new kwt steel profile-3aug outline brochures/files...15 the rolling mill plants 22 quality control...

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Page 1: NEW KWT STEEL PROFILE-3aug outline Brochures/files...15 The Rolling Mill Plants 22 Quality Control & Assurance Policy 23 Environmental Policy ABOUT KUWAIT STEEL 3 United Steel Industrial
Page 2: NEW KWT STEEL PROFILE-3aug outline Brochures/files...15 The Rolling Mill Plants 22 Quality Control & Assurance Policy 23 Environmental Policy ABOUT KUWAIT STEEL 3 United Steel Industrial
Page 3: NEW KWT STEEL PROFILE-3aug outline Brochures/files...15 The Rolling Mill Plants 22 Quality Control & Assurance Policy 23 Environmental Policy ABOUT KUWAIT STEEL 3 United Steel Industrial

CONTENTS:3 About KUWAIT STEEL5 Vision / Mission / Objectives7 Prominent Features Of The Steel Making Plant8 Electric Arc Furnace9 Ladle Refining Furnace10 Continuous Casting Machine11 Auxiliary Units15 The Rolling Mill Plants22 Quality Control & Assurance Policy23 Environmental Policy

Page 4: NEW KWT STEEL PROFILE-3aug outline Brochures/files...15 The Rolling Mill Plants 22 Quality Control & Assurance Policy 23 Environmental Policy ABOUT KUWAIT STEEL 3 United Steel Industrial
Page 5: NEW KWT STEEL PROFILE-3aug outline Brochures/files...15 The Rolling Mill Plants 22 Quality Control & Assurance Policy 23 Environmental Policy ABOUT KUWAIT STEEL 3 United Steel Industrial

ABOUT KUWAIT STEEL

3

United Steel Industrial Company (Kuwait Steel) is a private Kuwaiti Closed Shareholding Industrial Company that was established in the year 1996. In the four years that followed Kuwait Steel in collaboration with Voest Alpine of Austria erected the first fully-automated Rolling Mill in Kuwait. This Rolling Mill, which is built on a 40,000 square meter land has an annual production capacity of 750,000 tons of reinforcing steel bars with sizes ranging from 8mm to 40 mm in diameter. Since 2003, Kuwait Steel was able to cater major portions of domestic market demands for this vital product, since the manufacturing process is entirely capable of meeting recognized stringent international standards such as ASTM, DIN, BS, SASO and other standards required by the market.

The company’s production usually exceeds its yearly target, thus exporting its products to neighboring countries which has constantly been part of its business. In 2007, Kuwait Steel accomplished another goal by setting up its own Steel Making Plant which was awarded to M/s. Danieli & C. Officine Meccaniche of Italy. The new Steel Making Plant is built on a land admeasuring 96,000 square meters in the Shuaiba Industrial Area and has an annual production capacity of produce 1.2 million metric tons of steel billets.

The Steel Plant is designed according to the latest technology in the field of steel plant machinery equipment specifically. The technological solution is characterized by the choice of high quality and productivity facilities, by which it is possible to achieve extremely efficient operating results with low man-power and specific energy consumption thereby making the plant highly competitive. Upon commissioning in 2010 and after finishing the Guarantee Performance Test during the first quarter of 2011, the Steel Plant is in operation and producing to its full production capacity.

During the same year 2010, Kuwait Steel achieved yet another milestone by acquiring another Rolling Mill Plant in Kuwait that previously had an annual production capacity of 250,000 tons/year that has been completely revamped and upgraded by M/s. Siderimpes (S.R.L) of Italy, to increase its annual capacity to produce 650,000 tons of rebar which is fully operational and running at full capacity and utilization rates. Both rolling mill plants have a combined annual production capacity of 1.4 million metric tons.

Kuwait Steel is fully committed to minimize, if not eliminate the effects of its overall operations in the production of steel reinforcing bars and steel billets towards the environment. It is the company's goal to enhance and continually improve its environmental protection performance through effective implements of Environmental Management Systems (EMS).

Thus, it is worthwhile to mention that Kuwait Steel is the sole producer of steel rebar in the state of Kuwait. Last but not least, all of Kuwait Steel's products are Kuwaiti, ISO and UK CARES certified.

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VISIONWe aspire to constantly achieving excellence, leadership and value within the steel manufacturing industry in Kuwait and globally.

MISSIONTo be a leading company in the reinforcing steel bar and billet manufacturing industry. To continually serve, lead and satisfy the local and international market with high quality products to guarantee the utmost level of customer satisfaction.

OBJECTIVES1. To supply quality steel products promptly and competitively to assure customer satisfaction in addition to their

implied needs.

2. To consistently produce reinforcing steel bars and billets that meet the local and international quality standards.

3. To continuously provide adequate training and career development to KUWAIT STEEL's workforce to enhance and increase manpower skills.

4. To continuously improve, enhance and innovate KUWAIT STEEL's equipments by employing state of the art technology.

5. To constantly provide a healthy, safe and friendly working environment for KUWAIT STEEL's employees in order to achieve the best quality products and insure guaranteed customer satisfaction.

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PROMINENT FEATURES OF THE STEEL MAKING PLANTKUWAIT STEEL has adopted the latest technology for its Steel Making Plant for production of high quality steel billets. Its extremely efficient operations are characterized by the choice of highly automated production processes, state of the art facilities, rational & compact designed layout, optimized logistics and sound experienced low manpower.

The plant process control system is a highly advanced and reliable Three Tier Client / Server Architecture, with the latest Siemens S7 controllers to support the uniform and repetitive production of steel at low cost and high quality standards. The system access to the operators is very user friendly owing to reduced numbers of manual commands and fully automated visualization of WinCC.

KUWAIT STEEL has adopted extensive pollution control measures and a dedicated fume treatment plant. A massive Dog-house envelope for the entire furnace for noise and dust control is unique for the Gulf region and puts KUWAIT STEEL in the league of the World’s top 5% plants having this facility. An advanced SVC (Static VAR Compensator) system has been installed at KUWAIT STEEL’s substation for preventing any local grid disturbances during furnace operation.

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ELECTRIC ARC FURNACEThe high performing 120 ton Electric Arc Furnace is the result of choosing the best technology such as Ultra High Power (130 MVA transformer) design which allows to operate the furnace at high secondary voltage and longer Arc, resulting in shorter processing time for melting heat. The combination of eight shell mounted injector modules for oxygen, carbon and lime injection in the melt and HIREG® Digital Electrodes Regulation system, produces the most favorable foamy slag cover over the melt and thus produces the highest quality steel with optimum power, electrode & refractory consumption. Several other high end technologies such as furnace bottom stirring and Eccentric Bottom Tapping (EBT) ensure homogeneous and cleaner steel.

The EAF design flexibility of using various combination of electrical and chemical energy, allows optimal combinations of charge materials, such as different types of scrap, HBI & DRI, for the melting process. The scrap is transferred to the Furnace bay by a radio controlled scrap car and charged into the furnace by a 250 EOT crane. The charging of HBI/ DRI and slag builders is continuously done through the furnace roof during the melting stage. The whole melting process is performed in a fully automated and computerized sequence and the produced liquid steel is tapped into the ladle. The liquid steel is then transferred to the Ladle Refining Furnace for final composition control and refining.

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LADLE REFINING FURNACEIn the continuous endeavor for quality production, KUWAIT STEEL has invested in a “inert roof” type Ladle Refining Furnace where automated metallurgical process control systems ensure the utmost efficient refining and alloying of steel obtained from the Electric Arc Furnace. Inert gas stirring is performed at the ladle bottom all through the steel refining process.

The Ladle furnace ensures greater homogeneity of liquid steel and thus produces steel products with more uniform chemical composition, mechanical properties and provides flexibility to produce a variety of steel grades of interna-tional standards such as ASTM, BS, DIN, JIS, etc.

The Ladle Furnace is equipped with an 18 MVA transformer for optimum performance. Once the desired chemical composition and temperature is reached, the steel is transferred to the Continuous Casting machine.

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CONTINUOUS CASTING MACHINEThe steel attained from the Ladle Refining Furnace is cast in the final shape of billets, in a five strand Continuous Casting Machine of the utmost modern design. The whole casting process is automated and ensures the production of quality billets. This includes automatic caster startup, production, cast-end and continuous control of metallurgical parameters.

The liquid steel from the steel ladle is taken into the tundish, which supplies metal to all five strands of the caster. For ensuring product quality, the tundish has been designed through water-modeling and the metal level is maintained by an automatic slide gate control. Each of the five moulds of the caster is fed metal from the tundish through an advanced FNC® nozzle changing system, which assist in long casting sequences. Long sequences are mandatory for better productivity, yield and quality of the casted product.

The solidification process starts in a water cooled mould tube. The mould is equipped with an automatic mould level control and hydraulic oscillating system forming a uniform solid steel shell, which is further cooled by controlled water sprays to fully solidify and finally cut into desired lengths by automatic gas cutting machines. Billet length optimization models help in improving yield and quality.

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AUXILIARY UNITSAll plant supporting services are integrated into processes through high level of automation. The major auxiliary units comprise of an Air Separation Plant, Compressed Air Plant, Fume Treatment & De-Dusting Plant, LPG Storage & Handling, Workshops & Warehouses and a comprehensive Water Treatment Plant.

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PRODUCT SPECIFICATIONSKUWAIT STEEL employs a stringent quality assurance system ensuring that all its products conform to or even exceed specified quality requirements by international and local standards and complies with local and international regulations. Every product is attested by a Mill Test Certificate as guarantee of quality. We pride quality.

SPECIFICATION OF STEEL BILLETS:CHEMICAL COMPOSITIONKUWAIT STEEL has the technology of producing steel billets with a wide range of chemical compositions to satisfy the customer’s requirements. Currently our mainstream products conform to specifications of ASTM A615M, ASTM A706M, BS 4449:1997, BS 4449:2005 and KWS GSO ISO 6935-2. (Please contact our Commercial Department for a specific steel chemistry)

BILLET SIZE:Cross Section 130 mm x 130 mm 150 mm x 150 mmCutting Lengths 12 meters(Please contact our Commercial Department for other cutting lengths with min 6 m and max 12 m)

SIZE AND SHAPE TOLERANCES:Side Dimensions ± 2 % Face Bulging/ Depression ≤ 2.0 % Rhomboidity ≤ 2.5 % Camber (Bend) ≤ 5 mm / m to 50 mm max Angular Twist ≤ 0.8º / m to 8º max Cutting Length 0 / +70 mm

/D1 - D2/0.5 x (D1 + D2)

Expressed as percent in side length

R% = x 100

Measured on Cold Billet at least 150 mm from cut end.

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SURFACE AND INTERNAL QUALITY:The billets should be free from longitudinal cracks, transverse cracks, joint billet, scum, scab, shrinkage cavity and other surface and internal unsoundness that may adversely affect final product quality.

IDENTIFICATION:Heat Number Heat number to be stamped/hand written at the billet end.

Color Coding Color coding signifying grade or class to be painted at the end (as per customer’s requirement.)

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THE ROLLING MILL PLANTSIn Plant 1 the manufacturing process takes place in a fully automated and computerized sequence starting from its modern 110 T/H walking beam type – Reheating Furnace down to the compact-cassette roll-to-bearing assembly in the mill that is equipped with the latest stock slitting design, and its cutting length optimizations program for optimal process and operational control.

Rolling operations start with the loading of billets into the furnace charging table. Billets are automatically charged into the reheating furnace until they attain a rolling temperature up to 1150 degrees Celsius.

The continuous rolling mill train is designed with a constant pass line and comprises of horizontal and vertical arrangement stands. There are six stands in the roughing mill, six stands in the intermediate mill and six stands in the finishing mill.

The cross sectional area of the billet is continuously reduced as it passes through these stands. The production line flows with “no twist” continually through 18 stands and with minimal downtime.

The mill is equipped with a state of the art electronic control system, featuring level 1 and 2 automation and length cutting optimization.

The steel bars are then conveyed through a series of motorized rollers and cooled in the seventy six meter long Rake Type Cooling Bed. Plant 2 has the same design as plant 1. The furnace is of the Pusher type with a capacity of 75 T/H.

Both plants are equipped with a water quenching system installed between the rolling mill and the cooling bed, in order to perform the heat treatment of rebars.

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On the exit side of the cold shear, bars are moved towards the entry of the chain transfer conveyor. All cut bars less than 12m in length are separated from the standard length bars to ensure that the required sizes enter the specific chain conveyor. In the chain conveyor, bars are counted via a bar counting machine which ensures the exact quantity of bars in each bundle.

After each bundle is weighed, a tag containing all product information is generated automatically and attached onto the bundle. The tag in each bundle contains information that can trace the source of billet used.

All reinforcing steel bars being produced in the mills undergo a strict and thorough physical, mechanical and chemical tests in the quality control and assurance laboratory to ensure compliance to the specified standards and classifications. Supplementary international specifications can be produced upon the customer’s request (i.e. ASTM, BS, DIN, etc.).Kuwait Steel is ISO 9001, ISO 14001, OHSAS 18001, UK CARES and Kuwaiti certified.

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d≤8mm ±6.0%

d>8mm ±4.5%

8mm - 10mm ±6.5%

d≥12mm ±4.5%

d≤8mm ±8.0%

10mm - 12mm ±6.0%

14mm - 20mm ±5.0%

22mm - 40mm ±4.0%

REBAR SPECIFICATIONS:STANDARD SPECIFICATION AND GRADE NOMINAL DIAMETER, d (mm)

ASTM A615M Grade 40

ASTM A615M Grade 60

ASTM A615M Grade 75

ASTM A706M Grade 60

ASTM A706M Grade 80

BS 4449:2005 Grade B500B

BS 4449:1997 Grade 460B

KWS GSO ISO 6935-2 Grade B500C-R

8 10 12 14 16 18 20

40

40

40

40

40

40

40

36

36

36

36

36

36

36

32

32

32

32

32

32

32

28

28

28

28

28

28

28

25

25

25

25

25

25

25

22

22

22

22

22

22

22

20

20

20

20

20

20

20

18

18

18

18

18

18

18

16

16

16

16

16

16

16

14

14

14

14

14

14

14

12

12

12

12

12

12

12

10

10

10

10

10

10

10

8

8

8

8

8

8

8

Nominal Unit Mass (kg/m) 0.395 0.617 0.888 1.208 1.578 1.998 2.466 2.984 3.853 4.834 6.313 7.990 9.865

MASS TOLERANCE

REBAR SIZE WEIGHT VARIATION

ASTM

BS 4449:2005

BS 4449:1997

KWS GSO ISO 6935-2 B500C-R

ALL REBAR SIZES -6.0%

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Where “d” is the nominal diameter of specimen, mm.** The use of the latest edition of AWS D1.4/D1.4M is recommended.

32<d≤40 7d

STANDARDSPECIFICATION

AND GRADE

Min

imum

Yie

ldSt

reng

th (M

pa)

Max

imum

Yie

ld

Stre

ngth

(Mpa

)

Min

imum

Ten

sile

Stre

ngth

(Mpa

)

Min

imum

TS/

YS ELONGATION BEND / REBEND TEST

WEL

DABI

LITY

**

Reba

r Size

(mm

)

Min

imum

Elo

ngat

ion

(afte

r fra

ctur

e, A

5) %

Min

imum

Elo

ngat

ion

(@ M

axim

um fo

rce,

Ag

t) %

Bend

Ang

le

Rebe

nd A

ngle

Reba

r Size

Bend

ing

Pin

Diam

eter

(mm

)

ASTM A615M Grade 40

ASTM A615MGrade 60

ASTM A615MGrade 75

ASTM A706MGrade 60

ASTM A706MGrade 80

BS 4449:2005Grade B500B

KWS GSO ISO 6935-2 Grade

B500C-R

280 - - -

-

-

-

-

-

-

-

-

-

-

-

-

180⁰

180⁰

180⁰

180⁰

180⁰

90⁰ 20⁰

420

420 - -

-

620

8~10 1112~20 12

98

8~18 3.5d20 5d

8~22

28~4025

7

7

3.5d5d

8~18

28~3640

20~257d9d

520 - 690

1.25550540420

1.25690675550

1.08 5.0650 - -500

500 - - -1.15 8~40

8~40

45⁰ 23⁰1.08 5.0- - 14460 8~40

14 7.0 90⁰ 20⁰d≤16

16<d≤32

8~25

28~40 6

5d7d

8~25

4028~36

9d

3d4d

10~16

28~3640

18~256d

8d3.5d5d

10~16

28~3640

18~257d9d

Yes

Yes

Yes

YesBS 4449:1997Grade 460B

1412

10~22

40

25~36

10

10~36 12

40 10d≤16 4dd>16 7dd≤16 5d

3d6d

d>16 7d

MECHANICAL PROPERTIES:

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STANDARD SPECIFICATION AND GRADECHEMICAL COMPOSITION (maximum % by mass)*

ASTM A615M Grade 60

ASTM A615M Grade 75

ASTM A706M Grade 60

ASTM A706M Grade 80

BS 4449:2005 Grade B500B

BS 4449:1997 Grade 460B

KWS GSO ISO 6935-2 Grade B500C-R

CHEMICAL PROPERTIES:

C Mn Si P S N Cu Ceq

0.060

0.060

0.035 0.045

0.045

0.55

0.55

0.50

0.51

0.035

0.050

0.050

0.22a

0.30

0.25

0.060

0.050

0.050

0.012b 0.80

0.012b

0.060

0.30 1.50 0.50

1.50 0.50

* Cast Analysisa. It is permitted to exceed the maximum values of carbon by 0.03 % by mass, provided that the carbon equivalent value is decreased by 0.02 % by mass.b. Higher nitrogen contents are permissible if sufficient quantities of nitrogen binding elements are present.

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SPECIFICATION OF REINFORCING BARS:KUWAIT STEEL is capable of producing reinforcing bars according to specifications specified by a customer.

REBAR MARKINGS:

GRADE/YIELD STRENGTH LEVEL:4 - GRADE 420 (60)5 - GRADE 520 (75) ; B500C-R6 - GRADE 550 (80)

REBAR SPECIFICATIONS:S-ASTM A615MW-ASTM A706M

NOMINAL BAR SIZE:8-40mm

K-KUWAIT STEEL

NOTE: FOR KWS GSO ISO 6935-2 REBAR MARKINGS SHALL FOLLOW ASTM PROVISIONS

21

BS 4449:1997 GRADE 460B

ASTM A615M; ASTM A706M; KWS GSO ISO 6935-2 B500C-R

BS 4449:1997 GRADE B500B

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QUALITY CONTROL & ASSURANCE POLICYKUWAIT STEEL’s vision and mission has excellence in its very core. Driven by this aspiration, we have established a quality assurance system that ensures to continuously sustain and raise the bar of excellence – in our products, processes and people.KUWAIT STEEL takes pride in its products. Its products are guaranteed to be of superior quality that conform to local and international standards and to the satisfaction of the customers. All KUWAIT STEEL’s products pass through a thorough quality assurance process. This starts from selecting and inspecting raw materials, to in-process quality control, and to quality inspection and testing of finished products. Our process assures product quality, consistency and traceability.

Laboratory facilities are established on each of the manufacturing plants to provide on-time feedback to production. Each laboratory is equipped with the latest testing and analytical instruments, such as Optical Emission Spectrometer, a state-of-the-art Rib Measuring Device, Universal Testing Machines, bending machines and radiation detectors. Our main asset is our people who are well trained, experienced and highly capable in dispensing their duties to ensure that high quality level is maintained. KUWAIT STEEL operates a quality system that is accredited to conform to the requirements of ISO 9001 and is certified byUK CARES as a quality manufacturer and supplier of products conforming to BS4449:1997 460B and BS4449:2005 B500B.We inscribe our signature on each bar that leaves our Company.

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ENVIRONMENTAL POLICYUnited Steel Industrial Company (KUWAIT STEEL) is fully committed to minimize, if not eliminate the effects of its over-all operations in the production of steel reinforcing bars to the environment. It is the company’s goal to enhance and continually improve its environmental protection performance through effective implements of Environmental Management Systems (EMS).

To realize this commitment, we ensure:• Compliance with all applicable national environmental legislations and regulatory laws in the steel industry.• To minimize generation of waste that is harmful to the environment and Prevention of pollution.• To identify significant environmental impacts, establish and achieve objectives and targets.• To communicate this policy and the environmental protection performance to our customers, government

departments and the general public.• To enhance awareness and develop skills of our workforce to ensure involvement and commitment to further

develop the company’s environmental performance.

KUWAIT STEEL IS AN ISO 14001 CERTIFIED COMPANY

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REGISTERED OFFICEUnited Steel Industrial Co. (KSCC)Sharq Dasman Complex,P.O.Box 1370, Safat 13014, Kuwait.Tel : +965-23200000Fax : +965-22435229 , 22444232

STEEL MILL PLANTSUnited Steel Industrial Co. (KSCC),Block 4, ST. MA-8, Plot 71Shuaiba Industrial Area,Shuaiba, KuwaitTel :+965-23200000Fax :+965-23263024E-mail: [email protected]

www.kwtsteel.com

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