Kairali’s TMT steel has been catering to the construction requirements of many contractors, architects, engineers etc for many years. Our TMT steel’s strength, bendability, corrosion resistance, damage resistance and more are the reasons why it’s being widely chosen.
So, what gives our steel all these impressive attributes?
Our high-quality raw materials and unique manufacturing process are the key reasons. Wondering what makes our manufacturing process unique? Keep reading!
Let’s see in detail how our manufacturing works.
Before that, let us give you an outline of our rolling mill. Let’s get started.
Specialities Of Kairali TMT’s Rolling Mill
- Our rolling mill is fully automated, and this kind is the only one in Kerala.
- Since it’s automated, manufacturing requires less number of labours.
- Our machines and equipment are imported from Germany
- Minimal wastage of materials since our TMT bars are supplied in a fixed length of 12 metres. This also makes our mill eco-friendly.
- The automatic manufacturing technology is programmed to bolster safety.
- Our mill boasts an automatic cooling bed, which helps to give our bars a better finish and straightness. It also helps in consistent cooling.
Now, let’s dive into our manufacturing process.
Kairali TMT Steel’s Manufacturing Process
Our automated rolling mills are fully supervised by frontline metallurgists and engineers. And, we use imported high-quality raw materials. Here is our process:
Step 1 – Processing of Iron Ore
At Kairali, we use high-quality dolomite iron ore as the raw material along with coal, limestones etc.
Firstly, the raw materials are processed in the furnace in the molten state using hot gases. Now, the processed iron goes through beneficiation, which helps in keeping the impurities away and improving the quality of the iron. Next, the molten iron undergoes pre-treatment and ladle heating to not only convert to steel but also better the chemistry of the steel.
Step 2 – Producing Billets & Moulding Them
While converting the iron to steel, oxygen is blown into the furnace and this process helps to flush out carbon. Now, billets are produced by pouring the molten steel into a casting machine and heating it at 1200°C.
The next step is moulding the billet into the size and shape of the rebars. For this, the billets pass through a rolling mill stand, and thus, it gets the shape of bars.
Step 3 – Quenching
This is where the Thermo-mechanical treatment starts. Here, the hot bars converted from billets, undergo quenching. Quenching is a process where the hot bars go through a water spraying system called Thermex System.
Hence, the temperature of the bars plummets and this helps to convert the outer surface of the bar to Martensite material. This material toughens the outer surface, giving the bar enhanced tensile strength and durability.
At the same time, the core of the bar remains hot and soft.
Step 4 – Self-tempering
This is the second stage in the Thermo-mechanical treatment. As mentioned above, the core remains hot after the quenching process. The core then transfers the heat to the outer surface. Now, the Martensite material heats up and becomes Tempered Martensite, giving the bar extra toughness. On the other hand, the inner part of the bar remains in the same state.
Step 5 – Atmospheric Cooling
This is the final step in the whole manufacturing process and Thermo-mechanical treatment. Here, the bars are rested on an automatic cooling bed for atmospheric cooling. This levels the temperature difference between the core and the outer surface. Once cooled, the core changes to a structure called ductile ferrite-pearlite, making the bar flexible, robust and ready to be supplied.
Need High-quality TMT Steel Bars? Approach Kairali
Trust us, we provide top-notch TMT Steel bars. First of all, as said above, our manufacturing system is fully automated, making our products perfect in their size and shape. Furthermore, our products have high tensile-to-yield strength ratios, high ductility, excellent flexibility, corrosion-resistance ability and resistance ability to ageing. Most importantly, Kairali TMT Steel Bars use EQR German Technology, which has the ability to suppress energy waves released during Earthquakes, helping to reduce damages from seismic impacts.
Contact us to learn about the pricing of our TMT Steel Bars.