Melwire Rolling (Pvt) Ltd

100 % Sri Lankan Company

Melwire Products
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
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
 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
 MELWIRE ROLLING (PVT) LTD

Traceability Plan

Date : …………………..… Profile : ……………… mm

Consignment No No. of pieces Remarks

Date of Production

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

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

Videos on tensile testing and bending

 Compressive forces

Tensile forces

Why steel is used in concrete ?

Compressive strength is O.K.- 

Tensile strength not satisfactory

without steel
 Mechanical Properties of Steel

Property Test
 Yield Strength (YS)
( Characteristic Strength)
 Ultimate Tensile Strength (UTS)
 Ductility (% Elongation)
Tensile Test
( after fracture and Agt)
 Bendability  Bend or Rebend test
 Toughness or Impact properties
(Structural steel, if requested only)  Impact Test

 Hardness test X  Hardness test

 Testing of Steel products
(Mechanical Properties)

 Mechanical properties determine its capacity for

transmitting, sustaining or withstanding

mechanically applied loads, without giving

either controlled deformation or unexpected

fracture.

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Tfrd;a;= oSfï yelshdj jdfkaj, hdka;s%l .=K mÍlaIdj

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Simple Bending Device

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Re bending test :

Bend thr’ an angle of 90 0

(<16 4 D and > 16 7 D)

Age the specimen at 100 0 C for 1 hr

then re bend at least by 20 0 C
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

•Rib cutting & Rib
Geometry parameters

•Properties

•Our projects

•By Engineer Mr. Pradeep

Machining facilities - CNC and Spark Erosion
Machining TO OBTAIN Perfect Rib geometries
 Melwa 32
RB 500

Final set of Rolls

After CNC & spark
erosion roll cutting with
MELWA logo and other
details for embossing in
the QST bars.
 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)
Dimensional 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
Tolerances on mass per meter length:

Upto 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 / length

Cross sectional area (A):

A = M .
0.00785 L

(M is Mass 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 Diameter of Bending /

the mandrel
Steel bar Remark Rebending
(mm) -
(mm) Minimum
rate

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

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Outside independent Laboratory testing done

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

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 ITI
mechanical

Test

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NBRO

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 NBRO
mechanical
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 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.
Our values………

• Safety
• Welfare and Recreation
• Professional Development of
employees
• Melwa culture / Melwa brotherhood
/Melwa family concept
(everyone as a family
“together for a better future”)
 Building our employees’ self esteem

Melwire Rolling Cricket Winning team 2011

Melwire Rolling Cricket Winning team 2012
Year 2014 – MELWA Cricket playing teams
Industrial visit to MELWA by Eng. Undergraduate students
of University of Peradeniya on 2014-05-09
OUR SOCIAL RESPONSIBILITY
Green walk – Year 2013
 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 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
 Overseas projects :

for the building construction in

the Middleeast,
Seychells & Maldives

by

By Sanken Lanka Overseas

China Geo Engineering Corporation
Waste water disposal system for Ratmalana/Moratuwa /& Ja-ela areas
Greater Colombo Urban Transport Development Project

China Metallurgical Group Corporation - (MCC)

Construction of Colombo Katunayake Highway

Keangnam Enterprises Ltd.

Construction of Padeniya Anuradhapura Road and Road Projects

Ministry of Cultural & Arts

Construction of Cultural Centre at Nawimana.

Hunan Construction Engineering Group Corp.

Construction of RDA road projects

Sinohydro Corporation Ltd.

Construction of road and irrigation projects
Other projects using 100%MELWA reinforcement steel,-

China National Aero-Technology Int’l Engineering Corp.Ltd-(CATIC)

Construction of Kandy/Jaffna (A09) Road.
Mattala to Hambanthota flyover
Construction of all RDA road projects

State Development & Construction Corporation

All most all Constructions

China Harbour Engineering Co. Ltd.

Allmost all construction
Trincomalee / Batticaloa Road Construction (Especially Bridges)
Hambantota Port Development Project
Hambantota International Airport Development Project (Mattala Airport
Project)\
MT-Hogaard - Construction of Oluvil Harbour

Hitachi Plant - Baddegama Water Treatment Plant Project

Sathuta Builders Ltd.

Allmost all constructions / Housing project at Dematagoda

Access International (Pvt) Ltd.

Construction of Bridges – Flyovers, Labugama Water project
All the Constructions, ITC Hotel Project - Colombo

IVRCL Lanka Ltd.

Construction of Multy Storey Building Project - (UDA)

Nawaloka Construction Co.

Eppologama Ranaviru Housing Project& other projects
All Road and other projects
Nawaloka hospital extension project
State Engineering Corporation of Sri Lanka
University of Moratuwa - 8 storied Building, Lunawa Housing Scheme
Project & All other constructions

CML – MTD Construction Ltd. - Construction of Bridges,

A2 Road, Low Cost Housing Project

Sierra Construction (Pvt) Ltd. - David Peiris Hambantota Project& all the
Electricity Board projects, Manna Road, Kandy & Nuwara Eliya Water
Board project

BAM International (Pvt) Ltd - Construction of Fisheries Harbour –

Wattala.

ICC – International Construction Consortiun Ltd- A009 Road from

Dambulla to Thonigala, Construction of Hotel Chaaya Bay – Beruwala&
other constructions, High rise Building at R A De Mel Mawatha
Brandix Complex at Wattala
Construction of IT Campus at Homagama
Bar Dia. Rods / ton

10 mm - 270 Bars / t

9.5 mm - 294 Bars / t

9.0 mm - 328 Bars / t

How to select High quality products
in the market

 Factory standards and / or

Trade name “MELWA”
 Sri Lanka Standards - SLS
(National standards)
 Quality Management System Certification –
ISO International standards
 www.melwire.com

Thank You.
32 mm tensile graph

25 mm tensile graph