Republic of the Philippines

BATANGAS STATE UNIVERSITY

Alangilan, Batangas City
College of Engineering, Architecture and Fine Arts
Mechanical Engineering Department

TECHNICAL REPORT

IN

INDUSTRIAL PROCESSES WITH PLANT INSPECTION

SUBMITTED BY:

Flores, John Erick P.

Godez, Noreen Joyce B.

Gonda, Raneljohn E.

Robles, Darryl

Sotalbo, Amiel

ME-5101

SUBMITTED TO:

Engr. Mary Joan Leacille Manalo

October 24, 2018

A. Company Profile

SteelAsia in Calaca, Batangas or known as Calaca Works of SteelAsia house an

integrated rebar line or mini-mill. This rebar line is incorporated with its own scrap-based

billet production. It was established by BSII in 1999. It was suspended for a year due to

1997 Asian Financial Crisis and was acquired by the SteelAsia group in 2007. After

recovering and improving the facility, it was and re-commissioned in 2008. This

manufacturing line is called M3.

M3 is unique because it is the only integrated steel works in the Philippines.  M3 has

steelmaking capability. It utilizes different steel scrap purchased locally through melting

and casting into new semi-finished steel called billets. This feature is exceptional

because steelmaking in this process is linked to rolling.

Newly cast red hot billets are charged into the rolling mill facility.  The process,

which is called direct hot charging saves up to 40% on fuel consumption, compared to

simply buying and feeding cold billets into the rebar line.  The mill also features a twin

high-speed tungsten carbide monoblock.  M3 was the first mill to use this technology

and it gave it the ability to produce small rebar sizes with high precision while

maintaining speed and productivity.

SteelAsia Products

SteelAsia is a provider of rebar solutions.

As a manufacturer, it part of the solution to country growth, expanding to meet the

growing needs of the country.  SteelAsia has grown into is the largest manufacturer of

rebar in the Philippines with a total annual production capacity of 2.1 million tpy, and

anticipating a multi-decade growth trajectory for the country, has another 2.5 million

tons of capacity in its expansion pipeline.

Locating across the archipelago near economic and logistic hubs is solution that

makes rebar products accessible, not to mention the significant cost savings from the

elimination of sea freight.  Production sites in five sites (and three upcoming sites) in all

the major island groups is an enabler of country development, and lowers cost for both

the large corporate property developer and the small home builder. 

Investment in technological solutions has enabled SteelAsia to produce the full

specification range of rebar products, creating a one-stop-shop service.  Technology

has also helped the company push the cost of rebar down through its productivity,

efficiencies and scale. Downstream added value technologies such as create handling

and wastage savings. These advances put our industry and its service capabilities at

par with the best in the world.

Rebar is the common name for cylindrical shaped steel bars with uniformly spaced

protrusions called lugs or deformations. They are hot rolled from semi-finished steel

called billets. 
 Rebar are the predominantly consumed steel product of the construction industry

and are used specifically for concrete reinforcement.  Rebar creates tension in concrete

to help hold it in a compressed state.  Reinforced concrete gives infrastructure,

buildings, bridges, houses, and other construction the necessary structural integrity as

required by Philippine law and building codes.

SteelAsia carries the full line of rebar specifications used in the Philippines.

Rebar standards are detailed in the Philippine National Standard for Steel Bars for

Concrete Reinforcement PNS49 and for re-rolled bars PNS 211.

PNS 49 ASTM Mechanical Properties (min)

Type Common Color
Bar Equivalent Yield Tensile TS/YS
Code Nomenclature Code
Grades Grade Strength Strength Ratio
Grade
Grade 33 NC Regular White 230 MPa 390 MPa ---
230
NC Regular Yellow 275 MPa 480 MPa <1.25
Grade
Grade 40 Yellow
275 WC Weldable 275 MPa 480 MPa >1.25
& Red
NC Regular Green 415 MPa 620 MPa <1.25
Grade
Grade 60 Green
415 WC Weldable 415 MPa 550 MPa >1.25
& Red
Grade 75 NC Regular Orange 520 MPa 690 MPa >1.25

PNS ASTM Diameter (mm) Length (m)

49 Bar Equivale 1 1 1 2 2 2 3 3 4 5 7. 10. 1 13.
Grade nt Grade 6 9 15
0 2 6 0 5 8 2 6 0 0 5 5 2 5
Grade Grade
230 33            

Grade Grade               
275 40
              
Grade Grade                 
 60
415                 
Grade
75             

B. Processes and Equipment

Steel Asia Calaca is different from other steel asia companies in the Philippines

because it is the only one having meltshop, thus giving them advantage of saving

money from transportation of cold billets. They are also the one distributing billets to

other steel asia companies in the country.

MELTSHOP

1. Scrap Charge Preparation

Steel Asia Calaca uses scrap metals

purchased locally to be formed into rebars.

Each bucket of scrap metal weighs 65 tons

where metals are arranged with respect to

their density, allowing heavy metals to

settle at the bottom.

2. Scrap Charging
 In this process, metals are charged in a large fireplace where metals are heated

up to 1600°C using electric arc furnace.

3. Melting

Chemicals are added in this process to

increase the melting rate of the scrap or lower

the melting point

4. Refining

This process is done to know the

temperature, initial grade and chemistry or

composition of the mixture

5. Temperature and Chemistry Sampling

6. Tapping
 After knowing the composition, additives are added to correct or acquired the

required composition of the metal.

7. Ladle Furnace Refining

This process is the final sampling and

reheating. Slugs and impurities do not mixed

with the molten metal and are thus easily

removed.

8. Continuous Casting

This is the last process under melt shop.

Molten metals are shaped and cut into billets

and cooled down.

ROLLING MILL

1. First process includes reheating of cold

billets through a reheating furnace. If the

composition of the produced billet satisfies

the requirement of the client, it can be used

already by the rolling mill without going to the

reheating furnace, this is called direct-

charging.

2. These billets are then passed to series of

 rollers to transform rectangular billets into cylindrical rods.

3. Reinforced bars the cooled down and are tested to know the tensile strength,

bending, and diameter.

EQUIPMENTS

1. Electric Arc Furnace

An electric arc furnace is a furnace

that heats charged material by means

of an electric arc. Industrial arc furnace

ranges in size from small units of

approximately 1 ton capacity up to

about 400 ton units used for

secondary steelmaking.

2. Ladle Furnace

This is a small electric arc furnace

with an 8 to 25 megavolt-ampere

transformer, three electrode of arc

heating and the ladle acting as the

furnace shell
3. Continuous Casting Machine

Continous Casting machine is used to

solidify the molten metals into a “semi-

finished” billet, bloom or slab for

subsequent rolling in the finishing mills

4. Reheating Furnace

Reheating furnace in steel making

plants are used in hot rolling mills to

heat the steel stock (billets, blooms or

slas) to temperatures of around 1200°C

which is suitable for plastic deformation

of steel and hence for rolling in the mill.

5. Rolling mill

A machine where metal stock is

passed through one or more pairs of

rollers to reduce the thickness and to

make the thickness uniform.

 6. High speed block mill

Generally used for production of concrete reinforcement grades at high rate, in

straight condition and delivered into cooling bed.

C. Best Practices

1. Balance productivity and safety.

2. All safety equipment are provided by the company.

3. Near miss is better that accident.

4. Putting wedge on the rear and front wheel when stationary.

5. Strict implementation of danger tags. The personnel who put the tag is the only

one authorized to remove the tag.

6. Implementation of 5S: Sort, Set in order, Shine, Standardized, Sustain

D. Safety Rules and Practices

1. Before entering the company, let the security personnel inspect you and your

belongings. You are not allowed to bring the following:

 Obscene or vulgar magazines, pictures or movie

 Alcoholic beverages

 Cigarettes

 Drugs

 Deadly weapon

2. You are not allowed to enter the company drunk or under the influence of drugs

3. Steel asia is a smoke-free facility

4. Wearing shorts, ripped jeans or slippers is not allowed

 5. Gambling is not allowed

6. No horse playing within the company premises

7. Use pathways and pedestrian lanes

8. Driving within the vicinity of the company is limited to 20km per hour

9. Follow the designated parking areas

10. When parking large vehicles, always put wedge on the rear and front wheels.

Never load and unload with unsafe vehicles.

11. Hazard and head light of every vehicle should be properly working

12. Follow all the traffic signs and other sign boards

13. Every worker has the right to decline, when the work ordered is too risky

14. Every worker has the right to own personal protective equipment

15. Work with full responsibility to the safety of oneself, co-workers and the

company

16. When working or visiting the field, remove all you jewelries in the body

17. You are not allowed to go to the field without a tour guide

18. Taking pictures or video in the field is strictly prohibited

19. Use handrails

20. In case of emergency, stay calm

21. Report immediately to supervisor or safety officer when not feeling well or any

unlikely circumstances

22. Everyone in the company is oblige to follow all safety rules whenever inside the

company

OBSERVATION
 During the plant visit, we observed that the company really implements its safety

rules and regulations.

RECOMMENDATION

Since, they produced a lot of waste heat, it is better for the company to utilize it and

use it to produce electricity. Also, it is also advisable to have bins or containers for the

residues of the process in order to have a more pleasant environment. Lastly, we would

like to recommend the company to have shed along the way to the office.