The power of ADVANCED TECHNOLOGY

“JETMEX ” Technique is UNIQUE Quenching Process, Using Very Fast Cooling Rate & Uniform Cooling.

TMT REBARS QUALITY STANDARD

ASTM-Gr.300 (40), Gr.400 (60) and Gr.500 (75), ISI: - Fe – 415, 415D,500 ,500D,

550, 550D & 600 INTERNATIONAL QUALITY. INDIA’S FIRST

ECONOMICAL TMT TECHNOLOGY PROVIDER WITH

(HSQ) Technology.Quenching steel is not a simple process, but it proceeds in Three-stages with (HSQ) technology.

Unique, reliable, low-maintenance designs offering a wide range of cooling optionsTop: New design cooling nozzles and nozzle extensions.

Right: The new cooling nozzles and nozzle extensions installed as replacements for previous design nozzles.

Bottom: Example of mill temperature profile with multiple water cooling system for product quality control.

FULLY COMPUTERISED AUTOMATION CONTROL

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JETMEX Technologies JET MEX

INTRODUCTION

ABOUT THE COMPANY :- JETMEX TECHNOLOGIES are one of the leading state of the art technology providers of services for the installation, Commissioning & stabilization of the TMT plant for the production of cost effective, high strength TMT bars in India at a very economical rate. We strongly believe in Quality & consistency. We aspire to build, not just the quenching box, but also strong bonds with our customers by giving proper feedback as well as visiting their sites to solve the problems as & when needed by them. Our company is promoted by a group of qualified engineers & techno crafts, promises to deliver, and meet the standards & expectation of our customers. Customer satisfaction is our goal & moto.The technology being used for the production of TMT bars is based on Quenching & tampering, which guarantees the properties required by IS 1786/08 Fe-415,415D,500,500D,550,550D,600& INTERNATIONAL standards.

Basic Objectives of developing TMT Technologies:

It must be clearly comprehended that TMT Technology were developed in the mid-eighties to produce rebar’s that had far superior properties than that available in CTD bars. They essentially aimed at meeting the then global demand for low cost rebar’s that had high yield strength of about 450 to 500 N/mm2 (to effect saving in steel used) combined with good ductility so that adequate safety was feasible when used in high seismic zones. The quenched and tempered rebars, as produced by JETMEX technology Systems, genuinely gave civil engineers a product that was by far superior to CTD rebars.

TMT bars are being successfully used in most parts of the developed world. The Tmt Process imparts high strength to the bar using the latest technique of thermo mechanical treatment (TMT) as against cold twisting, which is used to manufacture traditional reinforcing bars.

What is "quenching” using the “jetmex” tmt process? "Quenching" can be defined as cooling, usually with pure water quench ant, at a rate several times higher than the rate of "normal" or conventional quenching. In contrast to conventional heat-treating

practices, “JETMEX” quenching calls for very high cooling rates for parts within the Marten site phase. Our research shows that very fast and very uniform part cooling actually reduces the probability of distortion, while improving the surface hardness and durability of steel Bars.

Advantages and Features of the Jetmex Water Cooling System.# The design provides cooling capacity for High Yield Quenched & Self Tempered ribbedreinforcing products as well as plain rounds and eliminates the need for different types of nozzlesfor different products.

# Replaceable wear parts within the cooling nozzle and extension.

# Common bore through the entire nozzle and nozzle extension provides excellent guiding of the stockalong the pass line.

# Reduction in water usage increases the life of pumps, valves and other critical components whilereducing water consumption costs.

# Less water in contact with the product reduces the tendency for cobbles, particularly in the case ofribbed products, enabling higher rolling speeds.

# Increased cooling efficiency provides more cooling capacity to existing cooling lines.

# Retrofit table replacement for previous generation split nozzle design water cooling system.

# Optional lift-out headers and traversable water cooling designs for minimizing change times.

JETMEX TechnologiesJET MEX

(HSQ) Technology. Modern technology Now in INDIA for HSDS bar manufacturing in grade Fe – 415,415D, Fe–500 ,500D, Fe-550,550D and Fe 600 according to BIS – 1786/08 standard in a bar rolling mills in INDIA. Developed by JETMEX, HSQ (High Speed Quenching) technology is method of controlled cooling. HSQ increases the strength specification of low-carbon steel by inserting a special three-phase controlled system of bar cooling into a rolling line.

“ JET MEX ” processes : - Steel billets are heated in a reheating furnace and rolled through a sequence of rolling stands, which progressively reduce the billet to the final size and shape of the reinforcing bar. The Jetmex Process takes over and the bar is subjected to heat treatment in three successive stages. I) The First stage of ‘Quenching’ begins when the hot rolled bar leaves the final mill stand and is rapidly quenched by a special water spray system. This converts the surface layer of the bar to a hardened structure called ‘Marten site’ while the core remains austenitic. II) The Second stage of ‘Self Tempering’ begins when the bar leaves the quenching box with a temperature gradient through its cross section, the temperature of the core being higher than that of the surface. This allows heat to flow from the core to the surface, resulting in tempering of the surface, resulting in tempering of the surface, giving a structure called ‘Tempered Marten site’ which is strong and tough. The core is still austenitic at this stage.III) The Third stage of ‘Atmospheric cooling’ takes place on the cooling bed, where the austenitic core is transformed to a ductile ferritepearlite core. Thus, the final structure consists of a combination of strong outer layer of tempered marten site and a ductile core of ferrite-pearliest. Among the key parameters of the process only three of them can be considered as independent control variables, namely: Finishing Rolling Temperature – Quenching Time – Water Flow Rate.The technological characteristics of the final product, particularly the tensile properties, exclusively depend on three factors : Volume fraction of marten site annular area – Tensile properties of marten site – Tensile properties of the core which are very strictly related to Quenching Parameters and Tempering Temperature.

JETMEX TechnologiesJET MEX

JETMEX’ THERMO MECHANICAL TREATMENT PROCESS:“JETMEX” processes : Steel billets are heated in a reheating furnace and rolled through a sequence of rolling stands, which progressively reduce the billet to the final size and shape of the reinforcing bar. The JETMEX Process takes over and the bar is subjected to heat treatment in three successive stages. The first stage of ‘Quenching’ begins when the hot rolled bar leaves the final mill stand and is rapidly quenched by a special water spray system. This converts the surface layer of the bar to a hardened structure called ‘Marten site’ while the core remains austenitic. The second state of ‘Self Tempering’ begins when the bar leaves the quenching box with a temperature gradient through its cross section, the temperature of the core being higher than that of the surface.This allows heat to flow from the core to the surface, resulting in tempering of the surface, resulting in tempering of the surface, giving a structure called ‘Tempered Marten- site’ which is strong and tough. The core is still austenitic at this stage.

The third stage of ‘Atmospheric cooling’ takes place on the cooling bed, where the austenitic core is transformed to a ductile ferritepearlite core. Thus, the final structure consists of a combination of strong outer layer of tempered marten site and a ductile core of ferrite-pearlite.

Quenching & Self-tempering Temperature ProfileADDITIONAL FEATURES:

I) AFFORDABLE FOR SMALLER MILLS: -

Mills producing as low as 700 to 1000 T/month (usually single drive) the technology has been mode more affordable. For range of size where shearing is not required before Cooling bed, Project cost gets further reduced.

II) WIDE RANGE OF COOLING CONFIGURATION: - Cooling configurations is now being designed individually as per mill specifications thus making it economical for smaller rolling mills. III) SS CONSTRUCTION FOR EASY MAINTENANCE: - Main part and all Hardware are made of high grade Stainless Steel that assures effortless maintenance for years of to come.IV) ADDITIONAL FEATURES: - The “JETMEX” Process offers additional features of Training of the Operating staff in production of TMT bar .A detailed operation and maintenance manual for the complete process is provided. Sample data sheets for recording is also providing so that the process can be monitored and reviewed.

JETMEX TechnologiesJET MEX

MECHANICAL CHARACTERISTICS OF TMT RE-BARS: Higher strength & elongation values as compared to CTD Bars. Carbon constituent is reduced below 0.20%, which allows excellent weld-ability. Favorable for construction of foundation or structure at the sites where dynamic & seismic loading

is expected; because of higher ductility & fatigue strength. Heat bearing capacity increases high as there is no loss in strength up to 600 deg. C. Easier to work at sites because of High bend ability and ductility.

Fulfills required standards as per IS: 1786/08 and IS: 456/78.

The physical properties of “JETMEX” TMT for Fe-415,415D, 500 ,500D and 550 ,550Dare given below: -

IS – 1786/08Grade (Fe)

YS (min.MPa) UTS (Min.Mpa) Elongation (min.%)

415 450 550 25

500 530 650 20

550 580 710 15

415D 465 565 27

500D 545 665 22

550D 595 730 20

PODUCTION CHARACTERITICS:CHEMISTRY (as per IS: 1786/08)

Grade (Fe) Carbon %Max.

Sulphur %Max.

Phos. %Max.

S+P % Max.

Fe-415 0.30 0.060 0.060 0.11

Fe-500 0.30 0.055 0.055 0.105

Fe-550 0.30 0.055 0.050 0.10

Fe-415D 0.25 0.45 0.45 0.085

Fe-500D 0.25 0.40 0.40 0.075

Fe-550D 0.25 0.40 0.40 0.075

JET MEX

JETMEX Technologies

COST SAVING THROUGH TMT Fe – 500. “JETMEX” TMT BARS, COMPARISION BETWEEN Fe- 500 AND Fe- 415.

Today the trend has started of moving towards TMT 500 steel barsor bars conforming to IS 1786 Fe 500. You can save about 16% ofsteel over Fe415 by proper design which is about Rs. 15000/- per truckload. Please see below for some basic calculations toconvince you of the same.

Typical comparison between Fe 415 and Fe 500(Calculations based on market rates as on 1st August 2005) (Please consult your structural engineer for calculating savings for your design)Based on Ultimate Strength Design Method as per IS 456 Comparison between Fe 415 and Fe 500 in Tension

Minimum guaranteed yield strength (0.2% proof stress) for TMT-415 confirming to IS:1786 Fe - 415 60000 Psi or 4250 Kg/cm2

Minimum guaranteed yield strength (0.2% proof stress) for TMT-500Confirming to IS: 1786 Fe- 500 72500 Psi or 5100 Kg/cm2

Therefore one ton of `TMT-500' is equivalent to 1 x 5100 / 4250 = 1.2 ton of `TMT-415'

One ton of TMT-415 costs Rs. 24500/- + Rs. 3000/- (per ton cost of transportation, cutting, bending, placing and binding at site.) = Rs. 27500/-

One ton of TMT-500 costs Rs. 25500/- + Rs. 3000/- (per ton cost of transportation, cutting, bending, placing and binding at site.) = Rs. 28500/- Equivalent cost of TMT- 415 (viz. 1.2 tone x 27500) = Rs. 33000/- Net saving in tension when one ton of TMT-500 is used in construction instead of Fe 415 = Rs. 33000 - Rs. 28500 = Rs. 4500/- Net saving of cost if TMT-415 is replaced by TMT- 500 = 4500 / 27500 x 100 = 16%

COMPARISON BETWEEN CTD BARS & JET MEX TMT BARS : -

0.2% proof stress) for Fe 500 TMT-415 Confirming to IS: 1786 Fe 415 60000 Psi or 4250 kg/cm2 But maximum value that should be used as per international code is 52500 Psi or 3700 kg/cm2Minimum guaranteed yield strength confirming to IS:1786 Fe 500 72500 Psi or 5100 kg/cm2

t maximum value that should be used as per international code is 60000 Psi or 4200 kg/cm2 Therefore one ton of `Fe 500' is equivalent to 1 x 4200 / 3700 = 1.14 ton of `Fe 415' Equivalent cost of TMT-415 (viz. 1.14 tonne x 27500) to one tonne of TMT-500 = Rs. 31350/- Net saving in compression when one ton of TMT-500 is used in construction of TMT-415 = Rs. 31350 - Rs. 28500 = Rs. 2850/- Net saving if TMT-415 is replaced by TMT-500 = 2850 / 27500 x 100 = 10%

You would have undoubtedly seen the savings by the above calculations. There is no problem of availability of Fe-500-grade steel today. It readily available from a COMPANY NAME.

JET MEX

JETMEX TechnologiesCOST SAVING THROUGH TMT MANUFACTURING.

A) Man Power Expanses: Large number of workers involved in cold twisting and handling process is not required for manufacturing of TMT bars. Here the manufacturing cost significantly reduces up to 10%.

B) Power Expanses: As explained earlier no twisting is required in manufacturing of TMT Bars, so the electrical power consumed by large number of electrical twisting motors is reduced, which results in saving in manufacturing cost up to 5%.

C) Maintenance Expanses: In Cold Twisting Process large number of tear & wear equipments are used as compared to TMT bar manufacturing process. The maintenance cost is negligible in TMT manufacturing process. This further reduces the manufacturing cost up to 3%.

D) Steel Saving: In cold twisting process rolled steel is wasted in form of scales, this wastage is quite high for smaller section of bars, as in TMT manufacturing process wastage in form of scales is totally avoided. This results in saving of steel which reduces the cost up to 2%.

Comparison between various processes of Bar manufacturing:

Below graph is representation of cost differences between commonly implemented processes of bar manufacturing:1. Cold Twisting. 2. Micro Alloying. 3. JETMEX Quenching process for TMT Bars.

ECONOMICS OF PRODUCTION PROCESS:

PROCESS TREATMENT PRODUCTION COST

DUTILITY WELD- ABILITY

A Cold twistingHardeningMethod:Twisting

HIGH (due to Twisting equipm-ent & manpower

POOR GOOD

B Micro alloyingAdd. Micro-Alloys like: Mn,Cr, Ni.

HIGH (due to Alloying process,& Materials.

GOODPOOR (due toHigh carbonEquivalent).

C MarquenchingProcess

Intense & contro--lled cooling. LOW EXCELLENT

EXCELLENT(Due to low car--bon equivalent)

JETMEX TechnologiesJET MEX

SOLUTION TO EARTHQUAKE RESISTANCE - TMT BARS.

The need for earthquake-resistance house has become all the more urgent.Building should be made in such a way that they do not collapse easily.The building should have a good foundation. As for the type of earth, it is advisable to avoid soft, wet soils. To construct building in earthquake areas one has to think about the stability of the ground.

According to the institute for steel development & growth (INSDAG), Steel is the safest and most effective alternative for building earthquake-resistance house.Internationally, in most high-rise building made of concrete, the reinforcing material is usually steel, but the quality of steel is very important.Previously, steel bars were used as reinforcing material. Following that came cold twisted ribbed bars. Thought in extensive use these bars at present, continue to have inherent problem of inferior ductility, weld ability and increased rate of corrosion due to presence of residual stresses and higher carbon content. The recent discovery has been thermo mechanically Treated (TMT) bars. These bars have the following inherent qualities that make them an ideal solution for earthquake resistance buildings.

High Ductility and high elongation. High fatigue resistance to dynamic / seismic loading. High UTS /Proof stress ratio.

JETMEX Technologies JET MEX

ADVANTAGES OF USING TMT BARS.The advantages of TMT bars over conventional CTD bars are many and include:

Savings in Steel. Reduction in Costs. Reduced Transportation Costs. Better Safety of structures because of higher Strength combined with higher Ductility. Easy working at site owing to better Ductility and Bend-ability. Pre-welded meshes can be

made. To eliminate manual binding at site. Reduces construction and fabrication time. Good Weld-ability and no loss of strength at weld joints. Resistant to Fire hazards.

SPECIAL FEATURES OF TMT BARS. Higher strengths combined with better elongation values as compared to conventional

CTD bars. Excellent Weld-ability because carbon is restricted to below 0.20%. Resistant to fire hazards as there is no loss of strength up to 500 deg.C. Excellent Ductility and higher Fatigue strength, which makes it suitable for structures and

foundations subject to dynamic and seismic loading. Better, Ductility and Bend-ability makes it easily workable at site. Fulfils Bond requirements as per IS: 456/78 and IS: 1786/85.

APPLICATIONSTMT bars find wide applications in different spheres.

General-purpose concrete re-enforcement structures. Bridges. Flyovers. Dams. High rise buildings. Industrial structures. Concrete roads. Underground structures.

PRODUCTS

Be it high rise buildings, bridges or dams, the high strength TMT bars offer a panacea for all applications. Our process is capable of following product range.

DIAMETER: 8,10,12,16,20,25,28,32,36,40, 45 mm.GRADES: Fe – 415, Fe – 500, Fe – 550. Fe -600High Strength Corrosion Resistant TMT bars for seismic zones & combating marine corrosion in grades of Fe – 415, Fe – 500 Fe – 550 and Fe - 600 Grade can be manufactured through JETMEX technology.

JETMEX TechnologiesJET MEX

FULLY COMPUTERISED AUTOMATION CONTROL MICRO (PLC) PANEL.

@: - COMPUTERIZED MICRO PLC HELPS IN CONTROLING OF TMT PROCESS WITH CONTROL PANEL & DISPLAY OF DIFFERENT PARAMETERS OF WATER FLOW, TEMPERATURE OF BAR, WATER TEMPERATURE, WATER LEVEL & VALVE CONTROLLER.

@: - ALL TMT PROCESS MONITOR AT ONE PLACE.@: - IBM COMPUTER P- IV, 17” COLOR MONITOR, 128 MB RAM, CD DRIVE, KEYBORD.@: - SOFTWARE OF QUENCHING PROCESS ALONG WITH OPERATING DATA CONTROL.@: - ADVANCED SCADA(USA) SCHNEIDRE 128 TAGS (Runtime) WITH DIGITAL CONTROLLER.@: - MICRO PLC PANEL WITH DULY WIRED.

Contact:-

JET MEX

JETMEX TECHNOLOGIESREGD. OFFICE: -

04/B, PANNA MARKET, NEAR PATLIPUTRA THANA , BELOW OF UNION BANK PATLIPUTRA PATNA 800013, (BIHAR) –INDIA . PHONE NO:- +91612-2276893 MOBILE No: 09334833056, 09709645363, 09386741533, Fax No. - +91612– 2279337. Email – jetmex@rediffmail.com

JETMEX Technologies