mean delays for the project in entirety which are often extremely costly. Expecting to be conducting a particular task on a particular day also means having the appropriate staff on-site who may not be able to do their jobs with low quality components – they do however still need to be paid.
Procurement processes are also becoming more robust, making it harder for inferior components to reach anywhere near the install phase.
Construction is expensive – this is a fact. Using lower quality product for the sake of a small cost-saving which could fail or at least incur further costs and delays simply does not make sense. As an industry, we must ensure that only the highest quality standards are adhered to, in turn leading to a much smoother supply chain, and one built on confidence and trust.
Recognising these challenges and daily pain-points is essential, and a number of manufacturers within the UK are working to ensure that the products they produce are always fit-for-purpose.
Rising Labour Costs
Following the huge loss of EU workers post-Brexit, health risks on-site posed by the ongoing pandemic, the abrupt stalling of projects caused by the conflict in Europe, and now the cost-of-living crisis in the UK, labour costs have had to increase in line with these global and domestic challenges.
In an industry where margins are already razor thin, contractors are continually seeking new methods of working which will allow them to secure work, whilst also being as cost effective as possible. With many projects over-reaching their budgets and experiencing delays, understanding how we as an industry can support better working practices will be essential to delivering the projects of the future on time and within budget.
One such method is through innovation. Certain systems within cable management have been employed for many years. The steel conduit tube system for example has been in use now for over a century. With the world speeding up at an ever-increasing rate, so to must construction.
It is here where manufacturers will play a key role, but it will not be an easy one. Fast-fix products which do not compromise on quality are now in extremely high demand and bringing new products to market which offer the same overall functionality is no easy feat. Additionally, and with the construction industry being largely traditional, offering innovations which also hold a familiar look and feel is an extra consideration which manufacturers would benefit from keeping in mind.
Already on the market, we are seeing more and more new concepts popping up, many which offer more than just labour savings. Greater on-site safety, consolidation of product, easy retrofitting and many other benefits are also being realised, painting an overall very encouraging picture.
Innovations For the Built Environment from Demon Cato
Conlok
With traditional systems, the spout threading process occurs after the protective galvanising is applied, stripping this protection away and leaving large areas of exposed material. Due to the innovative nature of Conlok’s built-in grub screw, there is no need for threaded spouts, meaning these areas remain fully protected, from manufacture to installation and beyond.
No threaded spout means no need to thread steel conduit tube. Based on testing with a certified UK contractor, a standard conduit box takes five minutes to install; Conlok however takes only one. Not only does this offer increased on-site safety, but it also results in labour savings of up to 75%
Rapid Saddle
Designed with a unique hinged strap, Rapid Saddle is a brand-new innovation catering for both traditional spacer bar and distance saddles, made possible through its 5mm deep base - perfect for uneven walls. Allowing steel conduit tube to be held in situ. and ideal for a single installer, Rapid Saddle offers the end user over 40% labour savings.
Rapid Saddle benefits from Delta Protekt® 120, a new finish for the electromechanical sector, and one which offers comparable anti-corrosion properties to Hot Dip Galvanising. It offers a cleaner and more aesthetically pleasing end product.
Rollatray
With a high number of exposed edges formed during the manufacturing process, Rollatray benefits from an additional application of a dry-to-touch oil mist before packaging. This extra step not only protects it in transit, but more importantly offers a protective coating to those raw edges, ensuring each coil will remain functional for an extended period of time.
Conceived and designed to dramatically reduce downtime in underfloor applications, Rollatray removes the need for couplers and brackets, with each 15-metre coil rolling out in 15 seconds. Fixed directly to a solid surface and lying flat once rolled out, Rollatray offers huge labour savings of up to 90%.
Conclusion
Overall, it is evident that construction projects come with challenges, but with the right strategies in place, these challenges can be managed successfully. Corrosion is a serious issue that can cause costly structural damage, but proper corrosion protection treatments and materials can help mitigate these risks. Quality issues should not be overlooked, as innovative materials and building practices can ensure that constructed structures are able to stand the test of time. Labour shortages have increasingly become an issue for many companies which make it necessary to use manpower optimisation technology to streamline their workflow.
Utilising products such as Demon Cato brand from Metpro can help you to over these issues.
If you have a question relating to Demon Cato products or want help choosing the right type of product to overcome the issues raised in this blog, please contact the CMW team by emailing sales@cmwltd.co.uk
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