In Plant 1 the manufacturing process takes place in a fully automated and computerized sequence starting from its modern 110 T/H walking beam type – Reheating Furnace down to the compact-cassette roll-to-bearing assembly in the mill that is equipped with the latest stock slitting design, and its cutting length optimizations program for optimal process and operational control.
Rolling operations start with the loading of billets into the furnace charging table. Billets are automatically charged into the reheating furnace until they attain a rolling temperature up to 1150 degrees Celsius.
The continuous rolling mill train is designed with a constant pass line and comprises of horizontal and vertical arrangement stands. There are six stands in the roughing mill, six stands in the intermediate mill and six stands in the finishing mill.
The cross sectional area of the billet is continuously reduced as it passes through these stands. The production line flows with “no twist” continually through 18 stands and with minimal downtime.
The mill is equipped with a state of the art electronic control system, featuring level 1 and 2 automation and length cutting optimization.
The steel bars are then conveyed through a series of motorized rollers and cooled in the seventy six meter long Rake Type Cooling Bed. Plant 2 has the same design as plant 1. The furnace is of the Pusher type with a capacity of 75 T/H.
This plant is equipped with a water quenching system installed between the rolling mill and the cooling bed, in order to perform the heat treatment of Rebars.
On the exit side of the cold shear, bars are moved towards the entry of the chain transfer conveyor. All cut bars less than 12m in length are separated from the standard length bars to ensure that the required sizes enter the specific chain conveyor. In the chain conveyor, bars are counted via a bar counting machine which ensures the exact quantity of bars in each bundle.
After each bundle is weighed, a tag containing all product information is generated automatically and attached onto the bundle. The tag in each bundle contains information that can trace the source of billet used.
All reinforcing steel bars being produced in the mills undergo strict physical, mechanical and chemical tests in the quality assurance laboratory to ensure compliance to ASTM Standared and Classifications. Supplementary international specifications can be produced upon the customer’s request (BS, DIN) and others.
Both rolling mill plants are ISO 9001 and ISO 14001 certified. The two ISO certificates were awarded by the Bureau Veritas Certification Company.