All About Hama Steel For The Wide Range Of Steel Rebar
Hama steel is one of the best steel manufacturing industry in Nepal. Started in the year 2046 BS, we have been focusing on providing quality products to our national as well as international customers. We specialize in producing various steel products such as SG rebars, mild steel bars, deformed steel rebar, nails, steel wire rods, and many more. From the vehicle you drive to the house, you live in; from the bridges, you cross to the hand tools that you use;
we strive to deliver unparalleled quality through our customized value-added solutions to make your life easier. This is made possible by our commitment to a culture of continuous improvement, through which we drive operational excellence in processes, products, and people. We are one of the few steel operations that are fully integrated – from mining to the manufacturing and marketing of finished products.
Continuous improvement in our product and service portfolio, along with success in value-creating initiatives for customers, allows us to serve global growth markets. With Consistency, Commitment, and Authenticity we have been delivering premium quality steel since 25 years.
Table Of Content:
Our Mission
· Quality
· Technology
· Commitment
· Authenticity
· Excellence
· Sustainability
We are proud of our leadership here in Nepal, for manufacturing Quality rebar because we believe in leading by example. It is hard to think of a better example we could set than that of a responsible citizen. We are looking forward to the future and will continually improve, innovate and execute in our path of quality in manufacturing. We also look forward to keeping you in the loop and updated on our process.
What is Steel
Steel is an alloy of iron with typically a few percent of carbon to improve its strength and fracture resistance compared to iron. Many other additional elements may be present or added. Stainless steel that are corrosion and oxidation resistant need typically an additional 11% chromium. Because of its high tensile strength and low cost, steel is used in buildings, tools, ships, trains, cars, machines, electrical appliances, and weapons.
There are more than 3500 different grades of steel. While the number might not be exact, the World Steel Association states that “there are more than 3,500 different grades of steel” and that “approximately 75% of modern steels have been developed in the past 20 years.” This number can definitely increase in the future given the number of research conducted. Also, you might be introduced to the type of steels that are even lighter and stronger than ever before.
Just like many other metals, steel is 100% recyclable. Also, steel is considered to be the world’s most recyclable material. This is because of the ferromagnetic properties present in the steel. This property in steel makes the steel easy to remove from the solid waste stream and divert into recycling plants.
According to statistics cited by the Institute of Scrap Recycling Industries (ISRI) in a 2015 report, “In the United States alone, 73 million metric tons of ferrous scrap was processed by the scrap recycling industry last year, nearly 55 percent of the volume of all domestically-produced material.”
One of the main reasons why people love stainless steel is due to its ability to resist corrosion. The ability to resist corrosion results in prolonged life and preservation of its strength. Here are some of the circumstances in which stainless steel can rust:
- If the mill welding machine electrodes and other equipment are not cleaned properly when moving from welding plain steel to stainless steel.
- If the same metal brushes are used for finishing both plain and stainless steel alloys.
To increase the useful life of stainless steel, proper care should be given during initial manufacture.
Another amazing fact about steel is that it is more elastic than rubber. Any material is said to be elastic if it can bounce back to its original shape after being deformed under stress. Since steel is able to come back to its original shape more quickly, it is considered to be more elastic than rubber.
Steel is roughly 1000 times stronger than iron. This is because of the amount of carbon added to the steel. When carbon is added to steel, it increases the tensile strength of the steel, which results in a superior level of strength compared to pure iron.
How Is Steel Made
Step 1: Reheating Furnace
The TMT manufacturing process starts with reheating the furnace. The steel billets, which are at room temperature of about 20 to 30 degrees Celsius, are reheated at a temperature ranging from 1050 degrees Celsius to 1150 degrees Celsius. Reheating the billets to this temperature will soften it so that it can be transformed into the desired length and thickness. The billets are heated on all sides to ensure efficiency and effectiveness.
Step 2: Rolling
After the billets are reheated, it goes through the process of rolling. This process is carried out to reduce the size of the millet bars to the desired diameters. Rolling mills at Hama steel are able to produce TMT bars of various sizes according to the needs of the customers. To ensure quality and produce high-quality steel bars, Hama Steel has been investing a lot in technology.
Step 3: Quenching and Tempering
The rolled billets are then taken for quenching and tempering. This process is carried out to give the steel billets their desired property. The steel bars produced through quenching and tempering are known as reinforcement bars.
During this process, we make sure that the bars spend an equal amount of time in the quenching chamber. Then, the cumming bars are sprayed with water, which changes the temperature of the outer layer of the bar. The temperature changes from 900 degree centigrade to 280 degree centigrade.
However, the temperature of the inner layer will remain consistent, i.e. 900 degree centigrade. Because of these different temperatures, the outer layer will remain hard and the inner layer will remain softer. The outer layer is known as Tempered Martensite, while the inner layer is known as Ferrite Pearlite.
Here are some of the advantages of reinforcement bars:-
- Consistent Quality
- High Ductility
- Simple and Easy Fabrication
- Highly Strong
Step 4: Flying Sheer
Finally, a computer-controlled flying sheer is used to cut the TMT bar. This is done in order to ensure all the edges of the bars are smooth and eliminate sharp edges if any. After the edges are cut with flying sheer, the tail breaker is used to slow the speed of the bar. Then the bar is taken to the cooling bed using a twin-channel arrangement controlled by PLC.
There is a twin-channel arrangement which is PLC controlled and guides the bar onto a cooling bed. This PLC controlled twin channel arrangement gives perfect rib geometry for superior strength and better bond strength.
Products Manufactured By Hama Steel
Hama SG Rebars
Hama steel has been producing high-quality SG rebars for the past few years. We have a strict policy of not using Low-Quality Billets (Raw Material). We use only the highest quality Prime Quality Billets. Our products meet the highest quality standards and have been used by corporate houses, embassies, government agencies, and the common man.
We produce ‘Billets’ of international standards by employing advanced technology in an INTEGRATED STEEL PLANT. Billets are further used in the production of the Thermo Mechanically Treated (TMT) Bars. Hence, self-manufactured raw materials contribute to economical production and are is advantageous for the end-user.
We continue to improve our processes and ways of doing things. This has resulted in us improving our final quality of re-bars. This improved the bonding strength making it 10x better than before. The ribs are cut by CNC machines and have uniform Rib height and distance.
The rib design follows the ASTM and Din 488 standards. This has also resulted in a more uniform variance in the mass/meter of the re-bar. Hama Guarantee Tags are state-of-the-art and are tamper-proof. The tags carry details like weight, number of rods in the bundle, date of manufacture, and date of dispatch.
These details cannot be erased, modified, or tampered with in any other way. Our guarantee tag, therefore, aims to ensure that the customer has the exact weight of the steel they buy.
Mild Steel Bar
Mild steel bars are characterized by plain surface and round sections of diameters from 6 to 50mm. With mild steel bars, rods are manufactured in long lengths and can be cut quickly and be bent easily without damage. Mild steel bars come in two grades, i.e.
- Mild steel bars grade-I designated as Fe 410-S or Grade 60
- Mild steel bars grade-II designated as Fe-410-o or Grade 40
Mild steel bars are used in concrete for special purposes such as dowels at expansion joints, where bars must slide in a metal or paper sleeve, for contraction joints in roads, runways, and for column spirals. It is not recommended to use Grade II mild steel bar for structures in areas of severe damage like earthquake zones and also for structures subject to dynamic loadings (other than wind loading) such as railways and highways bridges.
It is very important to test the mild steel bars in the laboratory before using them. Some manufacturers stamp their MS bars grade with their make /name and also give certification of test and grade. On the basis of the above information, you can store mild steel bars grade-wise at the site of work.
Deformed Steel Bar
A deformed steel bar is a steel bar with surface projections that increase its bond strength when used in reinforced concrete. Deformed bars are made of steel with a deformation on their surface which is designed to assist with minimizing slippage when installed into concrete by providing an increase in the bond for two materials.
The tensile stress in deformed bars is higher than in plain round bars. A deformed bar is used where extra reinforcing is required to fabric sheets or trench mesh. By using the reinforcing bar in construction, it creates a single, monolithic concrete structure with high durability, reliability, and integrity.
Nails
Nails are characterized by a slender metal shaft that is pointed at one end and flattened at the other end. They are primarily used in construction and carpentry for fastening objects to each other. Nails are usually made of steel but can also be made of stainless steel, iron, copper, aluminum, or bronze.
The pointed end of a nail is called the point, the shaft is called the shank, and the flattened part is called the head. There are two basic types of nails, i.e. common nails and finishing nails. Of these, common nails are used most widely. Common nails are characterized by a flat head that is driven in so that it is flush with the material’s surface.
Whereas, finishing nails are characterized by a smaller, narrower head that is driven in below the material’s surface with a special tool called a nail set, or punch; the small depression remaining is filled in with putty. Since finishing nails have a neater appearance, they are mostly used for interior paneling and cabinet work.
Other common types of nails are box nail, casing nail, wire nails, and spikes. At Hama Steel, Nails are made by feeding a thick, continuous steel wire into a machine where the wire is gripped between two dies and is cut to the desired length. Sufficient metal to form the head is allowed to protrude from the dies at one end and is then flattened into ahead by a blow from a mechanized hammer.
The other end of the piece of wire is cut into a point, after which the nail is ejected from the machine and maybe smoothed (to remove the rough edges), polished, or plated. Wire-nail presses can produce nails at speeds of up to 800 per minute.
Annealed Binding Wires
Annealed binding wires are created using low carbon steel wire. This carbon steel wire goes through the annealing process to transform it into annealed binding wires. The annealing process involves heating the wire to a specific temperature before cooling it at a prescribed rate in order to achieve the desired result.
Annealing is performed in order to increase the ductility of the wire and to reduce the hardness. This results in wires that are more flexible. With these properties, the annealed wire is self-tying and can stay in place when wrapped around itself. There are various types of annealed wires available in the market. Some of the most popular ones are merchant wire, box wire, and tie wire.
The merchant wire is black annealed wire wound into 100 pounds per coil, and a full stand holds 20 coils. The box wire is 100 pounds of wire wound into a tighter and smaller coil to fit in a box for cleaner transport. The tie wire is a general reference to either one of these two variations.
Annealed wires are most commonly used as baling wire or tie wire as this wire can offer impressive tensile strength while bringing the flexibility necessary to perform as a baling wire. This wire is able to adapt to the form it needs to take in order to bring together a bale or be tied up without breaking.
HB Wires
HB Wire is a raw material for manufacturing of G. I. Wire, Binding Wire, Weld Mesh, Welding Electrodes, etc, and for other uses such as Cement Pole, Cement Pipe, Bridges, and Handicrafts. H. B. Wire is highly used in manufacturing Nails and Cycle Spokes. These Mild steel wires (HB wires) are drawn through the ‘cold drawing process’ using steel wire rod, deriving from excellent quality raw material.
Wire Rod is first D-scaled with the help of Double plain descaler rid of the mild scale and then the cleaned wire rod is processed further to pass through a number of dies & drums with an average reduction of 25% to eventually achieve the targeted final product size and then it is taken in bundle shape of appropriate individual castings.
Steel Wire Rods
Steel wire rods are semi-finished products that are rolled from steel billet in a wire rod mill and is used primarily for the manufacture of wire. But, if you are looking it for a steel plant, then it is a finished product. Steel wire rod is usually cold drawn into wire suitable for further processing such as cold rolling, cold heading, cold upsetting, cold extrusion, cold forging, or hot forging.
Steel wire rods can be produced in several regular shapes (round, square, hexagonal, and rectangular), most of the wire rods rolled are round in cross section. Round wire rod is usually produced in nominal diameters of 5 mm to 15 mm, advancing in increments of 0.5 mm. ISO 16124:2004 gives diameters of round steel wire rods ranging from 5 mm to 50 mm, advancing in increments of 0.5 mm up to 20 mm and thereafter in the increments of 1 mm.
Wire rods are normally sold in the as-rolled condition. The user of wire rods prepares the wire rods for further processing by cleaning and coating, or by heat treating. The process involves cleaning and coating, heat treatment, and carbon steel wire rod.
Steel wire rods can be used for producing
- Rods for industrial use
- Bright rods to be chromium-plate used in house-furnishing, in white goods and agriculture
- Pre-stressed reinforced steel
- Wire for electrode and submerged arc continuous welding
- Spring wires
- Chains and welded mesh
- Wires and strands
Types of Rebars
Reinforcement bars, also known as rebars, are used to improve the tensile strength of the concrete since concrete is very weak in tension and strong in compression. Steel is only used as a rebar because the elongation of steel equals concrete at high temperatures.
Types of Rebars:
- Mild Steel Bar
- Reformed Steel Bar
- Others
Mild Steel Bars
Mild steel bars are used in concrete for special purposes such as dowels at expansion joints, where bars must slide in a metal or paper sleeve, for contraction joints in roads, runways and for column spirals. It is not recommended to use Grade II mild steel bar for structures in areas of severe damage like earthquake zones and also for structures subject to dynamic loading (other than wind loading) such as railways and highways bridges.
With mild steel bars, rods are manufactured in long lengths and can be cut quickly and be bent easily without damage. It is very important to test the mild steel bars in the laboratory before using them. Some of the manufacturers stamp their MS bars grade with their make /name and also give certification of test and grade. On the basis of the above information, you can store mild steel bars grade-wise at the site of work.
- Mild steel bars grade-I designated as Fe 410-S or Grade 60
- Mild steel bars grade-II designated as Fe-410-o or Grade 40
TMT Rebars
Thermo Mechanically Treated rebars also known as TMT rebars, are hot treated bars that are high in strength and used in Reinforced Concrete Cement (RCC) work. It is the latest induction in the MS steel bars with superior properties such as strength, ductility, wielding ability, bending ability, and highest quality standards at the international level.
Characteristics of TMT Rebars
- Better ductility and malleability
- High yield strength and toughness
- More bonding strength
- Earthquake resistant
- Corrosion-resistant
- Thigh thermal resistance
- Safe and economical
- No loss in strength at wielded joints
- Ordinary electrodes used for wielding the joints.
HSD Rebars
High Strength Deformed rebars, also known as HSD rebars are cold twisted steel bars with lugs, ribs, projection, or deformation on the surface. It is extensively and majorly used for reinforcement purposes in construction. These bars are produced in sizes or sections from 4mm to 50mm in diameter.
Characteristics of HSD Rebars
- Low Carbon Value
HSD rebars have lower carbon level, resulting in good ductility, strength and wielding ability.
- Superior Bonding Strength
HSD rebars are well known for their excellent bonding strength when used with concrete.
- Wielding Capability
Since these bars have lower carbon content, they have 100% wielding capability than conventional bars.
- High Tensile Strength
HSD rebars feature high tensile strength. They offer great asset in construction process which requires a lot of bending and re-bending.
- Wide Application Range
These bars have wide application range like in building residential, commercial and industrial structures, bridges, etc.
- Satisfactory Malleability
It has minimum weight and maximum strength along with being suitable for both compression and tension reinforcement.
Types of Rebar Based On Type Of Materials Used In Productions
European Rebar
It is made up of Manganese, which makes them easily bendable. They are not suitable for use in areas that are prone to extreme weather conditions or geological effects, such as earthquakes, hurricanes, or tornados. This is a low-cost type of rebar.
Carbon Steel Rebar
It is made up of carbon steel and is commonly known as Black Bar due to its black color. The main drawback of this rebar is that it easily gets corroded, which adversely affects the concrete and structure. The tensile strength ratio coupled with the value makes block rebar one of the best choices.
Epoxy-coated Rebar
Epoxy-coated rebar is black rebar with an epoxy coat. It has tensile strength but is 17 to 1700 times more resistant to corrosion. However, the epoxy coating is incredibly delicate. The greater the damage to the coating, the less it becomes resistant to corrosion.
Galvanized Rebar
It is only 40 times resistant to corrosion than the black rebar, but it is more difficult to damage the coating of galvanized rebar. In that respect, it has more value than epoxy coated rebar. This is why it is about 40% more expensive than epoxy coated rebar.
Glass Fiber Reinforced Polymer (GFRP)
GFRP is made up of carbon fiber. As it is made up of fiber, it does not entertain bending. It is very resistant to corrosion and is costly when compared to another rebar.
Stainless Steel Rebar
It is the most expensive reinforcing bar available. Its price is 8 times the price of epoxy coated rebar. It is also the best rebar available for most projects. However, using stainless steel in all but the most unique of circumstances is often overkill.
But for those who have the reason to use it, stainless steel rebar is 1500 times more resistant to corrosion compared to block bar. Also, it is more resistant to damage than any of the other corrosion-resistant or corrosion-proof types of rebar.
Difference Between Mild Steel Bar and Deformed Steel Bar
Mild steel bars are used in concrete for special purposes such as dowels at expansion joints, where bars must slide in a metal or paper sleeve, for contraction joints in roads, runways and for column spirals. It is not recommended to use Grade II mild steel bar for structures in areas of severe damage like earthquake zones and also for structures subject to dynamic loading (other than wind loading) such as railways and highways bridges.
With mild steel bars, rods are manufactured in long lengths and can be cut quickly and be bent easily without damage. It is very important to test the mild steel bars in laboratory before using them. Some of manufacturers stamp their MS bars grade with their make /name and also give certification of test and grade. On the basis of the above information you can store mild steel bars grade-wise at the site of work.
- Mild steel bars grade-I designated as Fe 410-S or Grade 60
- Mild steel bars grade-II designated as Fe-410-o or Grade 40
A deformed steel bar is a steel bar with surface projections that increase its bond strength when used in reinforced concrete. Deformed bars are made of steel with a deformation on their surface which is designed to assist with minimizing slippage when installed into concrete by providing an increase in the bond for two materials. The tensile stress in deformed bars is higher than in plain round bars.
A deformed bar is used where extra reinforcing is required to fabric sheets or trench mesh. By using the reinforcing bar in construction, it creates a single, monolithic concrete structure with high durability, reliability, and integrity.
|
Mild Steel Bar |
Deformed Steel Bar |
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The surface of mild steel bars is plain and round in shape. |
Deformed steel bars have ribs and indentation at the surface of the bars. |
|
They are available in various sizes of 6mm to 50mm |
This reduces the major problem that is faced by mild steel bar due to slippage and good bonding is achieved between concrete and rebar. |
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They are used in concrete for special purposes, such as dowels at expansion joints, where bars must slide in a metal or paper sleeve, for contraction joints in roads, runways, and column spirals. |
The tensile properties is higher compared to other rebars. |
|
They are easy to cut and bend without damaging. |
These rebars are produced in sections from 6mm to 50mm diameter. |
Construction Best Practices
Best construction practices does not involve just using good construction materials. Here we will discuss of factors to be considered while practicing good construction.
Schedule
The schedule phase involves the design phase and the bid/procurement phase. Try meeting with your architects and design team as early as possible so that you can collectively put together a schedule that suits your needs. Preferably, there is plenty of time to get everything done, though real world conditions and unforeseen construction project problems may make your project somewhat less than ideal.
To plan in time, note that many building components have very long lead times. HVAC equipment, doors, windows, and casework all take weeks if not months to manufacture – once the order is placed. Know that contractors need to do their own field measurements and shop drawing preparation, and your architects and engineers need to review their plans, prior to ordering. So planning on a 16 week lead time for an HVAC unit starting on the day you award a bid does not account for several of those necessary steps in the process.
If your completion date is fixed, think strategically about how to get the task done on time. Think creatively; phasing your work may cost bit more, but if you’ve set schedule as your primary project goal, that may be a choice you need to make to achieve completion within your timeframe. Also, put together a series of milestone dates. Make sure there are critical check-ins so you can have assurances that things are moving, and you won’t get to the eleventh hour with half of the work left to be done.
Utilize your architect to monitor this schedule, so they can assist the contractor in their efforts to recover any lost time. Ultimately though, realize that the contractor is the entity who controls when their work is done since you can’t direct their subcontractors or workers, or physically bring them to your site to work.
Scope and Quality
For better results, it is very important to understand the scope of the project. Sit down with your architect and make sure you are on track with what is happening, what gets removed, what is going in its place, how will everything be put together?
Investigate your existing conditions on a timely basis. Whether you’re dealing with a new office building on untouched soil, or an existing 1950s school, know what you’re dealing with. Consider going beyond standard visual reviews and doing exploratory testing or digging. Get into the ground, above the ceilings, perhaps utilize ground-penetrating radar to find pipes, conduits, or other hidden components that may not be documented anywhere else. Performing this due diligence upfront minimizes the chance of surprises during construction when the solution can cause all sorts of cost and schedule delays.
Pay attention to what’s going on around you. Your team should be knowledgeable and experienced. Think about having your architect increase the number or frequency of their site visits if you’re concerned about your contractor’s work. And ask questions if you don’t understand something.
Price
It is to the contractor’s benefit to purchase their materials and labor for as little as they can, and charge you as much as they can. That’s not to paint a picture of contractors as evil corporations, single-mindedly focused on their bottom line, but realize that even the best and most altruistic contractor out there can’t operate at a loss.
Scope, schedule, and price are three different concepts; but both scope and schedule greatly influence the price. “Off the shelf” or easily obtainable materials will usually cost less than custom pieces. Keep these concepts in mind as you’re making your design decisions.
Similarly, alternative procurement strategies may help reduce your cost. Eliminating a contractor’s markup by buying components yourself, or purchasing through a cooperative pricing system, may help your bill.
Understanding your project’s success metrics is key. It can help streamline and focus your decision-making process and can allay panic when trouble seems like it’s lurking around every corner.
Things to Consider When Choosing a Stainless Steel
Stainless steel has always been a top choice among the consumers, be it for construction purpose, commercial purpose or for use at home. With varieties of stainless steel available in the market, one needs to be very careful while choosing the right one. One of the major benefits of stainless steel is that its composition prevents the iron from rusting.
Stainless steel is not only versatile, but also inexpensive and beautifully sleek. There are over 60 different grades of stainless steel. Lower grades stainless steel work well when exposed to atmospheric and water environments while higher grades stainless steel is preferable for exposure to either alkaline or acidic solutions.
Here are some of the things that need to be considered while choosing a stainless steel:
Heat Treatment Ability
If you are buying stainless steel that needs to be heat-treated, you need to know that the heat treatment ability of stainless steel depends on different stainless steel grades. Stainless steel like austenitic stainless steel and ferritic steel does not harden when treated with heat. The heat-treatable stainless steels are martensitic or precipitation hardened.
Resistance to Corrosion
People love stainless steel due to its resistance to corrosion. However, the level of resistance to corrosion depends on the grade of steel. Austenitic stainless steel offers the most corrosion resistance due to the amounts of chromium.
So, if you need stainless steel with a high level of corrosion resistance, you need to go for grade 316 stainless steel. Martensitic and ferritic stainless steels are generally more affordable than austenitic stainless steel since they have less nickel and less chromium.
Machinability
Even though the majority of stainless steel grades can be machined, the metal is quite susceptible to work hardening. It is important to optimize the machining process to work at a rate that helps alleviate this problem. Also, make sure to use machining tools that are kept in good working condition. If you need to increase the machinability of steel you can add sulfur.
Weldability
While welding stainless steel, one can face issues like hot cracking, intergranular corrosion, and stress corrosion cracking. The austenitic group of stainless steels offers the best weldability. Make sure you use grades like 304L or 347 when welding this type of stainless steel. These types of stainless steel tend to have lower carbon while 347 has niobium stabilizers added to it to help in deterring intergranular corrosion.
Formability
If you want to use stainless steel for applications that require good formability, steer clear of the martensitic group of stainless steels. Instead, choose an austenitic grade like 304 or a ferritic grade like 430. Often, austenitic stainless steel is the right choice in terms of formable stainless steel.
Benefits of Stainless Steel
Strength
Stainless steel is preferred not only because of its strength but also due to its ability to resist both high and low temperatures at their extremes. Also, because of the cold work hardening properties of stainless steel, it can be used in various designs to reduce material thicknesses and reduce weight and costs. Stainless steel is very tough in nature and even lightweight stainless steel won’t get damaged under a great weight. These properties make it one of the most durable metals on the market.
Hygienic Properties
Stainless steel is mostly used in kitchens, hospitals, food processing facilities, etc due to its hygienic properties. Materials used in stainless steel do not support the growth of bacteria. In addition, they are easy to clean and maintain. All you need to do is clean it with a dishwasher or an all purpose cleaner.
Type 304 stainless steel have largely replaced traditional sink materials such as aluminum and plastic laminates. This is because it can be kept scrupulously clean and withstand aggressive chemicals.
Corrosion Resistant
One major advantage of stainless steel is that they are highly resistant to corrosion. While low alloyed grades of stainless steel can resist corrosion in atmospheric conditions, highly alloyed grades of stainless steel can resist corrosion in most acids, alkaline solutions, and chloride bearing environments, even at elevated temperatures and pressures.
Aesthetics
In relation to stainless steel, aesthetics refers to the beauty of the products made from stainless steel. The bright surface of stainless steel is what provides it with an attractive appearance. Also, stainless steel is available in many surface finishes. In addition, stainless steel appliances complement almost any kitchen, home design, and theme. Thus it has become a major choice among households today.
100% Recyclable
What’s better than materials that can be recycled and reused? Stainless steel can be recycled in required items when they wear out. This is one of the major benefits of stainless steel. Also, most of the stainless steel materials we use today are the product of recycled stainless steel.
According to the Steel Recycling Institute, one ton of recycled steel saves 2,500 pounds of iron ore, 1,400 pounds of coal and 120 pounds of limestone. It is also said that almost 50% of new stainless steel comes from old remelted stainless steel scrap, thereby completing the full life cycle.
Interesting Facts about Steel You Should Know
Grades of Steel
You would surely be amazed to know that there are more than 3500 different grades of steel. While the number might not be exact, the World Steel Association states that “there are more than 3,500 different grades of steel” and that “approximately 75% of modern steels have been developed in the past 20 years.” This number can definitely increase in the future given the number of research conducted. Also, you might be introduced to the type of steels that are even lighter and stronger than ever before.
100% Recyclable
Just like many other metals, steel is 100% recyclable. Also, steel is considered to be the world’s most recyclable material. This is because of the ferromagnetic properties present in the steel. This property in steel makes the steel easy to remove from the solid waste stream and divert into recycling plants.
According to statistics cited by the Institute of Scrap Recycling Industries (ISRI) in a 2015 report, “In the United States alone, 73 million metric tons of ferrous scrap was processed by the scrap recycling industry last year, nearly 55 percent of the volume of all domestically-produced material.”
Rusting Can Occur in Stainless Steel Wires
One of the main reasons why people love stainless steel is due to its ability to resist corrosion. The ability to resist corrosion results in prolonged life and preservation of its strength. Here are some of the circumstances in which stainless steel can rust:
- If the mill welding machine electrodes and other equipment are not cleaned properly when moving from welding plain steel to stainless steel.
- If the same metal brushes are used for finishing both plain and stainless steel alloys.
To increase the useful life of stainless steel, proper care should be given during initial manufacture.
More Elastic Than Rubber
Another amazing fact about steel is that it is more elastic than rubber. Any material is said to be elastic if it can bounce back to its original shape after being deformed under stress. Since steel is able to come back to its original shape more quickly, it is considered to be more elastic than rubber.
1000 Times Stronger Than Iron
Steel is roughly 1000 times stronger than iron. This is because of the amount of carbon added to the steel. When carbon is added to steel, it increases the tensile strength of the steel, which results in a superior level of strength compared to pure iron.
Difference Between Stainless Steel and Mild Steel
Stainless Steel
Stainless steel has always been a top choice among consumers, be it for construction purposes, commercial purpose, or for use at home. With varieties of stainless steel available in the market, one needs to be very careful while choosing the right one. One of the major benefits of stainless steel is that its composition prevents the iron from rusting. Stainless steel is not only versatile but also inexpensive and beautifully sleek.
There are over 60 different grades of stainless steel. Lower grades stainless steel work well when exposed to atmospheric and water environments while higher grades stainless steel is preferable for exposure to either alkaline or acidic solutions. Stainless steel is preferred not only because of its strength but also due to its ability to resist both high and low temperatures at their extremes, resistance, and 100% recyclability.
According to the Steel Recycling Institute, one ton of recycled steel saves 2,500 pounds of iron ore, 1,400 pounds of coal, and 120 pounds of limestone. It is also said that almost 50% of new stainless steel comes from old re-melted stainless steel scrap, thereby completing the full life cycle.
Mild Steel
Mild steel also known as low carbon steel is a type of carbon steel with a low amount of carbon. Generally, mild steel contains 0.05% to 0.25% of carbon by weight. Having less carbon content makes mild steel more ductile, machinable, and wieldable than high carbon and other steels. The low carbon content also means it has very little carbon and other alloying elements to block dislocations in its crystal structure, generally resulting in less tensile strength than high carbon and alloy steels.
Mild steel also has a high amount of iron and ferrite, making it magnetic. It is very well known for its versatility, cost-effectiveness, and performance. As the most common form of steel, its applications are vast and relied upon for everyday use, and it can be cut to size and modified to suit where required. Just like many other metals, mild steel is vital in the production of more of the same.
It can be recycled indefinitely without losing their quality, and due to its magnetic properties mild steel is particularly easy to recover from unsorted waste. In addition, just like copper and thermoplastics, mild steel is able to bend, stretch, and have relatively large forces applied to it, making it easier to form shape, and weld.
Type of Flux Core Stainless Steel Welding Wire
Flux core stainless steel welding wires contain various materials to facilitate welding process quite unlike gas metal arc welding wires which are solid throughout. There exist two types of flux cores stainless steel wires namely gas shielded & self-shielded. Usage however is decided depending upon nature of the project & budget.
For speedy arc welding, gas shielded flux cored wires are used as they have got a high disposition rate compared to a solid wire welder. The wire on the contrary would not be able to weld any thinner metal body like that of an automobile.
A self-shielded welding wire on the other hand is competent to produce gas shielding that is a protection armor required by both solid & gas shielding welding wires to protect the splash of metal. Various self-shielded welding wires are available in the market distinctively designed to serve each unique welding position.
Self-shielded flux cored wire with a high disposition rate, cater to welding of only thick metal bodies. This property is quite similar to that of gas shielded flux cored stainless steel wires. This wire doesn’t produce slag to capture the fluid on weld area hence cannot be applied for vertical welding. Removal of slag takes a great deal of time & effort on the part of the user.
A self-shielded wire on the contrary is ideal for welding in an outdoor location especially with the high-speed wind blowing. A self-shielded wire has high portability because it does not require an external shielding gas. The portability helps welding in agricultural operation where the field equipment repair can take place immediately with help of self-shielded flux core wires as the repair shop will be a few miles away.
These wires provide excellent penetration on thicker metals. Despite being expensive than solid wire, flux-cored wires give one more productivity. Unlike solid wires, they are capable of welding materials with long prevalent rust, mill scale, or oil-coated metals. The deoxidizing elements present in flux-cored wires eliminate these contaminants by holding them in slag coverage.
What is TIG Welding?
Tungsten inert gas welding (TIG Welding) is a type for the welding process while the gas shield is used while welding. This process is also known as the fusion welding process. The TIG welding process is used to obtain optimum quality and spatter-free weld seams. It is suitable for stainless steel, aluminum, and nickel alloys along with thin steel metal made of aluminum and stainless steel.
Its application can be found in container and pipeline construction, portal construction, and aerospace applications. In TIG welding, the required current is supplied using a tungsten electrode, which is temperature-resistant and does not melt. During the process, the electrode emits an arc that heats up and liquefies the material. The nozzle around the electrode protects the heated material from chemical reactions with the ambient air by shielding the gas.
The noble gases used for this purpose are argon, helium, or mixtures. The inert, i.e. non-reactive, gases prevent chemical reactions with the liquid weld pool and the heated material. This ensures high-quality weld seams. As the tungsten electrode does not melt, in TIG welding the filler material is fed in by hand or in mechanized form by an external wire feeder.
Duplex Steel
Duplex stainless steels have a ‘duplex’ two-phase micro-structure consisting of both austenitic and ferritic grains that gives them a combination of attractive properties. Duplex alloys were developed around a 22% Chromium addition level, which largely defines them from subsequent super duplex alloys which were developed around a 25% Chromium addition level for higher corrosion resistance still.
In general, they are twice as strong as either austenitic or ferritic stainless steels. They achieve good toughness and ductility, somewhere between the two. Their corrosion resistance is also very good, assuming comparable levels of Chromium, Molybdenum and Nitrogen in selected compositions. One important advantage over austenitic stainless steels is their resistance to stress corrosion cracking.
Super Duplex Steel
Yet they are significantly more cost effective, and less prone to price variability, due to their lower nickel content. Super Duplex stainless steels have a ‘duplex’ two-phase microstructure consisting of both austenitic and ferritic grains that give them a combination of attractive properties. Whilst duplex alloys were developed around a 22% Cr addition level, super duplex alloys utilize a higher 25%Cr base composition to increase the level of corrosion resistance achievable.
In general, they are twice as strong as either austenitic or ferritic stainless steel. They achieve good toughness and ductility, somewhere between the two. Their corrosion resistance is also very good, assuming comparable levels of chromium, molybdenum, and nitrogen in selected compositions. By increasing the level of chromium additions.
combined with significant levels of molybdenum and nitrogen, super duplex stainless steels achieve a Pitting Resistance Equivalent number (PREN) >40, which will match or beat all but the most highly alloyed austenitic stainless steels and often provide comparable performance to some nickel alloys also. One further advantage over austenitic stainless steels is their resistance to stress corrosion cracking.
ERW Stainless Steel Tubes & Pipes Exporters
Hama Steels is one of the largest ERW Welded Stainless Steel Tubes and Pipes Manufacturer & exporters in Nepal. Our precisely constructed stainless steel tubes and pipes are high in performance and known for their sturdiness, durability and credibility. Our products are ideal for all applications where greater strength and superior corrosion resistance is required.
Our manufacturing plant is capable of producing World’s finest quality ERW pipes and tubes in Round, Square, and Rectangular shapes. Our modern production facility is equipped with state-of-the-art, world-class machines to manufacture a very wide range of Stainless Steel pipes and tubes as per all international specifications, and suitably accommodating demands of customers in variable quantity and time frames.
Skilled engineers, workers, and modern machinery, they are the backbone of our company and provide the most needed skills to enable us to produce superior Stainless Steel products. Over the years, Hama Steel has secured a respected position in the Steel industry by making relentless efforts to cater to the clients with premium quality Stainless Steel Pipes and Tubes
Effective Ways to Improve Manufacturing Throughput
Here we will discuss some of the ways to improve manufacturing throughout:-
Inspect Workflow
The very essential part of improving manufacturing throughout is the inspection of the workflow. To better understand the manufacturing throughput, firstly you need to create a map of your workflow including labor, equipment, processes, and how they work together. This workflow map should also include where data will carry the most value, or indicate throughput effectors (areas and/or processes with the greatest effect on production throughput.
Identify Bottlenecks
Having a good workflow will definitely help you figure out the bottlenecks. Finding and streamlining bottlenecks might be as simple as improving communication between both machines and workers. In many cases, workers might already know where and why a bottleneck exists.
If not, it is important to collect machine data to find the bottleneck’s root cause. Some bottlenecks are from a lack of knowledge about equipment’s cycle times. Cycle times can be improved by adjusting the depth of cut, speed rates, and feed rates to reduce bottlenecks.
However, it is important to know about safe operating specifications. Operating within a safe operating range prevents extraneous wear and tear, or mitigate machine maintenance according to use to prevent bottlenecks caused by downtime.
Reduce Equipment Downtown
Proper maintenance of the equipment is the key to reducing downtime. You need to find the cost associated with downtime and how it affects ROI. This relatively easy to calculate the cost is often why many companies start a digital transformation plan based on preventative maintenance.
Finding better ways of documenting and tracking maintenance can be a good way to start small, find throughput effectors, and make informed decisions on scaling or adopting new technology. Using technology with reminders, real-time notifications, and alerts will keep machines running and help reduce downtime, and rejected parts.
Minimize Rejected Parts
Scrapping or reworking parts hinder manufacturing throughput. Monitoring machines more accurately can provide preventative maintenance, but monitoring production can find rejected parts faster.
Combining preventative maintenance and quality control data can predict errors to fix problems before they start to improve throughput. Using your workflow will determine where quality control is needed. If the inspection is too far downstream, more scrap parts might be made before an error is detected.
Depending on where the controls are located, more reject parts might be produced before the line is stopped or the error is fixed. Workers should be made aware of workflow and where quality control is needed so they understand why inspection or checking gages is so important.
Focus on Training Programs
Proper training and management play a major role in effective throughput. Employees that understand the entire production and why things are done in certain ways can help them see how mistakes create delays and ripple effects. Education can also help employees make changes that might save time downstream or reduce process and setup times.
Workers aware of the big picture are more likely to observe ways to improve their work station, eliminate extraneous steps, and more.
What Are The Steel Bars Applications And Uses
Flat Bars
Steel bars with a flat surface and rectangular face are recognized as flat bars. Since they are flat in shape, they are extremely versatile and can be used for various projects. For example, they are an essential component for frame construction, building support, improvements and additions, and industrial artwork. These flat bars are highly used for construction as they are durable and can withstand heavy construction weight.
Round Bars
Round bars are characterized by solid, circular, and versatile product that is easy to shape and form. Its smooth surface and dimensional accuracy make it ideal for cutting, welding, machining, forming, and bending. Round bars are commonly used for bracing, pins, hinges, balustrade, and vehicle axles, as well as items such as earth stakes and gazebo or tent pegs.
Channel Bars
Steel channel bars are commonly used in conjunction with I-beams and other steel products to build commercial and industrial buildings, such as warehouses. It can act as girts, studs, braces, joists, or other structural components where the added strength of an I-beam is not necessary. They are not only versatile but also strong, light-weighted, and relatively maintenance-free.
Square Bars
Square steel bars are widely used for general assembly or manufacturing in many industries. They are also used for general repairs of plant equipment and railings. Other applications of square steel bars include ornamental ironwork, gates, and protective barriers on windows.
Stainless steel square bars are also primarily used by manufacturing and engineering industries, due to their flexible application and durability. They are also used in the Marine and Food industries, as well as in the fabrication of framework, support, axles, and braces.