LTL Galvanizers (Pvt) Limited

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1 LTL Galvanizers (Pvt) Limited

2 LTL Galvanizers (Pvt) Limited LTL 1Galvanizers 1(Pvt) 1Limited 1(LTL) 1was 1established 1in in 1Sapugaskanda industrial zone which is 20km away from the Colombo city Sri Lanka, with its Fabrication & Galvanizing plants. LTL Galvanizers (Pvt) Limited started the design and manufacture of towers, and steel structures for a variety of purposes including power transmission lines up to 220 kv; poles, masts, antenna mounts and towers for wireless telecommunications; lighting, wind power, utility distributions systems, etc., in early LTL s commitment to Quality, and effective handling of orders by talented, well trained, and dedicated staff has virtually ensured every project, which came their way a success. Technical collaborations with internationally reputed organizations such as ABB Kraft of Norway, Betonmast Energie GmbH of Germany, and such others have enriched the design capability of LTL. Today LTL is equipped with the finest design tools and high caliber specially trained design engineers for tower and steel structure designing. Our vision is to be the market leader in the field of Fabricating & Galvanizing in South Asia, using the synergy of the combined forces of our professionalism, unmatched skills of our workforce and work methods thus achieving maximum client satisfaction by meeting and exceeding world standards of quality and conforming to requirements for a reasonable price while continuing to grow and extend our reach across the globe. Member of the American Galvanizers Association Member of the International Award for Galvanizing Excellence by AGA

3 Products & Services LTL provides design, fabrication, galvanizing and installation of Power Transmission Towers Telecommunication and Radio Towers. Cellular Communication installations Television Masts Substation Structures Antenna and feeder installations Other Lattice Steel Structures The towers, poles and structures manufactured by LTL are customized to the requirement of the client and strictly in compliance with international standards. POWER TRANSMISSION LINES LTL is the only Company in Sri Lanka, which design, manufactures and constructs transmission lines. It has already completed construction of over 150 k.m. of transmission line which includes the recently commissioned Katunayake to Unnaruwa 132 kv Transmission Line, Ratnapura to Balangoda 132 kv Transmission Line Project and the Kukule Ganga 132 kv Transmission Line from Kukule to Mathugama. These were the first projects where towers designed, and manufactured in Sri Lanka were used on 132 kv transmission lines. Telecommunication Towers LTL has designed, manufactured and delivered many telecommunication towers for large communication network expansion projects in Sri Lanka.

4 Engineering Towers are designed in accordance with the Standard ASCE or ANSI/EIA-222 Standard latest issue. Towers are also designed in compliance to other standards and specifications when required. Towers are designed for the specified wind and ice loading conditions applicable to the particular site conditions. Every LTL Tower starts here... in the engineering department. The engineering staff at LTL is among the best in the industry, comprised of dedicated, highly skilled and experienced in all aspects of tower design and product development. The focus is on clients unique application and to design and manufacture quality products to fully satisfy the client s needs. The engineering group at LTL understands the importance of client s application and strives to ensure that the products have been designed according to the latest industry standards and engineering techniques. All LTL Towers are created using the latest C.A.D. designs and thoroughly reviewed before a single section is cut or welded.

5 Manufacturing Modern factory with CNC machinery supports the fast and accurate production. Manufacturing facility of LTL is fully equipped with modern machinery with computer numerically controlled systems. Very high accuracy, repeatability and high rate of production of these machines put the plant in the high end of similar type of production lines and becomes the only facility of this type in Sri Lanka. Present production capacity of 350 tons per month is being upgraded to All structural steel conforms to BSEN or ISO 630 Standard and other standards as applicable. All welding conforms to the requirements of the American Welding Society D1.1 Standard. All material is hot-dip galvanized after fabrication to BS EN ISO 1461:2009 or ASTM Standard A123 Standard. All structural bolts conform to ISO 698: and are galvanized to BS EN ISO 1461:2009. All guy strands are galvanized. They are pre-stressed, measured and stripped when specified by the customer and/or designer. All other purchased parts are in accordance with applicable standards.

6 LTL's Galvanizing Plant Our Galvanizing Plant was established in 1991, and has since expanded to include a plant in Sapugaskanda in 1999, followed by the advancement to Phase II of the Sapugaskanda plant in We are backed by a highly skilled and committed workforce and our company's prime areas of growth and development have not only been in actual size but also in the expansion of scope and technical excellence; and in the standards of quality and reliability. Offering a production capacity of 6.2 MT per hour, we own one of the most up-to-date plants in South East Asia. Our galvanizing facility works with the highest quality German made operational equipment, applying ultra-modern technology and skills, also acquired and mastered in Germany. We offer you a product with a life period that goes beyond the expected levels of standards, and give you the guarantee of our highest quality. Our products are manufactured in strict compliance to BS, ASTM, DIN, ISO, AS/NZ and many other international standards. The plant also carries ISO 9001 quality management certification by Det Norske Veritas, Netherlands. Our Galvanizing Plant...Your source of quality metal protection. Galvanizing involves the following operations: 1. Inspection prior to Galvanizing & Loading With this important pre-requisite to processing, we ensure that the design of structures, welding and fabricating standards as well as the surface condition of material, are acceptable for galvanizing to the relevant specification.

7 The 'Corrosion' Problem and its Costs Corrosion is the tendency for metal to revert to its lower and more natural energy state, after production and shaping. In order for corrosion to occur, four elements must exist or be present at one time - anode, cathode, electrolyte and its return current path. Main causes of corrosion include: water, dirt, salt and other contaminants that can provide an electrical path which can vastly accelerate corrosion. 70% of the Earth s surface is covered in water. Therefore a majority of countries around the world suffer the ill effects of corrosion caused by moisture. The situation is compounded in countries bounded by the Oceans of the world. Not only is the problem of corrosion hazardous, but it can also cause damage to natural resources - if the longest product life is not possible, the result could be early project failures, requiring unnecessary consumption of resources. Corrosion can take place anywhere and at anytime - affecting everything from water pipes to steel sidewalk sections, and it is thus vital to extend the life and durability of steel in an attempt to minimize the problem. 2. Pickling In the second step of our process, we use high quality Hydrochloric acid to prepare steel for galvanizing. The acid is used unheated at a concentration of about 15%. Material is rinsed in water prior to the transfer to a flux solution.

8 The Process of Galvanizing A hot dip galvanized coating is produced by dipping the metal into a bath of molten zinc, where a metallurgical reaction is created between the metal and the zinc, and a series of hard abrasion resistant iron/zinc alloy layers are formed. These layers are overcoated with relatively pure zinc as the product is withdrawn from the galvanizing bath, and they all play a significant role in the provision of corrosion protection. For the coating to form, the steel surface is required to be entirely free from all contaminants such as mill scale, rusts, grease and oils. The Hot Dip Galvanizing process entails dipping or immersion into a series of cleaning and pre-treatment chemicals prior to immersion in the molten zinc. Project 3 3. Fluxing After pickling in acid, and rinsing in water we transfer the material to a flux solution which consists of ammonium chloride and zinc chloride, and this solution is heated to a º temperature of 70 C. The flux plays an important role in that it provides barrier protection to prevent flash rusting during the period between acid pickling and immersion in the zinc. It will act as a wetting agent.

9 Chemical Composition During galvanizing, the molten zinc reacts with the iron in steel to Eta (100% Zinc) 70 DPN Hardness form a series of zinc/iron alloy layers. A typical coating micro structure consists of three alloy layers and a layer of pure metallic zinc. The reason for the extensive use of hot dip galvanizing is the two-fold protective Zeta (94% Zinc) 179 DPN Hardness nature of the coating; Delta (90% Zinc) Gamma (75% Zinc) Base Steel 244 DPN Hardness 250 DPN Hardness 159 DPN Hardness As a barrier coating, it provides a tough, metallurgically bonded zinc coating that completely covers the steel surface and seals the steel from the corrosive action of the environment. The hot-dip galvanized coating consists of four separate layers. The first three layers have a mixture of iron and zinc, and the external top layer is typically composed of 100% zinc. The coating gives cathodic protection, where the steel is the cathode, which is protected by the Zinc layer which acts as the anode that is sacrificed. 4. Drying Our process specialists ensure that moisture is removed from the steel surface by initially preheating the material 0 0 at 120 c 150 c, by clean hot air blowing.

10 Why Galvanize? Hot dip galvanizing is lower in cost than many other commonly specified protective coatings for steel. It is more cost effective because it lasts longer and needs less maintenance. The life expectancy of hot dip galvanized coatings on typical structural members is far in excess of 50 years in most rural environments, and 20 to 25 years plus, even in severe urban and coastal exposure. Galvanizing at LTL is carried out to the appropriate standards for hot dip galvanizing, and is an assurance of its reliability. A hot dip galvanized coating has a unique metallurgical structure that gives outstanding resistance to mechanical damage in transport, erection and service. Every part of a hot dip galvanized article is completely protected - even recesses, sharp corners and inaccessible areas. Galvanizing enables a faster erection time - when assembly of the structure is complete, it is immediately ready for use or for the next construction stage. Caption Project 1 5. Hot Dip Galvanizing After fluxing and further drying, we dip the products into the molten zinc which is heated to a temperature of about 450ºC. The steel is immersed at a fairly rapid speed, and once the coating has formed, withdrawal is at a slower speed to ensure uniform drainage and a smooth finish.

11 Capacity/Specifications of the Plant Our plant at Sapugaskanda has a production capacity of 6.2 MT per hour. Using state-of-the-art equipment designed and manufactured in Germany, up to date technology and technical collaboration with American Galvanizers Association, we guarantee the best of quality in compliance with international standards. Bath Sizes Steel Bath Ceramic Bath Useful Dimensions L-7000 mm L-3000 mm W-1300 mm W-800 mm D-2100 mm D-1200 mm Normal Capacity 5000 kg/n Gross 1200 kg/n Gross Operating Temperature 450 c 450 c / 550 c *By double-end dipping, our bath can reach up to 13.5 m 6. Quenching With this process we solidify the zinc coating, as this ensure easy handling. It also arrests the alloying reaction in the case of reactive steels, which continues well below the melting temperature of zinc.

12 Why Choose us? Superior Edge LTL s state-of-the-art production plant is operated by an intensively trained workforce, positioning itself with this superior edge to take on the world s requirements, and to cater to any international market. With the entire galvanizing process carried out in-house, the proximity of the factory to the Port of Colombo gives an added edge to our commitment to consistent and prompt delivery time-the products reach the Port within an hour. Vast Experience Since inception in 1991 we have gathered almost 15 years of experience, and are still growing in our indefatigable pursuit of higher standards with every achievement, and uncapped standards of excellence. Key National Projects In our tenure, we have supported almost all projects in Sri Lanka. Some of these include major projects like the Kukuleganga and Balangoda Transmission Line Projects; Grid Substation Projects in Anuradhapura, Ampara, Kelaniya and Vavuniya; and also the telecom towers for the expansion of almost all telecommunication service providers in Sri Lanka. 7. Final Inspection In order to achieve the best possible coating standards, we undertake routine analyses of the coating thickness of Galvanized sections. Which is essential in the maintenance of consistency and quality to ensure that the required coating has been achieved.

13 Superior Products, Competitive Prices We do not limit ourselves we take on not only the nations requirements but also reach out into the international arena, catering to clients as far reaching as Asia, Africa, Europe and the Middle East including Germany, Norway, Japan, Australia, Maldives, Iraq, Palestine, Jordan and Qatar. We offer products of superior and world-class quality, at the most competitive prices that by any standards, are hard to match. Technical Excellence Our products are designed in-house using state-of-the-art technology and tools, and are guaranteed for the best of quality in compliance with international standards, through technical collaboration with the American Galvanizers Association. World-Class Workforce This is complemented by the high standards of our employees skills and technical knowledge, which is constantly upgraded to keep up with global trends through regular overseas exposures. International collaboration to give you the best of quality, the world over Our galvanizing facility works with the highest quality German operational equipment, applying ultra-modern technology and skill, also acquired and mastered in Germany. We have also gathered vast technical know-how through our many years of affiliation to the American Galvanizers Association, and implement continuous technology upgrading through European collaboration. We encourage continuous assessment and consultation from specialist German technicians, specifically in the areas of repairs & maintenance of plant and in upholding of quality standards. Standards of Quality As a member of the American and the Australian Galvanizers Associations, LTL s plant has recently won the International Award for Galvanizing Excellence, and is accredited with ISO 9001 quality management system certification by Det Norske Veritas of Netherlands. Further, our manufacturing process is in strict compliance with BS, ASTM, DIN, AS/NZ and many other international standards, assuring you of a world-class product of unrivalled quality. In addition to this, regular internal and external quality audits on our part, further ensures the full and continuous conformity with these standards. LTL offers you a strong commitment to excellence - backed by the combination of over a decade of experience, the servicing of key local and international clients, superior processes, technology, and innovation, an ultra skilled and committed workforce, worldclass quality standards, control and assurance and most importantly a guaranteed superior product.

14 Galvanizing & Fabrication Plant Block 3&4, LINDEL, Sapugaskanda, Makola. Sri Lanka. Telephone: Fax: Web:

15 Our Customers - A Global Footprint UK Norway Germany Palestine Iraq Jordan Qatar India Japan Maldives Madagascar Australia LT L Galvanizers (Pvt) Ltd.

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