Melwire Rolling (Pvt) Ltd

100 % Sri Lankan Company

Melwire Products
 Melwire Products contd….

Mel Brass
Industries
(Hinges)
fu,a n%dia bkaviaá%ia ms;a;, wiõ
irfkare fidhsn wdosh
TOWER BOLTS
 MELWA Products cont...

GI Pipe and GI Box bars

Melwire Industries (Pvt) Ltd. manufactures GI Box bars and GI Tubes to
suit the various needs of the housing construction and building structural
application adding value to interior design and finishing.

GI Box Bars GI Pipes

Our achievements:

No.1 in
Sri Lanka Year 2018 another mill
With Italian & Sweden
technology- 12m billet
feeding capacity / high
Speed production rate

Year 2012 new mill

with production
capacity 15,000 t per
month QST bars with
new technology
Year 2002 one Rolling mill
Commenced production
with Capacity 7000 t per
month. TOR steel bars
Our achievements………

Market share -
construction ~ 55 % &
Overall ~ 40 % - year 2017
With total capacity 22,000 t per month

Melwa
Others

No.1 in
Sri Lanka
 Our achievements contd……..

SLS 375 & SLS 26 certificates

 Our achievements contd……..

ISO 9001 QMS & ISO 14001 EMS certificates

  Massive expansion
possibilities as a factory located
– in 64 acre land
Only company
using 6m steel
billets without
cutting directly
into the reheating
furnace Imported virgin Steel billets in the Billet yard

Reheating furnace – 6 m billets

lengths can be accommodated
Prime quality steel billets
from selected countries
where Iron ore is used with
addition of lime and coke
with Blast Furnace use in
integrated mills.

In Sri Lanka Induction furnace

is used to melt steel with 100
% scrap use.
If scrap is melted in electric arc furnace refining
of quality of molten metal is much better.
Induction furnace is a close one with acidic
refractory lining. Hence removing of impurities
such as Sulphur, Phosphorous and non metallic
inclusions cannot be done here without
secondary metallurgy treatment process such as
ladle furnace or vacuum degassing.
Control Room Discharging Billets from Furnace

Hot Rolling of Steel Billets

Quenching and Self Tempering system
also known as thermo mechanical
treatment …..

There is a quenching box where Hot bar

after rolling is subjected to rapid Cooling
by a series of cooling elements Located
with in.
COLD TWISTING PROCESS jdfka oÕr lsÍfï ls%hdj,sh
QST &
RB500
QST EQUIPMENT Quenching box for QST manufacture

With in the box, bar surface is

rapidly cooled with core of
the bar remaining hot. Once
the bar exit out of quenching
box, heat from the core will
reach the outer surface to
give a tempering effect.

SPECIFICATIONS:
* Range : Dia 8mm to Dia 40mm
* Lines : 3 nos
* Length : 10 meters
* Water flow : 220 cubic meters / hour
FLYING SHEAR FOR BAR DIVIDING APLICATION
Flying shear designed for dividing the finished
QST bars to the desired length for further
handling at cooling bed.
 Emboss logo etc.. At
the final roll set

Quenching box
B
l
 Automatic cooling bed
QST Reinforcement bars

Wire rod section

AUTOMATED BAR COOLING BED Specifications:

Type: Fully automated, Rake type
Length : up to 75 meters
Bar speed : up to 40 meters per second
 Prior to start of wire rod production at
Melwire, 100 % import of Wire rods.
Therefore savings of foreign exchange
spending on the import of wire rods to the
country.
SLS 26 Sri Lanka Standard for Plain steel bars for Reinforcement
Chemical Composition : Sulphur - 0.05 % Max &
Phosporous – 0.05 % Max

Mechanical properties :

Yield strength : 300 Mpa,

Tensile Strength :
Elongation : 16% Min.

Nominal mass kg/m 0.222 + 8%

Cold shear machine for QST bars

 Diameter changes easily

without delay; so unforeseen
market demands can be
catered as required by our
valuable customers

 Length adjustable to suit

customer requirements to
reduce wastage (eg. 3m, 5m,
12m etc..
 Loading section

Loading to Lorries using overhead cranes

 Transportation
40 nos Fleet of lorries (for 6m, 12m or other special lengths)
Two 10 tons overhead cranes for faster loading saving time
 Hence no delay in deliveries islandwide.
 Two Weigh bridges (50 t and 80 t)

Fleet of Lorries of MELWA

Testing facilities @ MELWA
Chemical Testing – Spectrometer
 2017/03/20

Carbon Equivalent Value = C + Mn + Cr + Mo + V + Ni + Cu

6 5 15
Mechanical Testing – 1000 KN capacity
2 machines (Not with any other steel manufacturer in SL)
Tensile testing m/c with computer facility
New tensile testing mc

with hydraulic grips -

more advanced

technology
New Tensile
testing
Machine with
2000KN
capacity

for testing
QST bars upto
50 mm
Insert prima test report
Tensile test
summary report
32 mm tensile graph

25 mm tensile graph
Gauge length marks 5.65√A or 5D

Agt is the Elongation at Maximum force

Manual or extensometer method.

SLS 978 standard gives the test method

Power Bending
Machines 2 nos
-upto 25 mm &
Above 25 mm
•Identify MELWA reinforcement bar.

•Rib cutting & Rib Geometry parameters

•Properties and selection of steel products

•Our projects

•By Engineer Mr. Pradeep Jayasinghe

 Identify MELWA reinforcement bar
Eg: MELWA QST - RB500 25 mm

/ / M E L W A 25 / / / / / / / / / RB500 / /
 Final Roll
After CNC & spark erosion roll cutting with MELWA logo
and other details for embossing in the QST bars.

/ / Melwa 32 / / / /RB 500 / /

 Machining Facilities
CNC Lath Machining and Spark Erosion Machining to
obtain perfect Rib Geometries
 Testing of physical parameters

Mass per
Rib Geometry
meter(kg/m)

Strength Elongation Height of Height of Longitudinal Transvers Rib

Product Rib Spacing (mm)
(min) (Min) Transverse Rib Rib (mm) Inclination
Min Max
Min Max
Min ( 0.05D) Min (0.5D) Max (0.7D) (35° -90°)
(0.05D) (0.10D)
0.395
8 mm QST 500 MPa 14 % 0.40 0.40 0.80 4 5.6
0.371 0.419
0.616
10 mm QST 500 MPa 14 % 0.50 0.50 1.00 5 7.0
0.588 0.644
0.888
12 mm QST 500 MPa 14 % 0.60 0.60 1.20 6 8.4
0.848 0.928
1.580
16 mm QST 500 MPa 14 % 0.80 0.80 1.60 8 11.2
1.508 1.651
65°
2.470
20 mm QST 500 MPa 14 % 1.00 1.00 2.00 10 14.0
2.359 2.581
3.850
25 mm QST 500 MPa 14 % 1.25 1.25 2.50 13 17.5
3.678 4.023
6.310
32 mm QST 500 MPa 14 % 1.60 1.60 3.20 16 22.4
6.026 6.594
9.860
40 mm QST 500 MPa 14 % 2.00 2.00 4.00 20 28.4
9.420 10.30

Ref: SLS 375 : 2009 [Conforms to BS4449 : 2009 and SS560 : 2010]

Note: 65 degree is the factory standard for rib angle (conforming to BS standard)
Rib Geometry Properties :
Uniform rib height is better than
crescent shape as it has more grip in
bonding with concrete - rib height is more
and not reducing near the longitudinal
rib as crescent shape

As per construction requirements for

piling and slab adjustable elongation
and bendability
 Rebar Joining
[Lap Joint]
 Lap joint for Colum
 Lap Joint (Continue..)

 Lap joint for Beam

The guideline for Lap Length

Grade of Concrete
Grade of Rebar
M20 M25 M30 M35
Fe500 57 x d 50 x d 45 x d 40 x d
Fe600 68 x d 60 x d 55 x d 48 x d

(Lap length required in tension as per Cl. 26.2.1 of BIS456-2000)

 Mass Per Meter
Tolerances on mass per meter length:
Up to and including 10 mm + or – 4.5 %, for 8 mm dia. + or - 6.0 %

Calculation of mass per meter length :

Measure length in meters and weight in kg.
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑎𝑟 (𝑘𝑔)
𝑀𝑎𝑠𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟 (𝑘𝑔ൗ𝑚) =
𝐿𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑏𝑎𝑟 (𝑚)
Cross sectional area (A):

𝑀𝑎𝑠𝑠 𝑝𝑒𝑟 𝑚𝑒𝑡𝑒𝑟

𝐶𝑟𝑜𝑠𝑠 𝑆𝑒𝑐𝑡𝑖𝑜𝑛 𝐴𝑟𝑒𝑎 =
𝐷𝑒𝑛𝑠𝑖𝑡𝑦
𝑀
𝐴=
0.00785 𝐿
Where A is cross section area in mm2, M is mass of the sample in
kg and L is the length of the sample in m.
BS 8666:2005 - Scheduling, dimensioning, bending and cutting of
steel reinforcement for concrete - Specification

Size of the Steel Diameter of the

Remark Bending Speed
bar (mm) mandrel (mm)

10 40
4xD
12 48
4 5 radians per
16 64
minute or 2860
20 140
7xD per minute
25 175
7
32 224
Mechanical Properties :

Spec. SLS 375:2009 BS 4449 :2005 MELWA

Grade
CTD TMT B500A B500B B500C 500
QST
YS
(MPa) 460 500 500 500 500 500 Min
Min
UTS/YS >1.15, 1.15
ratio - Min 1.05 1.05 1.05 1.08
<1.35 Min
% El 14 14
(at fracture) (12 % SLS
375 : 2004) 14 Min
(Agt) 2.5 5.0 7.5
(at max. force)
 Chemical Composition ( maximum % by mass )

Carborn
C S P N Cu
Equivalent

Cast Analysis 0.220 0.050 0.050 0.012 0.800 0.500

Product Analysis 0.240 0.055 0.055 0.014 0.850 0.520

Ref: SLS 375 : 2009 [Conforms to BS4449 : 2009 and SS560 : 2010]

Virgin steel billets with strictly controlled chemical composition

Rib pattern B500A

Rib pattern B500B

(MELWA QST RB500)

Rib pattern B500C

 ITI
chemical

T
E
S
T

R
E
P
O
R
T

Outside independent Laboratory testing done

every month at ITI, NBRO, University of
Moratuwa etc….
 ITI
chemical

T
E
S
T

R
E
P
O
R
T
 ITI
mechanical

Test

R
E
P
O
R
T
NBRO

T
E
S
T

R
E
P
O
R
T
 NBRO
mechanical
T
E
S
T

R
E
P
O
R
T
 Tempered
martensite
ring of
MELWA
QST
Reinforcem
ent bars
 METALLURGICAL EXAMINE OF MELWA STEEL BARS
Project Members:- S.D.M. Samarasingha, P.K.A. Umayanga / Adviser:- Thilina Mathotarachchi

INTRODUCTION
Metallographic etching is a technique used to highlight
features of metals at microscopic levels.
These features include, but are not limited to, grain
boundaries, phase differences and inclusions. By studying the
character, quantity and distribution of these different features,
metallurgists are capable of predicting and explaining
physical properties and performance failures of a given
sample of metal.

PURPOSE OF ETCHANT
Chemical etchants can be designed to do most anything
to a metal surface. PROCEDURE
Some common practical uses of etchants are to: Procedure of nital etching
Sample preparation
Expose grain boundaries. The boundaries of metallic grains can corrode
very quickly when the appropriate etchant is used, highlighting the edges
of the grains and making it possible to determine their size and shape. Get etchant into the beaker.
• Cut the sample using hand-held hacksaws or band saws with
cooling agent.
Highlight metallic phases. Different phases will have different shading and Sectioning
texture after etching, allowing for phase fraction estimation and
identification of undesirable phases.

Identify inclusions. Nonmetallic inclusions often have characteristic shapes • Small and oddly shaped specimens are mounted to facilitate
easy handling during preparation and examination.
and coloration after appropriate etching, which allows for quick size Mounting
measurement and number density estimation. Then open the tap and allow water to
run, turn on the fan, air and light.
• After, cutting surface is prepared suitably for metallographic
examination as optically flat, reflective, smooth and scratch
Grinding free

After that pour several ml of etchant

CHEMISTRY BEHIND NITAL Polishing
• Polishing process should be done by using finer abrasive and
an appropriate liquid.(Diamond)
into a petri dish and dip the polished
surface of sample into etchant. Then

ETCHING
keep few second until just begin to see
a haze appear on the polished surface.

Differences in the rate of attack reveal the structure. In two phase

alloys, the potential of one phase is higher than that of the other Solution Preparation Of Nital etching
phase. During the etching, the more electropositive anodic Immediately wash the sample under
phase is attacked while the electronegative cathodic phase is running water
much less attacked
Nital will not attack austenite as it does ferrite and martensite.
Nital will not attack carbides but will enhance the interface Nital etchant can be prepared by mixing 2 ml of HNO3 which has density 1.4 g/ml
between the carbide and matrix. and 98 ml of ethanol which has density 0.79 g/ml.
The face, sides and back of the sample
must be completely dry before
observing naked eye.
 MELWIRE ROLLING (PVT) LTD

Traceability Plan

Date : …………………..… Profile : ……………… mm

Consignment No Date of Production No. of pieces Remarks

Batch No : ……………….

Notes : 1. If there are two or more profiles pl. state separately.

2. Batch No : Date of production, profile in mm & Mill No.

eg: 21/03/11/10/02( Date of prod. 2011-03-21, profile 10 mm & Production at Mill No.02 )

Issue No : 02 Issue Date: 2012-07-27 QAP 2.3 / QP 04

Master formats with original signatures are with the MR

 MELWA clients & their projects

Colombo Lotus Tower

with a height of 350 metre, used for
communication and observation, with
construction costing $104.3 million
Piling work by Nawaloka
completed and Construction
using MELWA is continued
INDOCEAN Apartment mixed development project
– 68 storied building near Beire Lake. Construction
work is going on now.
PRIMA Ceylon –
Silo project @
Trincomalee
Total requirement
15,000 t. Construction
work by Nawaloka is
being done at present.
John Keels Holdings
Water Front
Development project
 650 million USD 900 room hotel,
Apartment and office
Complexes @ Slave Island
Military Teaching hospital at Werahera – The Poly Technologies
Inc. of China will carry out the construction work of this 202 million US dollar
project, which is expected to be completed in two years. This teaching
hospital, which extends in 56 acre land in Werahera, has been designed by
Design Group 5 along Singaporean architects
Imperial Builders –
 47 storey building at Slave Island
Shopping boulevard and 200 apartment
complex

10 storey CGR building

Consultancy by SEC
COLOMBO KATUNAYAKE HIGHWAY
 Colombo –
Katunayaka
Highway

COLOMBO KATUNAYAKE HIGHWAY

 47 storey building at Slave Island
Shopping boulevard and 200
apartment complex –

Destiny towers

10 storey CGR building

Consultancy by SEC

Construction by Imperial
Builders
G+44 Twin Destiny towers
tower 200
apartment
complex and
shopping
mall by
Imperial
Builders
Shangri La 7 Star Hotel at Colombo
& 5 Star Hotel at Hambanthota
Ruhunupura Water supply project of
Water Board by Kolon Eng.
Low income Housing project
by UDA
Astoria building project by AVIC
KRRISH SQUARE,
COLOMBO

3 sky scrapers under

construction in Colombo;
80 storey mixed use tower
73 storey residential tower
60 storey commercial tower
4.3 Acres land by UDA
 Overseas projects :

for the building construction in

the Middleeast,
Seychells & Maldives

by

By Sanken Lanka Overseas

 Overseas projects :
For the building construction in the
Middleeast, Seychells & Maldives by
San Ken Lanka Overseas, CML MTD, etc.
How to Select High Quality Products in
the Market.
Factory standards and Trade name
Eg: “MELWA”
 National Standards
Eg: Sri Lanka Standards - SLS
International Standards
Eg: ISO9001 Quality Management System
ISO 14001 Env. Management System
Address : No. 122, Mahavidhyalaya Mawatha, Colombo 13, Sri Lanka
Tel : +94 112 473 905 E-mail : marketing@melwie.com
Fax : +94 112 399 805 Web : www.melwire.com