TLDR;
This video showcases the manufacturing process and quality control measures of iSTEEL TMT construction bars, emphasizing their durability, strength, and cost-effectiveness. It highlights the use of advanced technology in production, rigorous testing procedures, and customer-centric services like pre-cut bars and stirrups.
- iSTEEL uses high-quality raw materials and state-of-the-art manufacturing processes to produce durable TMT bars.
- The company emphasizes rigorous testing and quality control, including chemical composition analysis, strength tests, and bend/rebend tests.
- iSTEEL offers customer-centric services such as pre-cut bars and stirrups to reduce waste and save construction costs.
Introduction to iSTEEL [0:37]
iSTEEL aims to be a partner in creating durable, maintenance-free homes. The company has quickly gained a reputation for superior quality and uniqueness. With over 20 years in the steel manufacturing and marketing industry, iSTEEL operates a fully integrated facility with a state-of-the-art metallurgical laboratory. The company is ISO 9001:2000 certified and exceeds ISI specifications in product quality. Their TMT bar manufacturing facility is inspected and certified by L&T for quality and supply capabilities.
Manufacturing Process: From Raw Materials to Billets [2:17]
The TMT construction bars are manufactured using a computer-controlled water quenching process. High-quality raw materials are charged into a 25-ton steel-making furnace, and the liquid metal is regularly tested to ensure it meets ISI specifications. The chemical composition is crucial for achieving the desired properties in various steel grades like Fe 415, Fe 500, Fe 550, and CRS (corrosion-resistant steel). Carbon provides strength, while manganese offers flexibility. Once the liquid steel reaches 1,660 degrees Celsius, it is poured into a ladle and purged with inert gas to homogenize the temperature and remove dissolved gases. The steel is then cast into prime quality steel billets using a continuous casting machine, which ensures a superior grain structure free of internal defects.
Rolling Mill and Water Quenching Process [4:38]
The billets are cut and passed through a computer-controlled reheating furnace to ensure an even temperature, resulting in a better-quality finished product with uniform weight per meter. The billets then enter the rolling mill, where the bar size is reduced to the desired diameter, ranging from 8 to 32 mm. A critical step is water quenching and tempering, where the finished bars are heat-treated to achieve the desired properties. Pinch rolls guide the bars into the quenching chamber, ensuring consistent properties across the bar.
Tempering and Cooling [5:58]
The red-hot rod is rapidly cooled by spraying water, changing the outer layer temperature from 900°C to 280°C while the inner layer remains at 900°C. This process tempers the outer layer on the cooling bed, resulting in an equalization temperature of 575°C to 625°C, depending on the steel grade (Fe 415, Fe 500, or Fe 550). This forms a hard outer layer of tempered martensite and a soft inner layer of ferrite-pearlite, providing both strength and flexibility. iSTEEL uses a computer-controlled quenching system to vary the amount of water sprayed based on the bar's temperature, ensuring uniform strength along its length.
Rib Cutting and Quality Testing [7:26]
A computer-controlled flying shear cuts the bar, preventing sharp edges. The tail breaker slows the bar's speed onto the cooling bed, guided by a PLC-controlled twin-channel arrangement. iSTEEL bars have a unique surface due to the CNC-controlled rib cutting machine, which creates superior rib geometry for better bond strength. Every steel batch undergoes rigorous testing, including spectrometer analysis for chemical composition and universal testing machine (UTM) tests for bar strength.
Field Tests and Quality Assurance [8:56]
Simple tests can be performed to verify the quality of iSTEEL bars. The acid test reveals a "Ring of Confidence," indicating the bar was made through the TMT process. The bend and rebend test checks for strength and flexibility by bending the bar to 135 degrees, boiling it in water, and then rebending it to 157.5 degrees without surface cracks. Weighing the bar ensures it meets ISI standards, with weight per meter cards provided to dealers for verification.
Additional Services and Customer Focus [10:33]
iSTEEL does not stock TMT bars for long periods, ensuring "Factory Fresh steel" reaches customers. To reduce steel wastage at construction sites, iSTEEL offers pre-cut bars and pre-fabricated stirrups in standard sizes. A mobile laboratory is available to guide customers on steel testing at their sites at no cost. With an extensive dealer network, iSTEEL TMT construction bars are readily accessible. The company's innovative approach has earned the trust of clients like L&T, IVRCL, and Tata Consultant Services. iSTEEL is committed to enhancing the quality of life by providing strong and flexible steel for lasting homes.
