STEEL ROLLING MILL (M.S. ROD)

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Steel reinforcement bar is also known as rebar, reinforcing bar, reinforcing steel and reinforcement steel. It is a versatile constructional material which is widely used in the construction industry for making of the reinforced concrete. Reinforcement concrete (RC) is a composite material made up of concrete and some form of reinforcement – most commonly steel rods, bars, wires or mesh of steel rods and steel wires. The steel reinforcement bars usually consists of such shape and size that they may easily be bent and placed in the concrete so as to form a monolithic structure.

The properties of thermal expansion for both steel and concrete are approximately the same. This along with excellent bendability property makes steel the best material as reinforcement in concrete structures. Another reason steel works effectively as reinforcement is that it bonds well with concrete. When passive reinforcement (steel bars) is employed, the structure is known as reinforced concrete structure. In pre-stressed concrete structure, the reinforcement (steel wire) is stressed prior to subjecting the structure to loading, which may be viewed as active reinforcement. Passive steel reinforcing bars, also known as rebars, should necessarily be strong in tension and, at the same time, be ductile enough to be shaped or bent.

Steel rebar is most commonly used as a tensioning devise to reinforce concrete to help hold the concrete in a compressed state. Concrete is a material that is very strong in compression, but virtually without strength in tension. To compensate for this imbalance in a concrete slab behavior, reinforcement bar is cast into it to carry the tensile loads. The surface of the reinforcement bar may be patterned to form a better bond with the concrete.

Reinforced concrete gets its strength from the two materials, steel and concrete, working together. To get them working together, it is critical that the steel be adequately bonded to the concrete. Achieving this bond is called developing the bar, and many aspects of reinforcement design are geared toward achieving development.

Steel rebars are the time proven match for reinforcing concrete structures. RC structures are designed on the principle that steel and concrete act together to withstand induced forces. The aim of the reinforced concrete designer is to combine the reinforcement with the concrete in such a manner that sufficient of the relatively expensive reinforcement is incorporated to resist tensile and shear forces, whilst utilizing the comparatively inexpensive concrete to resist the compressive forces.

To achieve this aim, the designer needs to determine, not only the amount of reinforcement to be used, but how it is to be distributed and where it is to be positioned. These decisions of the designer are critical to the successful performance of reinforced concrete and it is imperative that, during construction, reinforcement be positioned exactly as specified by the designer.

Originally concrete structures were made without reinforcement. The use of rebars has started in construction since at least the 18th century. Earlier cast iron was the materials for the rebars. This was because cast iron rebars were of high quality, and there was no corrosion on them for the life of the structure. Later the technique was refined by embedding the steel bars in the reinforced concrete structures. Plain mild steel rebars of strength 250 MPa were used widely till about 1960s. Square twisted steel bars (deformed bars) were introduced in 1960s. But these were phased out due to their inherent inadequacies.

Description

INTRODUCTION
COMMON DEFINITIONS CONNECTED WITH STEEL REINFORCEMENT BARS
CHEMICAL COMPOSITION
THEORETICAL WEIGHT
USES AND APPLICATION
MARKET SURVEY
MARKET SIZE
HISTORICAL BACKGROUND
COMMODITIZING REBAR MARKETS
FRAGMENTED MARKETS
BRANDING IN THE REBAR INDUSTRY
FRP IN THE FRAY,
A GLOBAL EXPERIENCE
OUTLOOK
MARKET POSITION OF RE-BARS
LONG STEEL INDUSTRY – A SUNSHINE SECTOR IN INDIA
THE DEMAND TREND FOR VARIOUS LONG STEEL PRODUCTS
IS DEPICTED BELOW:
THE DEMAND BREAK-UP OF BARS AND RODS (NON-ALLOY)
FOR 2012-13 IS DEPICTED BELOW:
PRODUCT UPGRADES
TECHNOLOGY IMPACT
MARKET OPPORTUNITIES/DEMAND DRIVERS
CHALLENGES AND RESTRAINTS
EXPORT DATA OF TMT BARS
IMPORT DATA OF TMT BARS
BRITISH STANDARD (B.S)
MANUFACTURERS/SUPPLIERS OF M.S ROD
PROCESS FLOW CHART FOR RE-BAR
MANUFACTURING PROCESS OF M.S BILLET
INDUCTION FURNACE WITH CCM
(1) MELTING PROCESS
(2) CONTINUOUS CASTING PROCESS OF BILLET
THE MAIN OPERATIONS INVOLVED IN THE WHOLE PROCESS
OF TURNING OUT BILLETS ARE:
LUBRICATION
MOULD
SECONDARY COOLING
BILLET CUTTING
BILLET PROCESSING
(3) ROLLING PROCESS
A. ROUGHING MILL
B. INTERMEDIATE MILL
C. FINISHING MILL
(4) FINISHING SECTION
5. INSPECTION AND TESTING OF BAR
STAGE WISE INSPECTION DETAILS
FIGURE 8(A): INCOMING MATERIAL INSPECTION
FIGURE 8(B): IN PROCESS INSPECTION DATA COLLECTED FOR TMT RODS
6. DISPATCH:
WORKING PRINCIPLE OF CONTINIOUS CATING PROCESS
UNDERSTANDING THE PROCESS OF CONTINUOUS CASTING OF STEEL
REQUIREMENTS FROM LIQUID STEEL
TUNDISH APPLICATION
LIQUID STEEL SHROUDING
LIQUID STEEL FLOW CONTROL
MOULD AND HEAT TRANSFER
SECONDARY COOLING, STRAND CONTAINMENT AND WITHDRAWAL
CONTINUOUS CASTING OF STEEL BILLETS
THE PROCESS OF THE CONTINUOUS CASTING
OF STEEL BILLETS IS DESCRIBED BELOW.
STEEL LADLE
TUNDISH
MOULD
SECONDARY COOLING
CONTINUOUS CASTING MACHINE AND ITS EQUIPMENT
TYPES OF CONTINUOUS CASTING MACHINES
CONTINUOUS CASTING MACHINE EQUIPMENT
LADLE TURRET
TUNDISH
MOULD
SECONDARY COOLING
STRAND CONTAINMENT
BENDING AND STRAIGHTENING
DUMMY BAR
FACILITIES BEYOND BENDING AND STRAIGHTENING SECTION
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERIES
SCRAP BAILING MACHINE
INDUCTION FURNACE
ANNEALING FURNACE
HEATREATMENT FURNACE
CONTINIOUS BILLET CASTING COMPELETE PLANT
COOLING BED
DRILLING MACHINE
MILLING MACHINE
CNC LATHE MACHINE
BOARING MACHINE
POWER HACKSAW
GRINDING MACHINE
POWER PRESS
WELDING MACHINE
EOT CRANE
POWER TRANSFORMERS
ELECTRICAL PANEL
COOLING TOWER
EFFULENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
SHOT BLASTING MACHINE
JIGS AND FIXTURE
SUBMERSIBLE WATER PUMP
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PIG IRON
SUPPLIERS OF SPONGY IRON
STEEL SCRAPE
FERRO SILICON
COKE
LIME
DEGREASING CHEMICAL
PICKLING CHEMICALS

APPENDIX – A:

1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET

Additional information

Plant Capacity

100.00 MT./day

Land and Building

(12,000 sq.mt)

Plant & Machinery

US$ 2732857

Rate of Return

39%

Break Even Point

53%