EN 10210 Steel Hollow Sections: Common Mistakes to Avoid During Installation

If you've ever walked onto a construction site or peered up at a skyscraper under construction, you've probably seen them—sleek, sturdy steel sections forming the backbone of the structure. Many of those are likely EN 10210 steel hollow sections, the unsung heroes of modern structure works. From bridges to industrial facilities, these tubes are prized for their strength, durability, and versatility. But here's the thing: even the best materials can fail if installed the wrong way. Over the years, I've watched countless projects hit snags, delays, or even safety risks because of small, avoidable mistakes during installation. Let's dive into the most common ones—and how to steer clear of them.

Mistake #1: Cutting Corners on Handling and Storage

Picture this: A delivery truck rolls up to the site, and the team is in a rush to unload. They toss the EN 10210 sections off the truck bed, letting them clatter onto the ground. Later, they stack them haphazardly in a damp corner, exposed to rain and mud. Sound familiar? It's a scene I've witnessed too often, and it's a recipe for disaster.

EN 10210 steel hollow sections are tough, but they're not indestructible. Dropping them can dent the walls or bend the tubes, weakening their structural integrity. Stacking them unevenly can cause warping, making them impossible to align properly during installation. And leaving them out in the elements? That's an open invitation for rust, which eats away at the steel and compromises its strength over time.

How to avoid it: Treat these sections like the critical components they are. Use lifting slings or forklifts with padded arms to move them—never drag or ｄｒｏｐ them. Store them on a flat, elevated surface (like wooden pallets) to keep them off wet ground, and cover them with tarps if rain is in the forecast. A little care during handling saves hours of rework (and headaches) later.

Mistake #2: Rushing Measurements—"Close Enough" Isn't Good Enough

"It's just a few millimeters off—no one will notice." I've heard that line before, and it's almost always followed by a project delay. EN 10210 sections are designed to fit together with precision, especially in structure works where alignment directly impacts stability. A measurement off by even 5mm can throw off an entire frame, leading to gaps, misaligned bolt holes, or uneven weight distribution.

I once worked with a team that skipped double-checking their measurements for a warehouse frame. They cut a section 10mm too short, assuming they could "adjust" during welding. By the time they realized the mistake, the adjacent sections were already in place, and they had to cut and reorder new material—costing them two weeks of work and thousands of dollars.

How to avoid it: Slow down. Use calibrated measuring tools (no, a frayed tape measure won't cut it) and mark cuts with a sharpie or chalk line. Have a second person verify measurements before cutting. For complex angles, create a template first. Remember: In construction, precision isn't a luxury—it's a necessity.

Mistake #3: Skimping on Welding Prep and Technique

Welding is where the strength of EN 10210 installations truly comes to life—or falls apart. Too often, teams rush the process: they skip cleaning the metal, use the wrong welding settings, or let untrained crew members handle the torch. The result? Weak, brittle welds that crack under pressure, putting the entire structure at risk.

Take, for example, a bridge project I consulted on a few years back. The crew was behind schedule, so they started welding EN 10210 sections without removing the mill scale (that thin layer of oxide on new steel). The welds looked fine at first, but within months, rust started seeping through the cracks. An inspection revealed the welds had only bonded to the scale, not the steel itself—requiring a costly repair to prevent a potential collapse.

How to avoid it: Prep is everything. Grind or sand the welding area to remove rust, scale, and dirt. Use the right filler metal for EN 10210 (check the material specs!) and set the welder to the correct amperage and voltage. Most importantly, ensure the person welding is certified for structural steel work. A quick certification check can save you from catastrophic failures down the line.

Mistake #4: Ignoring the Environment—Weather and Site Conditions Matter

EN 10210 steel hollow sections don't exist in a vacuum—they're installed outdoors, in all kinds of weather. Yet many teams act like temperature, humidity, and even wind don't affect the process. Welding in freezing rain? Installing in a dusty industrial area without protecting the steel? These choices don't just slow you down—they damage the material.

In coastal areas, for instance, salt air accelerates corrosion. A project in Miami once ignored this, leaving EN 10210 sections exposed to sea spray during installation. Within six months, the uncoated ends of the tubes had started rusting, even though the rest of the structure was painted. The team had to sandblast and re-coat the affected areas, adding unexpected costs to the budget.

Cold weather is another culprit. Welding steel below 0°C (32°F) can lead to hydrogen cracking, where moisture in the air gets trapped in the weld and weakens it. I've seen this happen on a winter construction site in Chicago—welds that looked solid in the cold cracked when the temperature rose, forcing a complete redo.

How to avoid it: Check the forecast before starting work. In humid or coastal areas, apply a temporary corrosion inhibitor to exposed steel edges. For cold-weather welding, preheat the steel to the recommended temperature (usually 150–200°C) and keep the area sheltered from wind and rain. If conditions are too extreme, pause work—better to delay a day than risk a failed installation.

Mistake #5: Forgetting About Compatibility with Pipe Fittings and Connections

EN 10210 sections rarely stand alone—they connect to other components, like pipe fittings, flanges, or brackets. But here's a common oversight: assuming all fittings work with all steel types. Using the wrong fitting material or size can lead to leaks, misalignment, or even structural failure.

A petrochemical facility project comes to mind. The team was installing EN 10210 structural supports and needed to connect them to existing carbon steel pipe fittings. Instead of checking the compatibility, they used standard threaded fittings, not realizing the EN 10210 had a thicker wall. The threads stripped during installation, causing a delay while they sourced the correct heavy-duty fittings.

How to avoid it: Match fittings to the EN 10210 specs. Check the wall thickness, diameter, and material grade of both the section and the fitting. For high-pressure applications (like in industrial settings), use certified pipe fittings designed for structural works. When in doubt, consult the manufacturer's guidelines—they're there for a reason.

Quick Reference: Common Mistakes & Fixes