A billet is a length of metal that has a round or square cross-section, Billets are created directly via continuous casting or extrusion or indirectly via hot rolling an ingot or bloom. Billets are further processed via profile rolling and drawing. Final products include bar stock and wire.

Centrifugal casting is also used to produce short circular tubes as billets, usually to achieve a precise metallurgical structure. They are commonly used as cylinder sleeves where the inner and outer diameters are ground and machined to length. Because their size is not modified significantly, they are not always classified as semi-finished casting products. 

I.    Billet Size   : 150 X 150mm and 130 X 130mm
II.   Grade         :  ASTM A 615, SASO SSA 2, BS 4449, SAE 1006, SAE 1008, SAE 1010,
                          SAE 1012 and other grades as per customer specifications.

III.   Other Requirements and Tolerances.

 

It is part of our commitment at AL ITTEFAQ STEEL PRODUCTS CO. (ISPC) to provide our customers with assurance that they are receiving only the best-quality products. ISPC produces deformed rebar, rebar coil and plain wire rods in a wide range of standards to conform to our customers’ needs for use in welding electrodes, steel mesh, wires, bolts and springs, as well as bending/cutting machine use and cut to bend sizes.

We have in place the latest automation upgrades that enable each plain coil to weigh up to 1,700 kg. All of our products are manufactured to meet international standards for industrial, commercial, residential and infrastructure buildings. Each grade has a wide variety of diameters from which you can choose. You can also order according to your specifications. The rebar coil and plain wire rod are normally used in downstream industries to manufacture binding wires, barbed wires, wire nets, gabion and chain-link fencing, screws, hangers, nails and welded wiremesh.

Our adherence to both international and local safety standards means that we can guarantee our customers that every product we manufacture has met all the required health and safety specifications. The deformed rebar, rebar coil and plain wire rod are all certified in regards to their chemical and physical properties. This means that we produce only the highest quality standards of rebar products and plain wire rods.

The Wire Drawing Division of AL FAISAL STEEL PRODUCTS CO. has the world’s best wire drawing machines, which include advanced features. AL FAISAL STEEL PRODUCTS CO.’s international experience and knowledge have helped significantly expand its product range and manufacturing capabilities in recent years. One of these improvements is the introduction of in-line inspection using laser detection diameter measurements and pressure sensors with a PLC mechanism.

The drawing instruments are carefully designed to guarantee optimal quality in the production process. This includes:

• Uniform coil weight
• Traceability of coils

Cold drawn wires are manufactured according to ASTM and DIN standards from Low carbon and High carbon steel for diverse applications in the relevant industries. Wire rod is a Hot Rolled product that is usually annealed, pickled or surface treated. What is most important here is the processing of the wire rod using cold forming or drawing. This allows the production of an enormous variety of end products. These include:

1. Spring wires for general engineering

2. Spring wires for mattresses

Fusion Bonded Epoxy Coating (FBEC) is normally referred to as FBE Coating and is generally used to protect concrete reinforcing bars used in the construction industry. Over the last 35 years, FBE Coating has been used worldwide to protect reinforcing steel in concrete in the most adverse, corrosion-prone environments. FBE Coating is applied as a dry powder and at normal air temperature.

FAISAL STEEL’s fusion bonded epoxy powder coating is a high-quality and high-performance anti-corrosion coating. It provides excellent protection for concrete reinforcing bars used in any construction industry scenario. Some of the benefits that FBE Coating provides are:

• Excellent steel adhesion provides long-term corrosion resistance
• Advanced engineering and manufacturing techniques that can be customized to any specific project
• Tough physical properties that ensure no or minimal damage during handling, transportation, installation and operation
• High resistance to cathodic disbondment
• Full compatibility with mill applied FBE Coating
• Stability and resistance to high operating temperatures
• Stability and resistance to chemical contaminants in the environment

The powder is applied electrostatically to the cleaned surface of a hot steel rebar, where it fuses, melts down and cures to an adherent, continuous and chemically cross-linked protective film. FBE Coating is an environmentally safe thermosetting coating sprayed onto the Rebar. This coating significantly reduces the amount of current required for cathodic protection to prevent corrosion. FBE Coating has been laboratory and field tested to assure customers of field-proven protection that will last for generations.

TECHNICAL DATA SHEET OF FUSION BONDED EPOXY COATING

Standard : ASTM A775 / A775M (Chart)

FAISAL STEEL’s Cut & Bend Reinforcement Bar Division (C & B) was established to produce steel reinforcement bars in the required lengths and shapes for use in construction. This division is well equipped with ultra-modern, state-of-the-art equipment from the world-famous m/c manufacturer, as well as the latest software, including BBS detailing through CAD RC and ARMOUR software.

All of our equipment for cutting and bending conforms to international standards, ASTM, ACI-316, BS-4466, BS-8666 for reinforcing steel to cut down steel wastage and delivery time. This also produces steel products with higher dimensional precision. Our shear line, double bender, single bender and stirrup machines utilize advanced computer programming features to create distinctive shapes and sizes.

Our prefabrication standards help our customers raise productivity standards in their construction projects. Our solutions can be customized to any project’s requirements, such as timelines, manpower and inventory management, as well as reduce material wastage.

Adhering to international practices and standards for the construction industry has the following major benefits:

The advantage of using factory-cut and bent steel reinforcement bars is realized in labour requirements, machinery requirements, waste steel, time and quality consistency.

Finally, since the cutting and bending is carried out by machines, the measurements and consistency in the bending of multiple bars will be spot-on, which a manual process cannot practically achieve.

One of Al-FAISAL STEEL’s production departments is engaged in the manufacture of welded wire mesh products. It is equipped with a state-of-the-art welding machine that produces high-quality products in adherence to both local and international guidelines for manufacturing welded wire mesh. Our welding machine can customize both the size and properties of welded wire mesh.

Some of the benefits we offer our customers include precise size, unique spacing, high strength and flat surface welding. We use a signature automated weaving technique and a mesh welding machine that allow us to produce high-quality welded wire mesh at economical prices.

Welded wire mesh is also a steel reinforcement material used in concrete structures. AL-FAISAL STEEL’s welded wire mesh is strong and durable. The mesh can be used to replace conventional cut & bend mesh. Welded mesh is a combination of welded and pre-assembled reinforcements. It is composed of an arrangement of parallel and longitudinal wires with a precise spatial array welded to cross wires at pre-defined spacing. This spacing is defined by national and global standards, such as ASTM A 497, BS 4483, DIN 488 and SASO.

Welded wire mesh is made of high-quality steel wire through a pre-programmed and automated process using complex welding techniques. This produces a mesh with precise dimensional control, a top-notch product with considerable savings in time and labor costs.

 

WELDED WIRE FABRIC B.S. 4483

AL-FAISAL STEEL’s high-quality, low-relaxation prestressed concrete strands consist of helically laid wires spun together in the same direction. AL-FAISAL STEEL’s LRPC strand contains seven wires in a single LRPC strand.

LRPC strands are used in prestressed concrete girders for building roads, flyovers, river and railway bridges, prestressed concrete domes, hollow core slabs, steel beams and TT slabs, silos, hangars, aqueducts (waterways), viaducts and railway sleepers. By utilizing LRPC strands, you can achieve as much as a 10-percent reduction in the use of steel in construction. LRPC strands are also used where large spans are desirable, such as in the prestressed and post-tensioned Concrete Market for the construction of bridge beams, shopping centers, car parks and commercial buildings. AL-FAISAL STEEL’s PC strands are used extensively in prestressed and post-tensioned concrete structures.

PC strands consist of multiple wires spun together in the same direction. Super low relaxation PC strands can be used for either prestressing or post-tensioning of concrete. By reducing the required man-hours and saving on the amount of pillars, ducts, sheathings and wedges needed, there is a general reduction in the cost of the project.

AL-FAISAL STEEL’s low-relaxation prestressed concrete strands have the following benefits:

• Lower relaxation loss
• Higher proof load
• Higher breaking load
• Improved performance at high temperatures
• Higher resistance to fatigue and corrosion

Reducing the number of required structural parts significantly reduces the amount of cement used, helping boost a project’s viability.

 

TECHNICAL DATA SHEET FOR LRPC STRANDS

 

The 7 Wire Uncoated Low Relaxation Prestressed Concrete Strand is made according to
International standards, such as:

ASTM A 416

BS 5896

 

ASTM A 416 LOW RELAXATION

 

STANDARD	DIAMETER (MM)	AREA OF STRAND (MM2)		MIN. BREAKING LOAD (KN)	MIN. LOAD OF 1% EXTENSION (KN)	MIN. ELON (%)	MAX. RELAXATION AT 1000 hrs. 70%
Grade 1860 (270)	9.53	54.8	432	102.3	92.1	3.5	2.5
	11.11	74.2	582	137.9	124.1
	12.7	98.7	775	183.7	165.3
	15.24	140	1102	260.7	234.6
Grade 1725 (250)	7.94	37.4	294	65	58.1	3.5	2.5
	9.53	51.6	405	89	80.1
	11.10	69.7	548	120.1	108.1
	12.70	92.9	730	160.1	144.4
	15.24	139.4	1094	240.2	216.2

 

BS 5896 / 3 RELAXATION CLASS 2

 

STANDARD	DIAMETER (MM)	AREA OF STRAND (MM2)	WEIGHT OF STRAND (KG/KM)	MIN. BREAKING LOAD (KN)	MIN. LOAD OF 1% EXTENSION (KN)	MIN. ELON (%)	MAX. RELAXATION AT 1000 hrs. 70%
Standard Strand (1770)	9.53	52	408.2	92	81	3.5	2.5
	11.00	71	557.35	125	110
	12.50	93	730	164	144
	15.20	140	1091.2	232	204
Super Strand (1860)	8.00	38	298	70	61	3.5	2.5
	9.60	55	432	102	90
	11.30	75	590	139	122
	12.90	100	785	186	163
	15.70	150	1180	265	233
Net Weight of Coil		Approximately 3000 kgs or As Per Customer's Requirement
Packing		The Strands will be furnished on reeless pack having a minimum core diameter of 610mm unless otherwise specified by the customer.

AL FAISAL STEEL PRODUCTS CO. is famous for producing high-quality steel products, including galvanizing line end products. AL FAISAL STEEL PRODUCTS CO. is equipped with a modern, highly sophisticated 32 wire hot dip that has an automated galvanizing line with the facility for in-line Heat treatment (annealing) of drawn wire,and a nitrogen wiping facility for precision control of zinc coating film and consistency in the coating controlled by an automated Zinc Monitoring state-of-the-art facility.

Galvanized wire is a carbon steel wire coated with zinc. The two processes used to produce galvanized wire and coil are continuous hot dipping and electro-galvanizing. Generally speaking, the hot dip process consists of passing the steel through a bath of molten zinc. The electro-galvanizing process consists of the application of zinc by electrolytic deposition, or electroplating. The result is a layer of zinc tightly adhering to the base metal through an iron-zinc bonding layer.

A zinc coating is one of the most effective and economical methods of protecting bare steel from harsh environments. The zinc not only serves as a barrier between the steel and the environment, it sacrifices itself to protect the underlying steel wire.Galvanic protection occurs when two dissimilar metals are in contact and coupled with water and oxygen. Zinc corrodes preferentially to the iron in steel. This protection prevents corrosion of the steel from areas not covered with zinc. Thus, the spread of corrosion from cut edges, drill holes, etc. is minimized.

Because we adhere to the highest production standards, our steel wire can resist abrasion, bending fatigue and crushing. We understand the importance of producing a high-quality product that must perform at an optimal level to maximize its service life. Our technical expertise ensures that our galvanizing steel wire products are manufactured to the highest standards in the industry.

The processing line has an automated zinc coating monitoring system that can control steel wire of sizes ranging from 0.8mm to 4.5mm, which are used in electrical cable manufacturing,fencing, construction, barbed wires, nails, tying and binding wire.The galvanized wires are always tested according to the customers’ requirements. Highly trained and qualified professionals using the latest equipment conduct testing around the clock.

 

TECHNICAL DATA SHEET FOR GALVANIZED STEEL WIRE

 

• Galvanized steel wire is produced in adherence to International Specifications such as:
• Armouring Wire BS EN 10244
• Heavy Coating ASTM A 392
• Wipe Off Coating ASTM F-668
• Commercial Coating ASTM A 641

 

ARMOURING WIRE

The AL FAISAL STEEL PRODUCTS CO.’s Cold Rolling division has a high-speed rolling line from the best European rolling line machine manufacturer. This means that we use all modern Programming Logic Controllers (PLC) to gradually decrease the diameter of the rolled steel while increasing its tensile strength, dimensional accuracy and standard rib formation. This is necessary to optimize bonding strength for construction, and results in reduced steel weight while maintaining stronger tensile strength.

The engineering technology used in steel rolling from Rolling Cassette arrangement has included alternate measurements and consistency in product quality to guarantee reliability and value.