20mm x 20mm x 2mm Mild Steel Box Section Steel Square Tube

How do I Connect or Join Mild Box Section Steel Tubes?

1. Welding:

   • MIG (Metal Inert Gas) Welding: Common for mild steel due to its efficiency and strength. It’s suitable for both thick and thin-walled tubes.
   • TIG (Tungsten Inert Gas) Welding: Used for precision joins, especially when a cleaner finish is desired.
   • Stick Welding: An older method but can be useful for thicker sections or in environments where equipment portability is essential.

   After welding, it’s vital to clean the weld area and apply a protective coating to prevent rusting.

2. Bolting:

   • Drill holes in the desired locations on the tubes.
   • Use appropriate bolts, nuts and washers to secure the sections together.
   • This method allows for disassembly in the future.

3. Specialised Connectors:

   • There are various commercial connectors available designed specifically for square tubes. These might include T-joints, corner connectors or cross connectors.
   • They provide strong connections without the need for welding and can be particularly useful for modular structures.

4. Sleeve Joints:

   • One tube is inserted into a slightly larger one, essentially “sleeving” it.
   • The joint can then be secured using bolts, pins or even welding.

5. Adhesive Bonding:

   • Industrial-grade adhesives can bond steel sections together.
   • While not as strong as welding, adhesive bonding can be useful for applications with lighter loads or where welding might affect the material’s aesthetics.

6. Riveting:

   • Similar to bolting, rivets provide a permanent joint between tube sections.
   • It’s less commonly used than bolting or welding but can offer a distinctive appearance.

7. Flanges:

   • Flanges can be welded to the ends of tubes, allowing them to be bolted together.
   • This method is useful for connections that might need to be disassembled and reassembled.

8. Tab and Slot:

   • Tabs are cut out on one tube, and slots are made on the other.
   • The tabs are inserted into the slots and then welded for a secure connection.

How do I Cut Mild Box Section Steel Tubes?

1. Safety First:

   • Wear appropriate personal protective equipment (PPE) such as safety glasses, gloves and ear protection.
   • Ensure the work area is well-ventilated if cutting indoors, especially if you’re using power tools that generate fumes.

2. Marking the Cut:

   • Use a straight edge or ruler and a metal scribe or marker to mark the exact location of your cut. This ensures accuracy and reduces the chance of making mistakes.

3. Manual Cutting:

   • Hacksaw: Suitable for small projects or single cuts. Ensure you have a blade designed for cutting metal. When using a hacksaw, secure the tube with a vise or clamps and apply consistent pressure while sawing.
   • Cold Chisel and Hammer: Not the cleanest method, but it can be used in a pinch. Mark the cut line, place the chisel on the mark and strike with a hammer. This method is more labor-intensive and less precise.

4. Power Tools:

   • Angle Grinder: One of the most common tools for cutting steel tubes. Fit the grinder with a metal cutting wheel. After marking the cut, use the grinder to make a clean cut through the tube. Ensure you’re cutting in a well-ventilated area and away from any flammable materials.
   • Circular Saw: Equipped with a metal cutting blade, a circular saw can also be used. However, it can be bulkier and less maneuverable than an angle grinder.
   • Chop Saw: Ideal for multiple cuts or if you need very straight cuts. Always use a metal cutting blade.

5. Tubing Cutters: Specialised tube cutting tools, similar to pipe cutters, are available. These are typically hand tools that you rotate around the tube, gradually tightening to cut through the metal. They offer a cleaner, burr-free cut.

6. Band Saw: For more industrial applications or workshops, a band saw with a metal cutting blade can provide precise, repeatable cuts, especially for thicker-walled tubes.

7. Laser and Plasma Cutters: These are advanced, industrial-grade tools that offer high precision and clean cuts. They’re ideal for workshops or manufacturing setups that need to cut large quantities or require high precision.

8. Finishing the Cut:

   • After cutting, there might be sharp edges or burrs. Use a file or an angle grinder with a flap disc to smooth the edges and make them safe to handle.
   • If you’ve used an angle grinder or saw, you might see discoloration around the cut due to heat. If aesthetics are a concern, this can be cleaned with a wire brush or sandpaper.