Industry Overview
Steel reinforcement bar, commonly known as rebar, reinforcing bar, reinforcing steel, or reinforcement steel, is a fundamental construction material used to reinforce concrete structures. Reinforced concrete combines concrete's high compressive strength with steel's tensile strength, ductility, bendability, and strong bond with concrete. The similar thermal expansion characteristics of steel and concrete further support their effective combined performance.
The use of rebars in construction dates back to at least the 18th century, when cast iron was used before steel became the preferred reinforcement material. Plain mild steel rebars of 250 MPa strength were widely used until about the 1960s, followed by deformed bars and cold twisted deformed (CTD) bars. CTD round rebars with yield strength in the range of 415 MPa were introduced in the late 1960s. Quenched and self-tempered (QST) bars, popularly known in India as thermo mechanical treated (TMT) steel rebars, were introduced during the late 1970s.
TMT rebars are produced by rapidly quenching hot rolled bars with water and subsequently allowing them to cool under ambient conditions. This creates a composite structure with a tough tempered-martensite surface and a ductile ferrite-pearlite core, providing a combination of strength, ductility, and bendability. Proper characterization, storage, handling, bending, placement, concrete cover, and corrosion protection are essential for ensuring the durability and structural performance of reinforced concrete.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 600 MT/Day |
| Land & Building (48563 sq.mt.) | Rs. 141.54 Cr |
| Plant & Machinery | Rs. 114.50 Cr |
| Working Capital for 2 Months | Rs. 128.78 Cr |
| Total Capital Investment | Rs. 403.34 Cr |
| Rate of Return | 29% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- FIG 1 TYPICAL CROSS SECTION OF STEEL REBAR
- 460 STEEL REBAR BS-BRITISH STANDARD
- CHEMICAL COMPOSITION
- THEORETICAL WEIGHT
- 460 STEEL REBAR BS4449-1997-BRITISH STANDARD
- USES AND APPLICATION
- BRITISH STANDARD (B.S)
- 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
- 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 CONTINUOUS CASTING PROCESS
- REQUIREMENTS FROM LIQUID STEEL
- TUNDISH APPLICATION
- LIQUID STEEL SHROUDING
- LIQUID STEEL FLOW CONTROL
- MOULD AND HEAT TRANSFER
- SECONDARY COOLING, STRAND CONTAINMENT AND WITHDRAWAL
- FIG 1 SCHEMATICS OF CC PROCESS AND THE PHENOMENA IN THEMOULD REGION
- CONTINUOUS CASTING OF STEEL BILLETS
- FIG 1 SINGLE STRAND BILLET CASTER
- FIG 2 EIGHT STRAND BILLET CASTING MACHINES
- STEEL LADLE
- TUNDISH
- MOULD
- SECONDARY COOLING
- CONTINUOUS CASTING MACHINE AND ITS EQUIPMENT
- FIG 1 TYPICAL SECTION AND PLAN VIEW OF A CC MACHINE
- 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
- MARKET POSITION
- ROLLING MILL MARKET: SEGMENTATION
- BY MACHINE TYPE
- BY PROCESS
- BY APPLICATION
- BY END USE
- MARKET GROWTH
- PRESENT MANUFACTURERS/SUPPLIERS
- SUPPLIERS OF M.S RE-BAR
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF SCRAP BALING MACHINE
- SUPPLIERS OF INDUCTION FURNACE
- SUPPLIERS OF ANNEALING FURNACE
- SUPPLIERS OF HEAT TREATMENT FURNACE
- SUPPLIERS OF CONTINUOUS BILLET CASTING COMPELETE PLANT
- SUPPLIERS OF ROD ROLLING COMPELETE PLANT
- SUPPLIERS OF COOLING BED
- SUPPLIERS OF DRILLING MACHINE
- SUPPLIERS OF MILLING MACHINE
- SUPPLIERS OF CNC LATHE MACHINE
- SUPPLIERS OF BOARING MACHINE
- SUPPLIERS OF POWER HACKSAW
- SUPPLIERS OF GRINDING MACHINE
- SUPPLIERS OF POWER PRESS
- SUPPLIERS OF WELDING MACHINE
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PIG IRON
- SUPPLIERS OF SPONGY IRON
- SUPPLIERS OF STEEL SCRAPE
- SUPPLIERS OF FERRO ALLOY
- SUPPLIERS OF COKE
- SUPPLIERS OF LIME
- SUPPLIERS OF FERRO SILICON
- SUPPLIERS OF DEGREASING CHEMICAL
- SUPPLIERS OF PICKLING CHEMICALS
- PLANT LAYOUT
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Steel reinforcement bar is primarily used to provide tensile strength and reinforcement within concrete structures. Concrete performs strongly under compression but has limited tensile strength, so steel rebars are embedded within it to carry tensile and shear forces. Rebars are also used as distribution or thermal reinforcement, to control cracking, support concentrated loads, and maintain the position of other reinforcement bars. Their ribs improve mechanical bonding with concrete, allowing the two materials to act together as a reinforced concrete structural system.
Steel is suitable for reinforcing concrete because it provides high tensile strength, ductility, bendability, and effective bonding with concrete. Steel and concrete also have approximately similar thermal expansion characteristics, which helps the composite structure perform reliably when temperatures change. Reinforcement allows concrete to resist tensile forces that it cannot adequately withstand on its own. The resulting combination enables designers to use concrete primarily for compression while strategically positioning steel reinforcement to resist tension, shear, cracking, and other induced forces.
CTD rebars obtain increased strength primarily through cold working, while TMT rebars obtain their characteristic properties through quenching and self-tempering. CTD steel bars are produced by stretching and twisting mild steel beyond the yield plateau and subsequently releasing the load. TMT, or QST, bars are rapidly quenched after rolling and then allowed to cool in ambient conditions. Heat from the core tempers the hardened surface, producing a composite structure that combines a tough surface with a more ductile core.
Steel reinforcement bars can be manufactured through a sequence involving steel melting, continuous casting of billets, rolling, finishing, inspection, testing, and dispatch. The report describes induction furnace melting followed by continuous casting, including tundish application, liquid steel shrouding, mould operations, secondary cooling, strand containment, withdrawal, and billet cutting. The billets then pass through roughing, intermediate, and finishing mills. For TMT rebars, controlled quenching and self-tempering can be incorporated to achieve the required combination of strength, ductility, and bendability.
Correct concrete cover is essential because it protects reinforcement against corrosion and helps reinforced concrete members meet their design requirements. Too little cover can reduce the protection provided by the concrete and allow carbonation or salt penetration to reach the steel. Excessive cover can contribute to larger crack widths and associated durability problems. Corrosion can cause steel to expand, generating internal pressure that may produce cracking and spalling of surrounding concrete. Proper cover therefore contributes significantly to the long-term durability and structural performance of reinforced concrete.
Steel reinforcement bars should be stored neatly on a prepared platform above ground and protected from corrosion and contamination. The report recommends keeping the bars away from mud, grease, oil, paint, loose rust, and other deleterious matter. For prolonged storage or storage in a marine environment within 10 km of the sea, the piles should be covered. Bars should preferably be inspected before delivery to the point of use, and any significant pitting should be treated as a potential structural concern requiring rejection where it exceeds permitted limits.
Welding of reinforcement depends on the type and condition of the steel bar and should follow the applicable design and material requirements. The report states that welding is generally not permitted for high tensile steel because heating hot rolled bars can cause brittle fracture. For cold worked deformed steel bars, heating can eliminate the effects of strain hardening and cause the material to revert toward mild steel properties. Welding is normally permitted on mild steel and, in some cases, on quenched and self-tempered steel rebars when appropriate requirements are satisfied.
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