BUILD IT RIGHT WITH THE ASSURANCE OF SAFETY

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Tamsyn Ferguson
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1 BUILD IT RIGHT WITH THE ASSURANCE OF SAFETY

2 Why is ET Epoxy Protect the right choice to build it right? ET Epoxy Protect is a right choice for construction in moisture and chlorides prone areas. The ready-to-use epoxy coated TMT bars protect the constructions from corrosion due to moisture, various chlorides and acids and thereby results in long-lasting and low-maintenance structures.

3 WHAT HAPPENS IN THE ABSENCE OF EPOXY COATING? Water, air and salts come in contact with the iron bar Corrosion starts on the surface of the bar Corrosion develops further and the concrete surface cracks Corroded bar gets exposed The corrosion cycle of steel starts with the rust expanding on the surface of the bars causing cracks in the concrete. Gradually the corrosion builds-up and results in spalling, ruining the concrete.

ABOUT EPOXY COATING Fusion Bonded Epoxy coating, commonly referred as FBE coating is widely used to protect concrete reinforcement bars, steel pipes, piping connections etc. used in construction.

4 ABOUT EPOXY COATING Fusion Bonded Epoxy coating, commonly referred as FBE coating is widely used to protect concrete reinforcement 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.

5 BENEFITS The superior corrosion protection can extend the life of the epoxy coated tmt bars, resulting in significantly lower lifecycle costs over time. 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. Epoxy powder coated bar is a sustainable solution that is friendly to the environment, a primary concern for construction companies everywhere these days. Studies have shown that structures built with epoxy last longer than similar structures made with black steel. Epoxy coating is very cost-effective as it adds very little to the overall cost of the structure and lifecycle. As the technique is factory based, better quality control is achieved. It enables uniform thickness of coating. The bonding of coating with steel TMT bars is high as it has excellent adhesive property. 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. STANDARDS PARAMETER ASTM A775 : 2007 BIS : 1993 ET EPOXY PROTECT Bar Anchor Profile miles Nearly white metal Nearly white metal and miles Coating Thickness 7-12 miles (microns) (microns) (microns) Coating Holidays 3 holidays/m (max) 6 holidays/m (max) 5 holidays/m (max) Coating Flexibility (Achieved) 180 bent using 8D 120 (after rebound) 120 (after rebound) Resistance to Applied Voltage No Yes Yes

6 TESTING CHEMICAL RESISTANCE TEST The chemical resistance of coating is evaluated by immersing the bars in each of the following as per BIS 13620: Distilled water 2. A 3M aqueous solution of CaCl 2 3. A 3M aqueous solution of NaOH 4. A solution saturated with Ca(OH) 2 ADHESION OF COATING The adhesion of the coating is evaluated by bending coated reinforcement bars to 120 (after rebound) around a mandrel of size as mentioned in BIS 13620:2004 RESISTANCE TO APPLIED VOLTAGE The effect of electrical and electrochemical stresses on the bond of coating to steel and on the film integrity of the coating is assessed as per BIS 13620:2004 SALT SPRAY RESISTANCE TEST The resistance of the coating to a hot and wet corrosive environment is evaluated by exposing 250 mm long coated steel reinforcement bars containing intentional defects to salt spray as mentioned in ASTM A775. ABRASION RESISTANCE The resistance of the coating on coated panels to abrasion, by a Taber abrasor is tested as per the procedure mentioned in BIS 13620:2004 IMPACT TEST The resistance of the coated reinforcing bars to mechanical damage is determined by the falling weight test as mentioned in BIS 13620:2004

7 PROCESS 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 gives 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.

8 MANUFACTURING PROCESS OF ELECTRO 500 D LPS TMT BARS Blast Furnace 1 2 Iron Ore Steel Melting Shop 3 Sponge Iron Kiln 5 4 Billet Caster Rolling Mill Ladle Refining Furnace 6 7 Thermex Quenching System 8 Physical & Chemical Testing Lab 11 Storage & Dispatch 10 FBE Coating Pre-heating 9 ET EPOXY PROTECT PROCESS Surface Cleaning Curing & Cooling 14 Bundling Storage & Dispatch

9 ADVANTAGES OF ELECTRO 500 D LPS

10 PARENTAGE BUILD IT RIGHT Electro 500 D LPS reinforcement bars are a result of a relentless research led innovation and obsession with quality of a world-class organisation that is known for its Excellence in Metallurgy. Electrotherm (India) Ltd. is India s largest manufacturer of Induction Melting Furnaces and furnaces used for steel making. PERFECT BONDING Electro 500 D LPS TMT bars are manufactured using superior notch cutting machines that ensure consistent rib patterns and optimum rib depths. These machine crafted ribs facilitate superior bonding with concrete that is vital for long-lasting structures. SUPERIOR STRENGTH ELECTRO 500 D LPS has an unbeatable combination of strength and ductility that is far superior as compared to the minimum values specified by IS 1786:2008 standards. MECHANICAL PROPERTIES Ultimate Tensile Strength Yield Stress (UTS / YS) Ratio Elongation Total Elongation IS 1786:2008 (Fe 500 D) 565 N/mm N/mm % 5.0% ELECTRO 500 D LPS (typical) *19.0% 8.0% *Upto 20 mm 19% (min), above 20 mm 17% (min), in physical all single values are minimum and as obtained in 90% of heat COST SAVINGS Steel bars are bought in kilos and tonnes but their usage is in terms of metres. Electro 500 D LPS bars have a Higher metreage per unit weight which results in tremendous cost savings.

11 SUPERIOR MANUFACTURING PROCESS The state-of-the-art integrated manufacturing plant comprises of Sponge Iron Kilns, Blast Furnace, Melting Furnace, Ladle Refining Furnace, Continuous Casters, Rolling Mills with AC variable drives, best in class physical and chemical testing laboratories and a Spectrometer. The process uses 100% iron ore through a combination of Blast Furnace, Sponge Iron Kilns, Induction Melting Furnace and Ladle Refining Furnace. Good quality of iron ore is used in Blast Furnace of 128 m 3 and 63 m 3 Direct Reduced Iron (DRI) Kiln of 250 and 350 TPD. After melting the DRI from kilns and hot metal from Blast Furnace in the Induction Furnace, a unique and patented ERF-ELdFOS TM metallurgical process is used to dephosphorize the steel in the ladle and desulphurize the steel in the Electrotherm Ladle Refining Furnace (ERF) specially to meet the stringent phosphorus and sulphur requirement of Fe 500 D grade of TMT bars. Multistage testing of steel chemistry through Spectrometer ensures adherence to chemistry in close tolerance. In the ERF, 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 (100% iron ore) is the key to making superior quality TMT bars free from tramps like Cu, V, Ni,Cr etc. unlike other conventional manufacturers where scrap is used and there is no control on impurities. After refining the steel in LRF, it is rolled in required size in a state-of-the-art Rolling Mill and thermo-mechanically treated in Standard Quenching Box. Highly atomised quenching, self-tempering and atmospheric cooling ensures that 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. EXCELLENT BENDABILITY The advanced Thermex Quenching during the manufacturing process results in bars with a tough outer surface but a soft core that translates into excellent bendability. These bars can be bent around mandrels of small diameters which are a great advantage at the construction sites.

12 RAW MATERIALS (Based on 100% iron ore usage) Electro 500 D LPS TMT bars are made from billets that are manufactured in-house. The billets are also produced using sponge iron from kilns and hot metal from Blast Furnace. High quality of iron ore is used in the manufacturing process. 100% use of iron ore for steel making results into extremely low level of tramp elements in the billets and TMT bars as well. SUPREME WELDABILITY With a carbon content of maximum 0.25%, which is lower than the IS 1786:2008 specifications, Electro 500 D LPS TMT bars offer superior weldability as compared to other TMT bars. This superior weldability means these bars can be lap-welded with ease and without any loss of strength at the welded joints. PURITY The steel produced in Induction Furnace is further refined using Ladle Refining Furnace (ERF) which ensures lower sulphur (impurity) levels, lower inclusion levels, lower gas levels and results in cleaner steel. These pure steel billets with a much lower carbon content provide Electro 500 D LPS bars with uniform strength, excellent ductility and superior bendability. These bars have an inherently high fire and corrosion resistant properties which is suitable for creating structures in earthquake prone zones. CHEMICAL PROPERTIES Carbon Sulphur Phosphorus Sulphur & Phosphorus CE IS 1786:2008 (Fe 500 D) ELECTRO 500 D LPS (typical)

13 PEOPLE It s the men behind the machines that make the difference. Team ET comprising of engineers, technocrats and management professionals is a dedicated team obsessed with quality and passionate about excellence in everything it does. This results in products, solutions and services par excellence. ET ONE-STOP SHOP Electrotherm (India) Ltd. is a one-stop solution for modern day construction that manufactures all the crucial requirements for construction such as TMT bars, Cut & Bend TMT bars and epoxy coating facilities in its own state-of-the-art manufacturing unit in the entire west region of India. This makes the process of building easier and quicker since you don't have to spend your time and energy to pick different vendors for each product or compromise in quality. At Electrotherm we strive to bring forth quality and maintain precise consistency in our range of products for flawless constructions. Available Grades: Fe 415, Fe 500, Fe 500 D, CRS 500 & CRS 500 D Available Sizes: 8 mm to 36 mm

14 BUILD IT RIGHT Electrotherm (India) Limited, HO: 72, Palodia via Thaltej, Ahmedabad , Gujarat, India. Ph.: / 649

BUILD IT FOR A REASON. BUILD IT RIGHT.

BUILD IT RIGHT BUILD IT FOR A REASON. BUILD IT RIGHT. It s time to build over failures of the past. And build with materials strong and worthy. It takes strength, conviction and a solid core to build the