BUILD

IT RIGHT
WITH THE ASSURANCE
OF SAFETY
 Why is
ET Epoxy Protect
the right choice
to ‘build it right’?
ET Epoxy Protect is a right choice for construction
in moisture and chlorides prone areas.
The ready-to-use epoxy coated TMT bars protect
the constructions from corrosion due to moisture,
various chlorides and acids and thereby results
in long-lasting and low-maintenance structures.
WHAT HAPPENS
IN THE ABSENCE OF
EPOXY COATING?

Water, air and salts Corrosion starts

come in contact on the surface
with the iron bar of the bar

Corrosion develops
further and the Corroded bar
concrete surface gets exposed
cracks

The corrosion cycle of steel starts with the rust expanding on the
surface of the bars causing cracks in the concrete. Gradually the
corrosion builds-up and results in spalling, ruining the concrete.
ABOUT
EPOXY
COATING
Fusion Bonded Epoxy coating, commonly
referred as FBE coating is widely used
to protect concrete reinforcement bars,
steel pipes, piping connections etc. used in
construction. FBE coatings are in the form
of dry powder at normal atmospheric
temperature. The powder is applied
electrostatically to the surface of cleaned
hot steel bars and cured to form a protective
film after undergoing various chemical
processes. The epoxy coated bars last longer
due to the protective film and thereby
contribute to the quality of construction.
BENEFITS
The superior corrosion protection can extend the life of the epoxy coated tmt bars, resulting in
significantly lower lifecycle costs over time.

It needs little maintenance that leads to substantial savings in labour costs. It is flexible to allow
straight bars to be bent during fabrication on a special mandrel to protect the coating from damage.

Epoxy powder coated bar is a sustainable solution that is friendly to the environment, a primary
concern for construction companies everywhere these days.

Studies have shown that structures built with epoxy last longer than similar structures made with
black steel.

Epoxy coating is very cost-effective as it adds very little to the overall cost of the structure and lifecycle.

As the technique is factory based, better quality control is achieved. It enables uniform thickness of
coating.

The bonding of coating with steel TMT bars is high as it has excellent adhesive property.

The Fusion Bonded Epoxy coating acts as an insulator for electrochemical cells and offers barrier
protection to steel which prevents entry of chloride ions through it.

STANDARDS
PARAMETER ASTM A775 : 2007 BIS 13620 : 1993 ET EPOXY PROTECT

Nearly white metal

Bar Anchor Profile 1.5 - 4.0 miles Nearly white metal
and 1.5 - 4.0 miles

7 - 12 miles
Coating Thickness 100-300 (microns) 100-300 (microns)
170 - 300 (microns)

Coating Holidays 3 holidays/m (max) 6 holidays/m (max) 5 holidays/m (max)

Coating Flexibility
180˚ bent using 8D 120˚ (after rebound) 120˚ (after rebound)
(Achieved)

Resistance to No Yes Yes

Applied Voltage
TESTING
CHEMICAL RESISTANCE TEST

The chemical resistance of coating is evaluated by immersing

the bars in each of the following as per BIS 13620:2004
1. Distilled water
2. A 3M aqueous solution of CaCl2
3. A 3M aqueous solution of NaOH
4. A solution saturated with Ca(OH)2

ADHESION OF COATING

The adhesion of the coating is evaluated by bending coated

reinforcement bars to 120° (after rebound) around a mandrel of
size as mentioned in BIS 13620:2004

RESISTANCE TO APPLIED VOLTAGE

The effect of electrical and electrochemical stresses on the bond of

coating to steel and on the film integrity of the coating is assessed
as per BIS 13620:2004

SALT SPRAY RESISTANCE TEST

The resistance of the coating to a hot and wet corrosive environment

is evaluated by exposing 250 mm long coated steel reinforcement bars
containing intentional defects to salt spray as mentioned in ASTM A775.

ABRASION RESISTANCE

The resistance of the coating on coated panels to abrasion, by a Taber

abrasor is tested as per the procedure mentioned in BIS 13620:2004

IMPACT TEST

The resistance of the coated reinforcing bars to mechanical damage

is determined by the falling weight test as mentioned in BIS 13620:2004
PROCESS
SURFACE PREPARATION

TMT bar is cleaned for surface contamination such as

grease and oil by solvent cleaning. Shot blast cleaning is the
most commonly used method for preparation of steel surfaces.
This effectively removes rust, scales, slats etc., from the
surface and produces an industrial grade of a clean and
rough surface finish.

PRE-HEATING

Heating can be achieved by using several methods, but the

most efficient method is induction heating. TMT bars are
passed through a high frequency alternating current along
with a magnetic field, which heats according to the required
FBE coating application temperature. Typical application
temperature for a stand-alone FBE is 225°C to 245°C.

EPOXY POWDER APPLICATION

The FBE powder is placed on a fluidisation bed. The heated

TMT bar is passed through the coating booth with number of
electrostatic epoxy spray guns and the dry powder is sprayed
(cloud formation) on the hot TMT bar. Here, the powder
particles are suspended in a stream of air which is electrically
charged due to which epoxy powder particles are attracted to
the grounded TMT bar. As soon as the charged epoxy powder
particles hit the hot TMT bar, they melt and flow into the
anchor profile. The heat also initiates a chemical reaction
which causes the epoxy powder molecules to form cross linked
polymers which gives the coating its beneficial properties.

CURING AND COOLING

Epoxy coated TMT bars are given a thermal treatment

by keeping them at 225°C for a duration recommended by
epoxy powder manufacturer resulting in fully cured coating.
The coated bars are passed through a cooling tunnel after
curing, where water is sprayed on the bars to cool them.
The bars are then transferred to the final inspection rack
for testing and inspection.
MANUFACTURING
PROCESS OF
ELECTRO 500 D LPS
TMT BARS

Blast Furnace
1 2

Iron Ore Steel Melting Shop

3
Sponge Iron Kiln

5 4

Rolling Mill Billet Caster Ladle Refining

Furnace
6

7 8

Thermex Physical & Chemical Storage & Dispatch

Quenching System Testing Lab

11 10 9 ET EPOXY
PROTECT
PROCESS
FBE Coating Pre-heating Surface Cleaning

12

13 14

Curing & Cooling Bundling Storage & Dispatch

ADVANTAGES
OF ELECTRO 500 D LPS
 PARENTAGE

Electro 500 D LPS reinforcement bars are a result of a relentless research

led innovation and obsession with quality of a world-class organisation that
is known for its “Excellence in Metallurgy”. Electrotherm (India) Ltd. is India’s
BUILD IT RIGHT
largest manufacturer of Induction Melting Furnaces and furnaces used for
steel making.

PERFECT BONDING

Electro 500 D LPS TMT bars are manufactured using superior notch cutting
machines that ensure consistent rib patterns and optimum rib depths. These
machine crafted ribs facilitate superior bonding with concrete that is vital for
long-lasting structures.

SUPERIOR STRENGTH

ELECTRO 500 D LPS has an unbeatable combination of strength and

ductility that is far superior as compared to the minimum values specified
by IS 1786:2008 standards.

MECHANICAL PROPERTIES
IS 1786:2008 (Fe 500 D) ELECTRO 500 D LPS (typical)
Ultimate Tensile Strength 565 N/mm 2
610

Yield Stress 500 N/mm2 530

(UTS / YS) Ratio 1.10 1.15

Elongation 16.0% *19.0%

Total Elongation 5.0% 8.0%

*Upto 20 mm 19% (min), above 20 mm 17% (min), in physical all single values are minimum and as obtained in 90% of heat

COST SAVINGS

Steel bars are bought in kilos and tonnes but their usage is in terms of
metres. Electro 500 D LPS bars have a “Higher metreage per unit weight”
which results in tremendous cost savings.
SUPERIOR
MANUFACTURING PROCESS
The state-of-the-art integrated manufacturing plant comprises of Sponge
Iron Kilns, Blast Furnace, Melting Furnace, Ladle Refining Furnace,
Continuous Casters, Rolling Mills with AC variable drives, best in class
physical and chemical testing laboratories and a Spectrometer. The process
uses 100% iron ore through a combination of Blast Furnace, Sponge Iron
Kilns, Induction Melting Furnace and Ladle Refining Furnace. Good quality
of iron ore is used in Blast Furnace of 128 m3 and 63 m3 Direct Reduced Iron
(DRI) Kiln of 250 and 350 TPD. After melting the DRI from kilns and hot metal
from Blast Furnace in the Induction Furnace, a unique and patented
ERF-ELdFOSTM metallurgical process is used to dephosphorize the steel in
the ladle and desulphurize the steel in the Electrotherm Ladle Refining
Furnace (ERF) specially to meet the stringent phosphorus and sulphur
requirement of Fe 500 D grade of TMT bars. Multistage testing of steel
chemistry through Spectrometer ensures adherence to chemistry in close
tolerance. In the ERF, metal is also homogenised, alloying elements are
added and controlled in a very narrow range, dissolved gases in the steel are
lowered through mild purging of inert gases and inclusions are removed or
altered chemically to ensure high quality of steel. This refined steel is cast
into billets of required sizes in closed environment to have further control of
gases and other inclusions. Molten pig iron (hot metal) from Blast Furnace
and Direct Reduced Iron (DRI) from kiln (100% iron ore) is the key to making
superior quality TMT bars free from tramps like Cu, V, Ni,Cr etc. unlike other
conventional manufacturers where scrap is used and there is no control on
impurities. After refining the steel in LRF, it is rolled in required size in a
state-of-the-art Rolling Mill and thermo-mechanically treated in Standard
Quenching Box. Highly atomised quenching, self-tempering and atmospheric
cooling ensures that TMT bars have superior mechanical properties in
strength, weldability, ductility and bendability meeting or exceeding quality
standards. Quality control is highly stringent through NABL accredited labs
and equipment.

EXCELLENT
BENDABILITY
The advanced Thermex Quenching during the manufacturing process results
in bars with a tough outer surface but a soft core that translates into excellent
bendability. These bars can be bent around mandrels of small diameters
which are a great advantage at the construction sites.
 RAW MATERIALS
(Based on 100% iron ore usage)

Electro 500 D LPS TMT bars are made from billets that are manufactured
in-house. The billets are also produced using sponge iron from kilns
and hot metal from Blast Furnace. High quality of iron ore is used in the
manufacturing process. 100% use of iron ore for steel making results into
extremely low level of tramp elements in the billets and TMT bars as well.

SUPREME WELDABILITY

With a carbon content of maximum 0.25%, which is lower than the

IS 1786:2008 specifications, Electro 500 D LPS TMT bars offer superior
weldability as compared to other TMT bars. This superior weldability means
these bars can be lap-welded with ease and without any loss of strength
at the welded joints.

PURITY

The steel produced in Induction Furnace is further refined using Ladle

Refining Furnace (ERF) which ensures lower sulphur (impurity) levels, lower
inclusion levels, lower gas levels and results in cleaner steel. These pure steel
billets with a much lower carbon content provide Electro 500 D LPS bars with
uniform strength, excellent ductility and superior bendability. These bars have
an inherently high fire and corrosion resistant properties which is suitable for
creating structures in earthquake prone zones.

CHEMICAL PROPERTIES
IS 1786:2008 (Fe 500 D) ELECTRO 500 D LPS (typical)
Carbon 0.25 0.23
Sulphur 0.04 0.0375
Phosphorus 0.04 0.0375
Sulphur & Phosphorus 0.075 0.075
CE 0.42 0.38
 PEOPLE

It’s the men behind the machines that make the difference. Team ET
comprising of engineers, technocrats and management professionals is
a dedicated team obsessed with quality and passionate about excellence
in everything it does. This results in products, solutions and services par
excellence.

ET ONE-STOP SHOP

Electrotherm (India) Ltd. is a one-stop solution for modern day construction

that manufactures all the crucial requirements for construction such as
TMT bars, Cut & Bend TMT bars and epoxy coating facilities in its own
state-of-the-art manufacturing unit in the entire west region of India.
This makes the process of building easier and quicker since you don't have
to spend your time and energy to pick different vendors for each product or
compromise in quality. At Electrotherm we strive to bring forth quality and
maintain precise consistency in our range of products for flawless
constructions.

Available Grades: Fe 415, Fe 500, Fe 500 D, CRS 500 & CRS 500 D
Available Sizes: 8 mm to 36 mm
 BUILD IT RIGHT
Electrotherm (India) Limited, HO: 72, Palodia via Thaltej, Ahmedabad – 382115, Gujarat, India.
Email: steel@electrotherm.com | Ph.: +91 2717 660550 / 649

www.electrothermsteel.com