Melwire Rolling (Pvt) Ltd

100 % Sri Lankan Company

Factory &
office buildings
1.Introduction to steel in construction industry

2.SLS requirement – for Reinforcement steel for

concrete

3.Identification and testing of MELWA QST RB 500

re bars

4.Use of re bars in construction industry

5.MELWA projects
 We are the only co. manufacturing variety of steel products including
structural steel (Flat Iron, MS Rounds, Channel Iron), QST bars & wire rods
in Sri Lanka with a total production capacity of 35, 000 t per month.
 Melwire Products

QST Reinforcement Bars , Structural steel

MS Wire Rods

 Melwire Products contd….

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

Presentation by Eng. Lakshan Fonseka
Our achievements:

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

Market share - construction ~ 55 % &

Overall ~ 40 % - year 2013
With capacity 22,000 t per month

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 contd……..

SLS 375 & SLS 26 certificates

 Our achievements contd……..

ISO 9001 QMS & ISO 14001 EMS certificates

OHSAS 18001
Occupational
Health &
Safety
Management
System
  Massive expansion
possibilities as a factory located
– in 64 acre land
Only company
using 12m steel
billets without
cutting directly into
the reheating
furnace Imported virgin Steel billets in the Billet yard

Reheating furnace – 12 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.
 What is QST ?

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.
 New Rolling Mill
– fully automated

1. Reheating Furnace – 12 m
billets can be
accommodated.

2. Control room
Hot Rolling Process

1. Roughing Mill Comprises of

stands 1-6
2. Intermediate Mill 6 – 12
3. Finishing mill 13 - 18
Slitting line technology to speed up the production

for 8 mm, 10 mm and 12 mm profiles (4 lines, 3

lines and 2 lines respectively)

Divide shear is used for chopping the Length
of the billet to the length of cooling bed.
 Quenching box for QST manufacture

QST EQUIPMENT

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.
Cooling Bed
 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..
Counting and bundling – Automatic process
The automatic Bundling system consists of the Vertical Chain
Transfer and a strapping machine.
 Loading section

Loading to Lorries using overhead cranes

 Emboss logo etc.. At
the final roll set

Quenching box
B
l
 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 : 330 MPa
Elongation : 16% Min.
Nominal mass kg/m 0.222 + 8%
 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
 2019/03/20

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
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 Snr 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
 Rib Geometry
lïì kdrá PHdñ;sh
Vernier caliper
jksh le,smrh
 Rib Geometry - lïì kdrá PHdñ;sh
Mass per Rib Geometry
meter(kg/m)

Height of Height of Longitudinal Transvers Rib

Product Rib Spacing (mm)
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 0.40 0.40 0.80 4 5.6
0.371 0.419
0.616
10 mm QST 0.50 0.50 1.00 5 7.0
0.588 0.644
0.888
12 mm QST 0.60 0.60 1.20 6 8.4
0.848 0.928
1.580
16 mm QST 0.80 0.80 1.60 8 11.2 65°
1.508 1.651
2.470
20 mm QST 1.00 1.00 2.00 10 14.0
2.359 2.581
3.850
25 mm QST 1.25 1.25 2.50 13 17.5
3.678 4.023
6.310
32 mm QST 1.60 1.60 3.20 16 22.4
6.026 6.594
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
Rib pattern B500A

Rib pattern B500B

Rib pattern B500C

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

(Agt)
375 : 2004) 14 Min
(at max. force)
2.5 5.0 7.5
 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.

Cross sectional area (A):

Where A is cross section area in mm2, M is mass of the sample in

kgand L is the length of the sample in m.
 Quality Assurance at MELWA
fu,ajd wdh;kfha ;;a;aj wdrlaIKh
 The very best virgin billets are imported from
Premium Billet Manufacture.
wdkhkh lrk b;d fyd| ;;a;ajfha wuq øjH

 Sampling, inspection and testing from Raw

materials stage to semi –finished and finished
products
ksheos mrSlaIdj wuq øjH wjia:dfõ isg
w¾Oksñ iy wjidk ksIamdok olajd
 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

 Testing parameters : ^mrSlaId lrk foaj,a&
Raw Material (Billets) Test: ^wuq øjH ^ì,Ü&
mrSlaIdj&
 Chemical composition,
ridhksl ixhq;sh
 Dimensional checking,
ññ mrSlaIdj
 Inspection for defects.
wfkla wvqmdvq fyda mˆÿ wdosh mrSlaIdj

Semi-finished products : ^w¾O ksñ ksIamdok&

 Dimensional checking
ññ mrSlaIdj
 Rib Geometry and Mass per meter run
lïì kdrá PHdñ;sh iyd ógrhl nr ^lsf,da .%Eï j,ska&
 Finished products :
wjika ksIamdok(

 Dimensional checking,
ññ mrSlaIdj
 Mass per meter run & Pitch
ógrhl nr lsf,da .%Eïj,ska iy msÉ
 Mechanical Testing
(Tensile & Bend / Rebend)
hdka;%sl mrSlaId
^fgkaihs,a iy keùfï mrSlaIdj&
 Rebar Storage at Site
fldkal%SÜ jer .ekakqï jevìfï .nvd lsrSu

w.,A 6 (15 cm)

 Rebar Cutting Machine
l=vd jev ìïj, lïì lemSfï hka;%
a) Metal Cutting Saw b) Bolt Cutter

d) Grinder Wheel
c) Steel Cutting Chop Saw
 Rebar Bending
l=vd jev ìïj, lïì keóu
ksjeros l%uhg
Benches used kjdconstruction
in small we;s sites
l=vd jev ìïj, keófï l%u
jdfka lïì

l=vd keùfï wrh yd wEka.,aj, ;shqKq

fl<jr ksid keófïoS ydks isoqfõ

(b)
 Bending Using Two GI pipe
cS whs mhsmam lE,s folla fhdod jdfka
l+re keùu
 Simple Bending Device
keófï mÍlaIdj i|yd ir< WmlrKhla
 Simple Bending Device
keófï mÍlaIdj i|yd ir< WmlrKhla
 Mandrel
(Cylindrical steel bar or rengthen GI pipe)
Yla;su;a lrk ,o cS whs
mhsmamhla

Tor steel bar

keùug wjYH jdfka l+r
 Power Bending Machine
úoq,s n,fhka l%shd lrk keófï hka;%
 BS 8666:2005 fldkal%SÜ jer .ekakqï i|yd ie<iqï
lsrSu" ñkqï" keùï iy lemSï wdosh ms<sn|j î
%;dkH m%ñ;shg wkqj keùu i|yd Ndú;d l< hq;=
wju ueKav%,a úIalïNh
Size of the Steel Diameter of the
bar (mm) mandrel
ueKav%,a Remark ie<lsh hq;=hs
jdfka l+rej, úIalïNh
úIalïNh (mm) ñó wju

10 40 4xD
lïìfha úIalïNh fuka
12 48 4xD 4
y;r .=Khla
16 64 4xD

20 140 7xD
lïìfha úIalïNh fuka
25 175 7xD 7
y;a .=Khla
32 224 7xD
 Every month all profiles are tested at two independent
laboratories
wNHka;r mrSlaIdj,g wu;rj cd;sl f.dvke.s,s
m¾fhaIK wdh;kh fudrgqj úYaj úoHd,h jeks
ms<s.;a wdh;k j,ska (NBRO, ITI, UOM) iEu
uilu mrSlaId lrkq ,nkjd

 Y%S ,xld m%ñ;s wdh;kh (SLSI)

SLS tiat,atia iy;slh & SLS ISO 9001 : 2008 ;;a;aj moaO;s
iy;slh ksid jrska jr wdh;khg meñK idïm, mrSlaId
lrkq ,nkjd
 TYING REINFORCING STEEL
A. SNAP TIE or SIMPLE TIE.
The wire is simply wrapped once around the two crossing
bars in a diagonal manner with the two ends on top. These
are twisted together with a pair of side cutters until they are
very tight against the bars. Then the loose ends of the wire
are cut off.
Application : Used on floor slabs.

B. WALL TIE.
This tie is made by going about 1 1/2 times around the
vertical bar, then diagonally around the intersection,
twisting the two ends together until the connection is tight,
but without breaking the tie wire, then cutting off the
excess.
Application : Used on light vertical mats of steel.

C. DOUBLE-STRAND SINGLE TIE.

This tie is a variation of the simple tie.
Application : It is especially favored for heavy work.
 TYING REINFORCING STEEL
D. SADDLE TIE.
The wires pass halfway around one of the ban on either side
of the crossing bar and are brought squarely or diagonally
around the crossing bar with the ends twisted together and
cut off.
Application : Used on special locations, such as on
walls.

E. SADDLE TIE WITH TWIST.

This tie is a variation of the saddle tie. The tie wire is carried
completely around one of the bars, then squarely across
and halfway around the other, either side of the crossing
bars, and finally brought together and twisted either
squarely or diagonally across.
Application : This is used for heavy mats that are to
be lifted by a crane.
F. CROSS TIE or FIGURE-EIGHT TIE.
This type of tie has the advantage of causing little or no
twist in the bars.
Application : Used in special location
 Rebar Threading Rolling Machine
lïì fmdg lemSfï hka;% ^,shjk mÜg,h&
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
16 64
5 radians per
minute or 2860
20 140 per minute
7xD
25 175
7
32 224
mandrel
NBRO mrSlaId jd¾;djla oÕr jdfka ( 10 – 32 ñó m%udK i|yd)
Mill certificates can be issued on
delivery at the factory.
 Advantages of MELWA QST (TMT) Bars:
MELWA QST jdis
• Higher Strength & Ductility
(Safer & Stronger with lesser quantity of steel. Savings 13 – 19%)

wê Yla;sh yd uDÿ nj
• Better Weldability- mEiaiSfï yelshdj jeä nj
• Better Bendability - keùfï yelshdj jeä nj
• Better Earthquake resistance -
N+ p,kj,g Tfrd;a;= oSfï yelshdj jeänj
 Advantages of QST (or TMT) Bars cont..
QST jdis
• Better fire resistance
.skakg Tfrd;a;= oSfï yelshdj jeänj
• Corrosion resistance better than
Mild steel or CTD bars. (Protective layer)
u<lv lEug Tfrd;a;= oSfï yelshdj
jeänj
• Better ageing properties
os.= l,lg Tfrd;a;= oSfï yelshdj jeänj
 MELWA CLIENTS ( fu,ajd
Land Reclamation and)Development Corporation
mdrsfNda.slhska
 Sri Lanka
Y%S ,xld bvï f.dv lsrSfï iy ixjr®Okh lsrSfï
ixia:dj
Almost all constructions (eg. ADB funded project – Local Govt.
Infrastructure Development project @ Maharagama)
 State Development and Construction Corporation
rdcH ixjr®Ok yd ksr®udK kS;s.; ixia:dj
Moragahakanda Irrigation Project and all other constructions
fudr.ylkao jdrsudr®. jHmD;sh
 Sri Lanka Cement Corporation
,xld isfuka;s ixia:dj
 State Engineering Corporation of Sri Lanka
රරජය ඉඉජනනර සඉසථරව
 Central Engineering Consultancy Bureau (CECB)
මධයම ඉඉජනනර උපනදශන කරරයරඉශය
 Central Engineering Services (Pvt) Ltd (CESL)
මධයම ඉඉජනනර නසවර පදගලක සමරගම
 Sri Lanka Army
ශ්‍රී ලලංකකා හමුදකාව
 Sri Lanka Navy
ශ්‍රී ලලංකකා නකාවික හමුදකාව
 Sri Lanka Air Force
ශ්‍රී ලලංකකා ගුවන් හමුදකාව
Defence Head Quarters Building at Akuregoda, Thalawathugoda
 Gunathilaka Constructions (Pvt.) Ltd.
Sport Complex - Pallekelle

 ICC
Chaaya Bay Hotel at Beruwala
 Bela International - RDA Road Construction
fn,d bkagr®keIk,a - udr®. ixjr®Ok wêldrsh
boslsarSï
 Hitachi Plant - Baddegama Water Treatment Project
ysgdÉ ma,dkaÜ - noafo.u c, jHdmD;sh
 Tudawa Brothers Ltd. - Construction of Flats
;=vdfj n%or®ia - uy,a ksjdi boslsarSï

 Maeda – Nishimatsu Joint Venture

Upper Kothmale project.
by< fld;auf,a ú¥,s n,d.dr
jHdmD;sh
 Nawaloka Constructions - Eppologama
Ranaviru Housing Project
kjf,dal boslsrSï - bfmdf,d.u rKõre
ksjdi jHdmD;sh
 Edward & Christie - RDA – Construction of
Bridges
tâjâ & l%siaà iud.fï - md<ï
boSlsrSï ^ud¾. ixj¾Ok wêldrsh i|
yd&
 Access International (Pvt.) Ltd.
Bridge Construction – Flyovers
welaiia bkag¾keIk,a mqoa.,sl iud.u 

 Department of Irrigation : Deduru Oya Project

jdrsud¾. fomd¾;fïka;=j - oeoqreTh
jHdmD;sh
 Ceylon Electricity Board – Minor projects.
 China Harbour Corporation - Sooriya Wewa Stadium
iQrshjej l%Svdx.kh

 24 storey building at Colpetty by

Premier Pacific Topaz (PVT) Ltd.
uy,a 24 fld,a,qmsàh m%sñh¾
fgdmEi f.dvke.s,a,
Low income Housing project
by UDA
Blue Star project by Access Eng. and China State
Construction Eng.
  Altair – Apartment Building

One tower of Altair was made to lean on the other to

maximize the infiltration
INDOCEAN of the mixed
Apartment sun and the sea and
development take
project.
advantage of
68 Colombo’s wonderfully
storied building near Beiremaritime climate. work
Lake. Construction
Invested byisINDOCEAN DEVELOPERS (PVT) LTD.121A, Sir
going on now.
James Pieris Mawatha ,Colombo 02
 Ruhunupura Water Supply project of Water Board
by Kolon Engineering.
රහණපර ජල සමපරදන වයරපපතය
  Road Development RDA
udr®. ixjr®Ok wêldrsh
 Keangnam Enterprises Ltd (lsfhkakEï tkagr®m
%hsia)
Mahiyanagana/Padiyathalawa Road
(uyshx.k mosh;,dj udr®.h)

 China Harbour Engineering Corporation

phskd ydn¾ bkacsfkare ixia:dj
Trincomalee Infrastructure Integrated project (Muttur/
Batticaloa road, including 5 bridges constructed to
replace the ferry services between Baticaloa &
Trincomalee)
;%sl=Kdu,h - uvl,mqj ud¾.h
^úfYaIfhka md<ï wdosh& 
  E01, E02 & E03 Express Way
අධනවග මරරග
 China Harbour Engineeing Corporation – Greater Colombo
Outer Circular Road

Outer circular road at Kottawa joining southern Express way

 Southern Express way (Kottawa – Matara)

 Southern Express way extension (Matara – Hambanthota)
 Southern Container Terminal Project Sri Lanka Port
දකණ බහරලම පරයනතය
  Hambanthota Mattala International Airport
yïnkaf;dg u;a;, cd;Hka;r .=jka
f;dgqfmd<
By China Harbour Engineering Corporation & Accesss Engineering
phskd ydn¾ bkacsfkare ixia:dj iyd welaiia
bkacskshrska
 Colombo Lotus Tower (with a height of 350m)
නකරළඹ නනළම කලන (උස මටර 350)

Piling work is done by

Nawaloka Piling, using MELWA
steel.
 Overseas projects :
For the building construction in the
Middleeast, Seychells & Maldives by
Sanken Lanka Overseas, CML MTD, etc.

Velaan International Airport project by Beijin

Urban Construction Group, &
Nasadan Apartment project by Zhong Tian
Construction Group - ZTDH
Thank You.
ia;=;shs