Reinforcing Steel Production Line | High-Efficiency Rebar Manufacturing Equipment-gyssljx

Equipment introduction

What is a Reinforcing Steel Production Line?

Understand the core concepts and components of a reinforcing steel production line, and how it transforms raw materials into finished rebar products.

Rebar Production Line Configuration

A reinforcing steel production line is an integrated industrial system designed to manufacture steel bars, commonly known as rebar, used for reinforcement in concrete structures. This line typically involves a series of processes including rolling, cutting, bending, and sometimes welding, to produce rebar that meets specific dimensional and strength

Advanced technology and processes

At gyssljx, our production lines are engineered with state-of-the-art technology to ensure high efficiency, precision, and consistency. The system starts with raw steel billets, which are heated and rolled into the desired shape and size.

What is a Reinforcing Steel Production Line?

Customizable

Then, advanced cutting and bending machines tailor the rebar for various construction applications. Our lines are customizable to handle different steel grades, diameters, and production volumes, making them suitable for projects ranging from residential buildings to large infrastructure developments.

Quality Control

With a focus on automation and quality control, gyssljx's production lines minimize human error and maximize output, providing reliable solutions for the global construction industry.

Type Display

Reinforcing Steel Production Line Type

Reinforcing steel production lines primarily fall into two main categories: hot-rolled and cold-rolled. The type of production line used is determined by the final product's desired properties, such as its strength and ductility.

Hot-Rolled Production Lines

This is the most common method for producing reinforcing steel, or rebar. The process involves heating steel billets to a high temperature (over 1000°C) and passing them through a series of rollers. This process reduces the billet's cross-section and forms the distinctive ribs or deformations on the surface.

Cold-Rolled Production Lines

Cold rolling is a process that occurs at room temperature, after the initial hot rolling of the steel wire rod. This process deforms the steel and increases its tensile strength and yield strength.

Mesh Welding Production Line

This line doesn't produce the individual rebar, but rather fabricates reinforcing steel mesh from pre-produced reinforcing bars (either hot-rolled or cold-drawn).

Bending and Fabrication Lines (Secondary Processing)

While not "production" in the raw material sense, these lines are crucial for preparing reinforcing steel for construction. They take standard rebar and cut and bend it to specific shapes required by architectural and structural designs.

Our technology

Core Technologies of Reinforcing Steel Production Line

The core technologies of a modern reinforcing steel production lines are centered on high-speed, automated, and precise processes that transform raw steel into finished products with specific mechanical and physical properties.

1. Reheating Furnace Technology:

Purpose: To heat steel billets (the raw material) to the required rolling temperature (typically 1100-1250°C).

Key Technologies:

Walking Beam Furnaces: Offer excellent temperature uniformity and minimize billet surface defects.

Regenerative Burners: Improve energy efficiency by preheating combustion air with exhaust gases.

Advanced Control Systems: Precisely regulate temperature and fuel consumption, often using AI/ML for optimization.

Low NOx Burners: Reduce nitrogen oxide emissions for environmental compliance.

2. Rolling Mill Technology:

Purpose: To progressively reduce the cross-section of the heated billet and form it into the desired bar shape and size.

Key Technologies:

Continuous Rolling Mills: Feature a series of stands (roughing, intermediate, finishing) arranged in a continuous line for high production rates.

Housingless Stands: Offer greater rigidity, quicker roll changes, and improved dimensional accuracy.

Slit Rolling (Multi-Slit): A highly efficient method where a single billet is slit into multiple strands in the finishing stands, significantly increasing output.

Controlled Rolling: Precisely controls temperature and deformation during rolling to achieve desired mechanical properties (e.g., strength, ductility) in the final product.

Automatic Gauge Control (AGC): Uses sensors and hydraulic systems to maintain consistent bar diameter and shape.

Groove Design: Optimized roll pass designs are crucial for smooth material flow, minimizing defects, and achieving accurate dimensions.

3. Cooling Technology:

Purpose: To cool the hot rolled bars in a controlled manner to achieve the desired metallurgical structure and mechanical properties.

Key Technologies:

Walking Beam Cooling Beds: Allow for natural air cooling of bars, ensuring straightness and uniform cooling.

Quenching and Self-Tempering (QST) / Thermex Process: This is a critical technology for producing high-strength ribbed (rebar) bars. It involves intense water quenching immediately after the finishing mill, followed by self-tempering using the residual heat in the bar's core. This creates a hard, tempered martensitic outer layer and a softer, ductile pearlitic core.

Water Boxes/Sprays: Used for precise and rapid cooling in QST processes.

4. Shearing and Finishing Technology:

Purpose: To cut the long rolled bars into specific lengths, bundle them, and prepare them for dispatch.

Key Technologies:

Flying Shears: Cut the moving bar to pre-set lengths without stopping the rolling process, ensuring continuous operation.

Cold Shears: Used for cutting cooled bars to precise lengths.

Bundling Machines: Automatically collect, count, and strap bars into bundles.

Tying Machines: Secure bundles with wire.

Bar Counters and Weighing Systems: Ensure accurate product quantity and weight.

5. Automation and Control Systems:

Purpose: To integrate and manage all aspects of the production line for optimal performance, quality, and safety.

Key Technologies:

Supervisory Control and Data Acquisition (SCADA) Systems: Monitor and control the entire process from a central location.

Programmable Logic Controllers (PLCs): Automate individual machines and sequences.

Human-Machine Interfaces (HMIs): Provide operators with real-time data and control capabilities.

Sensors and Instrumentation: For continuous measurement of temperature, speed, dimensions, and other critical parameters.

Artificial Intelligence (AI) and Machine Learning (ML): Increasingly used for predictive maintenance, process optimization, quality control, and energy management.

Step: 01

Raw Material Preparation

Scrap Metal Sorting and Pre-treatment: If using scrap, it's sorted to remove impurities and pre-treated (e.g., cut into smaller pieces, baled) to optimize melting.

Iron Ore and Coking Coal: For integrated steel mills, iron ore is reduced in a blast furnace using coking coal to produce molten pig iron.

Step: 02

Melting and Refining

Electric Arc Furnace (EAF): Scrap metal, or a mix of scrap and direct reduced iron (DRI), is melted in an EAF. Electrodes generate an arc that melts the charge.

Basic Oxygen Furnace (BOF): Molten pig iron from a blast furnace is refined in a BOF, where oxygen is blown through the melt to remove impurities like carbon and silicon.

Ladle Metallurgy: After the primary melting, the molten steel is transferred to a ladle for further refining. This step allows for precise control of chemical composition by adding alloys and removing unwanted elements (e.g., desulfurization, deoxidation).

Step: 03

Continuous Casting

Tundish: Molten steel flows from the ladle into a tundish, which acts as a buffer and distributes the steel evenly into the molds.

Molds: The steel then flows into water-cooled copper molds. The outer shell of the steel solidifies as it passes through the mold.

Secondary Cooling: Below the molds, water sprays cool the partially solidified strand further.

Straightening and Cutting: The solidified strand, often in square or rectangular sections (billets or blooms), is then straightened and cut to desired lengths.

Step: 04

Rolling

Reheating Furnace: The billets or blooms are reheated to a high temperature (around 1100-1200°C) to make them malleable for rolling.

Roughing Stands: The hot billets pass through a series of roughing stands, which progressively reduce their cross-section and increase their length.

Intermediate Stands: Further reduction and shaping occur in intermediate rolling stands.

Finishing Stands: In the final finishing stands, the desired rebar diameter and deformation pattern (ribs or indentations) are achieved. These deformations are crucial for improving bond strength with concrete.

Quenching and Self-Tempering (QST) / Thermex Process: This is a common technology for producing high-strength rebar. Immediately after the last rolling stand, the hot rebar is rapidly cooled with water (quenching) to harden the outer surface. The core remains hot, and as heat transfers from the core to the surface, the surface self-tempers, resulting in a desirable microstructure with a tough core and a strong, hard outer layer.

Step: 05

Cooling, Shearing, and Bundling

Cooling Bed: After rolling and the QST process (if applied), the rebar is transported onto a cooling bed, where it cools down uniformly.

Shearing: Once cooled, the rebar is sheared to the final specified lengths.

Bundling and Tagging: The finished rebar is then bundled, weighed, and tagged for identification before being sent to storage or dispatch.

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Why Choose
Shenlong Machinery
for Your Rolling Mill Needs

Partner with Shenlong Machinery for unparalleled expertise, quality, and support in rolling mill solutions. Discover the benefits that set us apart in the industry.

Design and Planning

With 30 years of rich experience in steel rolling metallurgical technology, we can customize the overall solution and planning of steel rolling mill according to customer needs and the design principle of more economical and energy-saving.

Manufacturing and Fabrication

We strictly follow China's national industry standards and quality control system to complete the precision machining of the core components of the rolling mill and the assembly of the entire system, creating rolling mill equipment with stable performance and efficient operation.

Commissioning and Training

We can dispatch a professional technical team to the site to provide installation guidance and optimize the operating parameters through systematic commissioning to ensure that the rolling mill quickly reaches the designed capacity and product accuracy requirements, while also training the customer's own technical team.

Production and Profit

We can recommend professional production teams to help customers quickly achieve stable production, accelerate the return of customer investment funds and enable customers to achieve profits as soon as possible.

Spare parts and Production Line Upgrades

We provide long-term and stable spare parts and technical support. At the same time, according to customers' needs for capacity expansion and product upgrades, we provide rolling mill transformation, increase of multiple types of rolling mill equipment, and production line upgrade solutions to extend equipment life and expand production capacity.

Reinforcing Steel Production Line Solutions by gyssljx