Field Trip No.

Company Profile
Corporate Profile In 1995, Steel Asia was established to put up the country's first modern
steel bar mill. It was a quantum leap in technology and manufacturing capacity, intended to bring
the Philippine steel industry to world class levels of quality, service and manufacturing
efficiency. With innovation and continuous improvement as mantra, Steel Asia quickly
established and entrenched itself as the Philippines' preferred supplier of rebar. With a majority
share of market that continues to grow, its capacity has expanded to 2.0 million metric tons per
annum. Steel Asia Manufacturing Corporation, a joint venture with TATA Steel from India, is
located in Bulacan in the Philippines and produces reinforcing steel bars (also referred to as
rebar) for use in construction. The plant was commissioned in 1996 and currently has 400
employees. Annual production is 360,000 tons of steel bars compared to its 400,000 tons annual
designed capacity, which is mostly consumed by the domestic market. The company participated
in the project to sustain their effort to improve the operation, cut down on production cost
through energy efficiency and cleaner production and prepare for an application for Integrated
Management System (ISO 9001, ISO 14001 and OSHAS 18001) certification.

Vision:
  Leading the development of a Philippine steel industry - the backbone of a growing
economy.
 
Mission:
We provide our country with world-class steel products and services by innovating and
adapting to changing customer needs. We fulfill our role in nation-building by producing steel
locally and enriching communities and the environment.
History

SteelAsia is a company borne out of a partnership that started in 1965. Filipino

businessmen Benito Yao and Go Kim Pah (founder of Equitable Bank), joined forces to put up a
rolling mill called Island Metal. The small rebar facility would eventually bloom into one the
world’s largest and most modern rebar manufacturing companies today.
In the late 1980s, under the leadership of successor Benjamin Yao, the company would
embark on an expansion and modernization of its manufacturing capability, as a platform for
helping the Philippine steel industry to become part of the solution.  Up until the mid-1990s, the
highly fragmented Philippine steel industry was composed of over 50 small steel bar rolling mills
of circa 19th century and early 20th century technology.  Obsolete and inefficient, the Philippine
steel industry could hardly be a positive factor in contributing to the country’s economic
development, burdening the construction and property development sector with its high cost of
production, inefficiency and spotty track record of quality and timely delivery. The solution was
scale and modernization.
In 1994, a project to establish the Philippines’ first state-of-the-art steel bar rolling mill
was underway.  Driving the endeavor, the SteelAsia Manufacturing Corporation had envisioned
a facility that would truly be a national asset; world class steel products and services would lower
the cost of construction, and help spur economic growth.  When the mill- a showcase of
European technology, commissioned in 1996, it was a statement to the ASEAN steel community,
that the Philippines had finally joined the ranks in modern industrialization.
SteelAsia today plays a key role in national development. 
Around one out every two steel bars installed in construction are manufactured by
SteelAsia.  More than 80% of the steel bar requirements for land, air, sea, power and
communications infrastructure are supplied by SteelAsia.  It is the preferred supplier of the
largest contractors and property developers in the Philippines. 
It is has vertically integrated both upstream and downstream, having the largest and most
modern steel billet making facility and the largest rebar fabrication plant in the country.  Already
with 6 plants operating across the archipelago, it is adding two more- among the world’s largest
and most modern steel bar mills, to meet the needs of today’s unprecedented economic growth.

Nature of Business and 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.
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

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.

* "Weldability" refers ONLY to a TS/YS Ratio of greater than 1.25, or a bar intended for
seismic conditions.
 It is common nomenclature and a misnomer in that it does not refer to a capability of a bar to
be welded or not.
 

 
Rebar standards are detailed in the Philippine National Standard for Steel Bars for Concrete
Reinforcement PNS49 and for re-rolled bars PNS 211.

Manufacturing Process

The Calaca Works of SteelAsia houses a mini-mill or an integrated rebar line.  The rebar
line is directly integrated with its own scrap-based billet production. The mill was established by
BSII in 1999.  It mothballed a year later soon after the 1997 Asian Financial Crisis and acquired
by the SteelAsia group in 2007.  After rehabilitating and upgrading the facility, it was and re-
commissioned in 2008.  We call this manufacturing line M3.
M3 is unique because it is only integrated steel works in the Philippines.  M3 has
steelmaking capability.  It recycles domestically purchased steel scrap which it melts and casts
into semi-finished steel called billets.  The unique feature of this process is that the steelmaking
is linked to the 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.
It featured many other modern technologies such as an in-line rolling train configuration,
independent drives, Level-2 automation, quick size change among others, and these brought the
mill to world standards of productivity, conservation and operational health and safety. 
Originally commissioned as a 300,000 tpy mill, SteelAsia has upgraded its equipment
and technologies to its current capacity of 500,000 tpy. 
 M3 is located in an industrial park with its own port.  This logistic feature improved
service to Visayas and Mindanao consumers of rebar.  Though M3 primarily serves Region 4
customers, it continues to be an able back-up during spurts of rebar requirements of construction
projects in Metro Manila and the southern islands of the Philippines.
Products
Calaca Works offers

 PNS49 Rebar (sizes 10mm to 50mm, lengths 6M to 15M)

o Grade 415 (ASTM Grade 60) regular and weldable
o Grade 275 (ASTM Grade 40) regular and weldable
o Grade 230 (ASTM Grade 33) regular and weldable

Technical Description
Calaca Works
Detailed Flow Chart of the Manufacturing Process

Steel Scrap Recycling

Recyclable steel materials which may be drawn from vehicles, old appliances and buildings.

Melting
Melting of scrap materials by means of electric arc heat.

Refining
Refining and regulating of the temperature and chemical composition of molten steel in
preparation for continuous casting

Continuous Casting
Molten steel is molded and shaped into a solidified raw material such as a billet, bloom or slab.

Reheating
Process wherein the charge is heated to rolling temperature.

Rolling
Metal forming process in which charge is passed through a pair of rolls
to create desired formation of steel.

Cut and Bend

Precision cutting and bending of rebars into shapes of exact specification, in a consistently accurate
manner performed in a factory environment using shear lines and power bending machines.

Major or Finished Product Minor

Raw The cut and bended rebars are embedded with the company initials (SA) Materials
and the dimensions of the bar.
 Steel Billets,
Steel Scrap
Utilities
 Steam, Cold Water
Waste and Waste Management Practices

Environmental, health and safety management

SteelAsia is the first and only company in the Philippine steel industry to be certified to ISO
14001 (Environmental Management Systems), and the first and only as well to certified to
OHSAS 18001 (Occupational Health and Safety Management).
Embedded into every steel bar that SteelAsia delivers are the technological investments that
reduce the environmental impacts, protect the health and safety of the public and employees of
SteelAsia.

 SteelAsia mills have zero-wastewater. 100% of the water exiting the operations line are
not drained as effluent but rather channeled into a dedicated waste-water treatment facility on
the premises, and cycled back into operations.
 SteelAsia has been on the cutting edge of resource-usage minimization. It has
implemented rainwater-collection, from the roofs of its buildings and roads at its plant site.
Rainwater is increasingly the main source of water for SteelAsia, as in its Davao plant
operations which operates while recycling 80 cu. meters of rainwater every hour.
 Air-oil lubrication is a new technology that SteelAsia has implemented. Lubrication is in
a closed system, rather than an external application of lubrication that latter of which may
result in ground contamination from used oil.
 SteelAsia uses automated furnaces. Through sensors and automation the optimum fuel-air
mixed is achieved, minimizing particulate emissions. This also ensures optimum burning
saving fuel by up to 30% compared to zero-automated furnaces.
 Hot-charging technology reduces fuel consumption further by another 35% in SteelAsia’s
mini-mill.
 Furnace stacks are up to 50 meters high ensuring that with air dispersion, emissions stay
well below the allowable limits at ground level.
 The pioneering use of AC motors driven by individual Process Logic Controls saves on
power consumption by more than to 25% and significantly reduces noise levels.
 In-line rolling stands increase the safety of the mill compared to accident prone cross-
country configurations.

SteelAsia uses heat recuperators to recycle energy and save on fuel.

 

Reference
 https://www.steelasia.com/company/plant-facilities/calaca-works
 ttps://www.scribd.com/document/323349105/Steel-Asia-Final-project-pdf
Documentation

Reflection