Corrugated galvanised iron or steel, colloquially corrugated iron (near universal), wriggly tin (taken from UK military slang), pailing (in Caribbean English), corrugated sheet metal (in North America) and occasionally abbreviated CGI is a

building material Building material is material used for construction. Many naturally occurring substances, such as clay, rocks, sand, wood, and even twigs and leaves, have been used to construct buildings. Apart from naturally occurring materials, many man- ...

composed of sheets of hot-dip galvanised

mild steel Carbon steel is a steel with carbon content from about 0.05 up to 2.1 percent by weight. The definition of carbon steel from the American Iron and Steel Institute (AISI) states: * no minimum content is specified or required for chromium, cobal ...

, cold-rolled to produce a linear ridged pattern in them. Although it is still popularly called "iron" in the UK, the material used is actually steel (which is iron alloyed with carbon for strength, commonly 0.3% carbon), and only the surviving vintage sheets may actually be made up of 100% iron. The corrugations increase the bending strength of the sheet in the direction perpendicular to the corrugations, but not parallel to them, because the steel must be stretched to bend perpendicular to the corrugations. Normally each sheet is manufactured longer in its strong direction. CGI is lightweight and easily transported. It was and still is widely used especially in rural and military buildings such as sheds and water tanks. Its unique properties were used in the development of countries such as Australia from the 1840s, and it is still helping

developing countries A developing country is a sovereign state with a lesser developed industrial base and a lower Human Development Index (HDI) relative to other countries. However, this definition is not universally agreed upon. There is also no clear agreem ...

today. Corrugated galvanised iron is also called corrugated steel sheet or corrugated steel metal. This is used as a roof of trench for soldiers in the military to protect them from enemy's fire attack. It can also be used as the roof of the commander's post. The phrase "Corrugated Steel Sheet" was used in the book, "Infantry Combat", therefore, we can assume that corrugated galvanised iron is used as corrugated steel sheet in the military.

History

Henry Robinson Palmer, architect and engineer to the London Dock Company, was granted a patent in 1829 for "indented or corrugated metallic sheets". It was originally made from

wrought iron Wrought iron is an iron alloy with a very low carbon content (less than 0.08%) in contrast to that of cast iron (2.1% to 4%). It is a semi-fused mass of iron with fibrous slag inclusions (up to 2% by weight), which give it a wood-like "grain" ...

. It proved to be light, strong,

corrosion Corrosion is a natural process that converts a refined metal into a more chemically stable oxide. It is the gradual deterioration of materials (usually a metal) by chemical or electrochemical reaction with their environment. Corrosion engi ...

-resistant, and easily transported, and particularly lent itself to prefabricated structures and improvisation by semi-skilled workers. It soon became a common construction material in rural areas in the United States, Argentina, Spain, New Zealand and Australia and later India, and in Australia and Argentina also became (and remains) a common roofing material even in urban areas. In Australia and New Zealand particularly it has become part of the cultural identity, and fashionable architectural use has become common. CGI is also widely used as building material in African slums and informal settlements. For roofing purposes, the sheets are laid somewhat like tiles, with a lateral overlap of one and half corrugations, and a vertical overlap of about , to provide for waterproofing. CGI is also a common construction material for industrial buildings throughout the world. Wrought iron CGI was gradually replaced by

from around the 1890s, and iron CGI is no longer obtainable, but the common name has not been changed. Galvanised sheets with simple corrugations are also being gradually displaced by 55% Al-Zn coated steel or coil-painted sheets with complex profiles. CGI remains common.

Corrugation today

Today the corrugation process is carried out using the process of roll forming. This modern process is highly automated to achieve high productivity and low costs associated with labour. In the corrugation process

sheet metal Sheet metal is metal formed into thin, flat pieces, usually by an industrial process. Sheet metal is one of the fundamental forms used in metalworking, and it can be cut and bent into a variety of shapes. Thicknesses can vary significantly; ex ...

is pulled off huge rolls and through rolling

dies Dies may refer to: * Dies (deity), the Roman counterpart of the Greek goddess Hemera, the personification of day, daughter of Nox (Night) and Erebus (Darkness). * Albert Christoph Dies (1755–1822), German painter, composer, and biographer * Jos ...

that form the corrugation. After the sheet metal passes through the rollers it is automatically sheared off at a desired length. The traditional shape of corrugated material is the round wavy style, but different dies form a variety of shapes and sizes. Industrial buildings are often built with and covered by

trapezoidal sheet metal A quadrilateral with at least one pair of parallel sides is called a trapezoid () in American and Canadian English. In British and other forms of English, it is called a trapezium (). A trapezoid is necessarily a convex quadrilateral in Eucli ...

. Many materials today undergo the corrugation process. The most common materials for corrugated iron are

ferrous In chemistry, the adjective Ferrous indicates a compound that contains iron(II), meaning iron in its +2 oxidation state, possibly as the divalent cation Fe2+. It is opposed to " ferric" or iron(III), meaning iron in its +3 oxidation state, suc ...

alloys An alloy is a mixture of chemical elements of which at least one is a metal. Unlike chemical compounds with metallic bases, an alloy will retain all the properties of a metal in the resulting material, such as electrical conductivity, ductility, ...

(e.g.

stainless steel Stainless steel is an alloy of iron that is resistant to rusting and corrosion. It contains at least 11% chromium and may contain elements such as carbon, other nonmetals and metals to obtain other desired properties. Stainless steel's r ...

s), aluminium and copper. Regular ferrous alloys are the most common due to price and availability. Common sizes of corrugated material can range from a very thin 30

gauge Gauge ( or ) may refer to: Measurement * Gauge (instrument), any of a variety of measuring instruments * Gauge (firearms) * Wire gauge, a measure of the size of a wire ** American wire gauge, a common measure of nonferrous wire diameter, es ...

() to a relatively thick 6 gauge (). Thicker or thinner gauges may also be produced. Other materials such as plastic and

fiberglass Fiberglass ( American English) or fibreglass (Commonwealth English) is a common type of fiber-reinforced plastic using glass fiber. The fibers may be randomly arranged, flattened into a sheet called a chopped strand mat, or woven into glass cl ...

are also given the corrugated look. Many applications are available for these products including using them with metal sheets to allow light to penetrate below.

Pitch and depth

The corrugations are described in terms of pitch (the distance between two crests) and depth (the height from the top of a crest to the bottom of a trough). It is important for the pitch and depth to be quite uniform, in order for the sheets to be easily stackable for transport, and to overlap neatly when joining two sheets. Pitches have ranged from 25 mm (1 inch) to 125 mm (5 inches). It was once common for CGI used for vertical walls to have a shorter pitch and depth than roofing CGI. This shorter pitched material was sometimes called "rippled" instead of "corrugated". However nowadays, nearly all CGI produced has the same pitch of 3 inches (76 mm). A design of corrugated galvanised steel sheets "Proster 21", used as

formwork Formwork is molds into which concrete or similar materials are either precast or cast-in-place. In the context of concrete construction, the falsework supports the shuttering molds. In specialty applications formwork may be permanently i ...

, has 21 millimetre deep V-shaped pits. Hückeswagen - Kölner Straße - Tennishalle 02 ies

Echo

Clapping hands or snapping one's fingers whilst standing next to perpendicular sheets of corrugated iron (for example, in a fence) will produce a high-pitched echo with a rapidly falling pitch. This is due to a sequence of echoes from adjacent corrugations. If sound is travelling at and the corrugated iron has a wavelength (pitch) of this will produce an echo with a maximum wavelength of that order, which corresponds to a frequency of 4500 Hz or so (approximately the C above top A on a standard piano). The first part of the echo will have a much higher pitch because the sound impulses from iron nearly opposite the clapper will arrive almost simultaneously.

Corrosion

Although

galvanising Galvanization or galvanizing ( also spelled galvanisation or galvanising) is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerg ...

inhibits the corrosion of steel, rusting is inevitable, especially in marine areas – where the salt water encourages rust – and areas where the local rainfall is acidic. Corroded corrugated steel roofs can last for many years, particularly if the sheets are protected by a layer of

paint Paint is any pigmented liquid, liquefiable, or solid mastic composition that, after application to a substrate in a thin layer, converts to a solid film. It is most commonly used to protect, color, or provide texture. Paint can be made in many ...

References

External links

Corrugated Metal Roofing & Paneling

Heritage Roofing in Victoria, Australia (PDF, 181 kB)
{{DEFAULTSORT:Corrugated Galvanised Iron Steels Building materials Corrugation Roofing materials