Product

ET TMT CRS bars are an example of ‘Innovation meets product excellence’. Striking a fine balance between the life of the structure and its cost, these corrosion-resistant bars help in reducing the rate of corrosion from the time of construction and thus enhances the life span of the structure.

CRS TMT bars are produced with an addition of corrosion resistance elements such as copper, chromium, and phosphorus. Thus, are considered to be more advanced and have a longer life than ordinary TMT bars. ET TMT CRS comprises CRS Fe 500 and CRS Fe 500 D grades. The high corrosion resistant feature makes them an ideal choice for projects near coastal areas and structures such as bridges and dams.

The state-of-the-art plant located at Kutch, Gujarat is a fully integrated steel plant comprising of Sponge Iron Kilns, Induction Melting Furnaces, Ladle Refining Furnaces, 6/11 Continuous Casting Machines, Fully Automatic 5.0 LTPA Continuous Rolling Mill with variable AC drives and Advanced 3 stage Thermo-Mechanical Treatment Facility. As our steel plant is located in Gujarat, timely delivery is assured.

Advantages of ET CRS Bars:

• Made from high quality BIS certified billets produced in-house
• Longer life due to superior pitting corrosion resistance
• Can be bent and re-bent around very small mandrels
• High yield strength coupled with ductility and bendability
• Stringent quality control through NABL accredited in-house physical and chemical laboratories
• Suitable for application in seismic zones
• Single largest production capacity of TMT bars in Gujarat 5.0 LTPA

The process of making ET TMT CRS Bars

Captively produced billets ensure that high quality input is available for production of CRS bars. Even these captive billets are produced using high quality sponge iron produced in-house. The steel is made to an accurate chemical composition. Spectrometer testing ensures that the chemistry is precisely controlled in every heat of billets produced. Corrosion resistance elements like copper, phosphorus, and chromium are added in the correct proportion to make the steel resistant to corrosion.

The quenching technology used after rolling ensures that there is a presence of selftempered layer over martensitic layer. This ensures high strength with high ductility. The distribution of corrosion resistance elements is homogeneous from the core to the surface. The high strength enables the steel to resist applied forces. The high ductility ensures the steel can undergo permanent changes in shape without rupturing.

The practice of cutting and bending TMT bars at a construction site to meet individual requirements can be labour-intensive, expensive, time-consuming, space-occupying and results in enormous material wastage. ET TMT Cut and Bend bars come in a ready-to-use format and are made in an automated plant ensuring efficiency, accuracy, and uniformity which leads to a quicker construction process. They are best suited for critical design structures such as windmills, flyovers, bridges, etc. Cut and Bend TMT bars comprises Fe 500, Fe 500 D, Fe 550 and Fe 550 D grades.

ET TMT Cut and Bend technology is the result of our constant research to offer the best option to our customers the Builders, Architects & Engineers as they work towards constructing superior and safer buildings.

Advantages of ET TMT Cut and Bend Bars

Made from the world’s finest machines
Electrotherm (India) Ltd. has the best 100% automatic machines procured from Italian manufacturer Schnell to manufacture all kinds of designs from 8 mm to 40 mm.

Perfect Joints (Rings)
Perfect Joints are closed loop of reinforcement ET TMT bars that are used to hold the main reinforcement bars together in a structure. In a column, the Perfect Joints provide the lateral support to the main bars against buckling. When used in beams, the Perfect Joints (stirrups) are termed as shear or transverse reinforcement since they withstand the sheer force.

Reduce dependency on manpower
The technology inspires working that requires minimal manpower as well as ensures faster turnaround time. This increases overall efficiency and improves the quality of Cut and Bend bars required in the construction process saving on both manpower and manhours.

Cost-effective
The cost of processing decreases considerably due to lesser inventories, reduced wastage, and saving on labour cost.

Instant usability
Another important benefit that can be drawn from ET TMT Cut and Bend bars is that it promotes instant usability. The Cut and Bend bars can be put to use instantly as it proves to be profiting on-ground solution for all your construction requirements.

Timely delivery
ET TMT Cut and Bend bars are made in 100% automated plant of Electrotherm (India) Ltd. assuring greater efficiency in production and shortest turnaround time.

Simple and Safe
Handling of 12-metre bars is eliminated and neatness is improved, thus decreasing the risk of accidents, making it safer for manpower at the site.

Eliminates the storage / Stock problems
Material is ordered and supplied as per the need and is made available to the construction site for assembling thereby eliminating the storage problems.

Making of the ET TMT Cut and Bend bars

The ET TMT Cut and Bend bars are manufactured at the state-of-the-art facility of Electrotherm Steel using the Stirrup Technology. Cut and Bend bars are prefabricated bars customised as per requirement and exact specifications. This ensures that only the required quantity and size of the bars are provided to the customer. The ET TMT Cut and Bend bars are ready to use bars.

In order to manufacture the bar at ET TMT, captively produced billets are used to ensure that only high-quality input is available for production of Cut and Bend bars. The captive billets are produced using steel from the best quality Iron Ore. This steel is also produced in-house at ET TMT. The steel made here is produced with a precisely calibrated chemical composition.

The chemistry of each billet is precision controlled by using Spectrometer testing. To increase the corrosion resistance property of the ET TMT Cut and Bend bars, elements like copper, phosphorus and chromium are added in the desired proportion to ensure a high corrosion resistance property in the steel bars right from inside i.e. at grain boundary. The quenching technology of tempering steel bars is also used after running the bars through the rolling mill to ensure that there is a presence of self-tempered layer over martensitic layer. The application of this process imparts high force resistant strength and high ductility to the bars.

The distribution of corrosion resistant elements is also homogeneous from the core to the surface. The superior strength of the bars ensures that they offer high resistance to applied force. The high ductility ensures that ET TMT Cut and Bend bars can easily be cut and modified to precision to suit the specific needs of a structure without displaying wear and tear.

Epoxy coated TMT bar, one of the best TMT bars in India, are a highly corrosion resistant variant of steel bars which are protected by Fusion Bonded Epoxy (FBE) coating. Fusion Bonded Epoxy coating, commonly referred to as FBE coating is widely used to protect concrete TMT bars, steel pipes, piping connections etc. used in construction. FBE coatings are in the form of dry powder at normal atmospheric temperature. The powder is applied electrostatically to the surface of cleaned hot steel bars and cured to form a protective film after undergoing various chemical processes. The epoxy coated bars last longer due to the protective film and thereby contribute to the quality of construction.

Advantages of Epoxy Coated bars:

Economical
The superior corrosion protection can extend the life of the epoxy coated TMT bars, resulting in significantly lower lifecycle costs over time.

Requires Less Maintenance
It needs little maintenance that leads to substantial savings in labour costs. It is flexible to allow straight bars to be bent during fabrication on a special mandrel to protect the coating from damage.

Environment-friendly
Epoxy powder coated bar is a sustainable solution that is environment friendly.

Long lasting
Studies have shown that structures built with epoxy last longer than similar structures made with black steel.

Cost-effective
Epoxy coating is very cost-effective as it adds very little to the overall cost of the structure and lifecycle.

Superior Quality
As the technique is factory based, it enables uniform thickness of coating which adds to the quality of production.

Excellent Bonding
The bonding of coating with steel TMT bars is high as it has excellent adhesive property.

Offers Barrier Protection
The Fusion Bonded Epoxy coating acts as an insulator for electrochemical cells and offers barrier protection to steel which prevents entry of chloride ions through it.

Process of manufacturing Epoxy TMT Steel Bars:

 Surface Preparation
TMT bar is cleaned for surface contamination such as grease and oil by solvent cleaning. Shot blast cleaning is the most commonly used method for preparation of steel surfaces. This effectively removes rust, scales, slats etc. from the surface and produces an industrial grade of a clean and rough surface finish.

Pre-Heating
Heating can be achieved by using several methods, but the most efficient method is induction heating. TMT bars are passed through a high frequency alternating current along with a magnetic field, which heats according to the required FBE coating application temperature. Typical application temperature for a stand-alone FBE is 225°C to 245°C.

Epoxy Powder Application
The FBE powder is placed on a fluidisation bed. The heated TMT bar is passed through the coating booth with number of electrostatic epoxy spray guns and the dry powder is sprayed (cloud formation) on the hot TMT bar. Here, the powder particles are suspended in a stream of air which is electrically charged due to which epoxy powder particles are attracted to the grounded TMT bar. As soon as the charged epoxy powder particles hit the hot TMT bar, they melt and flow into the anchor profile. The heat also initiates a chemical reaction which causes the epoxy powder molecules to form cross linked polymers which give the coating its beneficial properties.

Curing and Cooling
Epoxy coated TMT bars are given a thermal treatment by keeping them at 225°C for a duration recommended by epoxy powder manufacturer resulting in fully cured coating. The coated bars are passed through a cooling tunnel after curing, where water is sprayed on the bars to cool them. The bars are then transferred to the final inspection rack for testing and inspection.

ET TMT Refined steel bars comprises Fe 550, Fe 500 D and Fe 550 D grades. These bars are made using the “integrated iron ore – induction furnace – ladle refining furnace” route which ensures the elimination of major impurities from steel. Use of iron ore as the raw material (as against scrap) ensures that the steel is tramp free. The refining in the LRF ensure low level of harmful impurities of sulphur and phosphorous. The “D” in Fe 500 D and Fe 550 D grades denote the enhanced ductility of the product. Fe 500 D has superior elongation properties and a high UTS/YS ratio. Lower quantities of carbon, sulphur and phosphorous, helps in preserving the steel and resisting earthquake shocks. Thus, making it the most appropriate choice for seismic zones, high-rise apartments, industrial structures, flyovers, windmills, highway construction, railway bridges, cantilever structures, airports, tunnels, ports, etc

On the other hand, Fe 550 D TMT bars come with superior tensile strength, better elongation properties, and a high UTS/YS ratio and thus is considered to be the perfect choice for large scale commercial projects and infrastructure projects in earthquake-prone areas.

At Electrotherm (India) Limited, advanced steel manufacturing facilities as well as the stringent quality controls at every step ensure production that complies with BIS specifications. After refining the steel in LRF, it is sent to a rolling mill and thermo mechanically treated in standard quenching box. Highly atomised quenching, selftempering and atmospheric cooling ensures that TMT bars have superior mechanical properties in strength, weldability, ductility and bendability meeting quality standards.

Sulphur and Phosphorus (S & P) are damaging impurities in steel. High levels of phosphorus can lead to ‘cold shortness’ in steel which makes it brittle under extreme cold conditions while high level of sulphur can lead to ‘hot shortness’ in steel, a condition in which the melting point of steel gets lowered thereby reducing its strength under high temperature. However, lower levels of S & P can be achieved only through advanced steel making technology.

Advantages of Refined Steel in manufacturing TMT bars:

• Dephosphorization improves ductility
• Desulphurization improves transverse ductility and weldability
• Lower carbon level results in excellent ductility and weldability
• This grade is ideal for construction in areas prone to earthquake due to better shock resistant properties
• Stringent quality control through in-house NABL approved physical and chemical laboratories
• Higher resistance to failure
• Avoids localised shear failure

ET TMT 500 D is ideal for:

• Critical structures in seismic zones III, IV and V
• High-rise buildings
• Bridges
• Flyovers
• Dams
• Foundation of wind turbines
• Industrial structures
• Concrete roads
• Underground structures
• Thermal and hydroelectric power stations
• General purpose concrete reinforcement structures

Process of manufacturing refined steel:

Steel at Electrotherm is made using high quality raw material. The best quality iron ore is used in a Blast Furnace of 128 m3 and 63 m3, Direct Reduced Iron (DRI) kiln of 250 and 350 TPD. For this 100% iron ore is used. Steel scrap is not used in the melting process as it usually contains a high level of impurities. After melting the DRI from kilns and hot metal from Blast Furnace in Induction Furnaces, a unique and patented ERF-ELdFOSTM metallurgical process is used to dephosphorus the steel in the ladle and desulphurised the steel in Electrotherm Ladle Refining Furnace (LRF) specially to meet the stringent
phosphorus and sulphur requirement of all grades of TMT bars.

Multistage testing of steel chemistry on the spectrometer ensures adherence to the desired chemistry in close tolerance. In the LRF, metal is also homogenised, alloying elements are added and controlled in a very narrow range, dissolved gases in the steel are lowered through mild purging of inert gases and inclusions are removed or altered chemically to ensure high quality of steel.

This refined steel is cast into billets of required sizes in closed environment to have further control of gases and other inclusions. Molten pig iron (hot metal) from Blast Furnace and Direct Reduced Iron (DRI) from kiln is the key to making superior quality refined steel.

ET TMT bars are free from tramp elements like Cu, V, Ni, Cr etc. because they are manufactured from refined steel, unlike other conventional manufacturers where scrap is used and there is no control on impurities.

After refining the steel in LRF, it is rolled according to the required size in a state-of-theart Rolling Mill and thermomechanically treated in a Standard Quenching Box. Highly atomised quenching, self-tempering and atmospheric cooling ensures that refined steel TMT bars have superior mechanical properties in strength, weldability, ductility and bendability meeting or exceeding quality standards. Quality control is highly stringent
through NABL accredited labs and equipment.

ET TMT Superior quality bars comprises Fe 500 grade which has a lower percentage of sulphur and phosphorus, which are harmful to steels used in construction. These bars are produced under strictly regulated manufacturing process and thus have good corrosion resistance, excellent ductility & bendability, high weldability, high strength and strong resistance on dynamic loading. The Fe 500 TMT bars also have the capacity to absorb sudden loads which make them an ideal solution for various natural disasters like earthquakes, tsunamis, and cyclones.

All this makes it a perfect choice for RCC constructions in building, housing construction and other concrete structures.

Advantages of superior quality Fe 500 Steel Bars:

 -Superior quality TMT bars are free from tramp elements like Cu, V, Ni, Cr etc. unlike other conventional manufacturers where scrap is used and there is no control on impurities.

-Superior quality bars are more reliable and safer for use in critical infrastructure due to better force resistance and load bearing capacity.

-Superior quality steel bars come in a variety of grades which are suitable to varying needs of construction work to be undertaken.

– Superior quality steel bars are manufactured with the state-of-the art processes which rule out impurities, irregularities and surface defects in them leading to higher corrosion and stress resistance in them.

-Superior quality steel bars have higher load bearing capacity than regular variants and are also available in customizable variants which reduces wastage and is cost effective.

-Superior quality bars are best TMT Bars for construction requiring superior strength, including –

• Critical structures in seismic zones III, IV and V
• High-rise buildings
• Bridges
• Flyovers
• Dams
• Foundation of wind turbines
• Industrial structures
• Concrete roads
• Underground structures
• Thermal and hydroelectric power stations
• General purpose concrete reinforcement structures

Process of manufacturing superior quality refined steel:

At Electrotherm India all bars are manufactured only from high quality refined steel. No scrap steel is used. To ensure that the best quality steel is used in our products we refine steel at our own manufacturing facility to ensure that the refined steel is cast into billets of required sizes in closed environment to have further control of gases and other inclusions. Molten pig iron (hot metal) from Blast Furnace and Direct Reduced Iron
(DRI) from kiln is the key to make superior quality refined steel.