Emirates

Steel

1 Welcome to Emirates Steel

1.1 Company Objectives1.2 Production Processes1. :Kere to nd us2 Product Specifications

2.1 Rebar, Wire rod & Rebar in coil2.2 7ecKnical 6pecication2.2.1 Straight Rebar2.2.2 Wire Rod2.2.3 Rebar in Coil2.2.4 Chemical Composition2.3 Heavy Sections2.3.1 Section Families

3 Quality

3.2.1 Quality Control3.2.2 Quality Assurance3.2.3 Environmental Aspects3.3 Contact us

4 Organizational Charts

4.1 Emirates Steel Organization Chart 4.2 Quality Assurance Department Organization Chart4.3 Technical Services Department Organization Chart

5 Images of Emirates Steel

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Contents

1 Emirates

Steel

1 Welcome to Emirates Steel

Emirates Steel is owned by Senaat, the UAEs largest industrial conglomerate and a driving force for implementing the Abu Dhabi governments industrial diversication policy. Strategically located in the Industrial City of Abu Dhabi, some 35 kilometers away from the heart of the city of Abu Dhabi, Emirates Steel is the only integrated steel plant in the UAE, utilizing the latest rolling mill technology to produce rebar, wire rod and heavy sections.

Established in 1998, Emirates Steel grew in a relatively short period of time from a simple re-roller of imported steel billets to a complex integrated manufacturing plant, using modern solutions to tackle traditional industrial problems to generate value for its various stakeholders. In 2012, the Company began producing at a capacity of 3.5 million MTPA, following two expansions and the investment of AED 11 billion (US$ 3 billion).

Emirates Steels underlying business goal is to be an efcient and competitive producer of nished steel products. To achieve this, the Company continually and signicantly invests in expansions in the areas of processing, manufacturing and information technology. In addition, these investments help to improve product and service quality, reduce the Companys environmental footprint and increase safety for workers and customers.

DRI Plants

Three Plants to produce direct reduced iron from iron oxide pellets based on HyL Technology. Annual capacity: 3.2 million tons.

Steel Making Plants

Three Steel Making Plants, two with a 150 ton Electric Arc Furnace (EAF), Ladle Furnace and 6-strand Billets Continuous Casting Machine, and one with a 60 ton EAF, LF and 4-strand billets CCM.Annual capacity:Phase I: 1.4 million tons 130 x 130 billets and 150 x 150 billets. Phase II: 1.4 million tons:Billets 150mmx150mm 200 t/hr 1,400,000,Blooms 220mmx350mm, BB1 430mmx350mmx90mm, BB2 480mmx250mmx90mm, and BB3 500mmx435mmx90mm, BB4 670mmx350mmx90mm, BB5 1050mmx460mmx120mm.EISC: 0.4 million tons.Billets 100x100, 125x125, 130x130 and 150x150 mm.

Rolling Mills

Phase I: Three rolling mills, producing Rebar, Rebar in Coil and Wire Rod.Total annual capacity: 2.5 million tons.Phase II: One rolling mill producing Heavy Sections.Total annual capacity: 1 million tons.

Vision

To be a world class steel manufacturer providing the highest quality products, services and solutions to our customers and maximizing returns to our shareholders.

Mission

To provide the construction, manufacturing and industrial sectors with their requirements of high quality steel products.Maintain safe and environmentally friendly work practices across our operations.Create employment opportunities and inspire our workforce to excel.Contribute to the industrialization and diversication of the UAE economy in line with Abu Dhabis 9ision 2030.

Core Values

Honesty, Integrity, Creativity, Innovation and Quality.Pursuit of continuous improvement across all aspects of our business.

1.1 Company Objectives

Emirates

Steel

2

Emirates

Steel

1.2 Production Processes

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51- Pellets2- DRP (DRI)3- Electric Arc Furnace4- Ladle Furnace5- Continuous Casting6- Billets7- Reheating Furnace8- Descaler9- Roughing Mill10- Intermediate mill11- Finishing Mill12- Quenching Tempering Bar Line13- Cooling Bed 14- Cutting Length15- Binding Machine16- Rebar Yard

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Rebar in Coil - Wire Rod1- Pellets2- DRP (DRI)3- Electric Arc Furnace4- Ladle Furnace5- Continuous Casting6- Billets7- Reheating Furnace8- Descaler9- Roughing Mill10- Intermediate mill11- Finishing Mill 12- Compacting Machine13- Wire Rod yard

1- Pellets 2- DRP (DRI) 3- Electric Arc Furnace 4- Ladle Furnace 5- Continuous Casting 6- Billets, Blooms, BB7- Reheating Furnace 8- Descaler 9- Break Down Mill 10- hot saw 1 11- Ultra Flexible reverse12- hot saw 2 13- Cooling Bed 14- Roller Straightener 15- Cold Saw (1,2 &3) 16- Stacker 17- Binding Machine 18- Heavy Sections Yard

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Sections

3 Emirates

Steel

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ROUTE MAP TO EMIRATES STEEL (ES) ICAD MUSSAFAH FACILITIES

Emirates Steel, PO Box 9022, Mussafah, Abu Dhabi, UAE, Tel: +971 2 551 1187 Fax: +971 2 507 2181 www.emiratessteel.com

Way to Emirates Steel:- Stay on the E30 till Delma Mall is on your right.- Take the rst right after Delma Mall before the third bridge.- Access ICAD 1 and keep going straight.- After crossing ve roundabouts you will see Emirates Steel right in front of you.

1.3 Where to find us

Emirates

Steel

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Deviation Permitted For no.of bars/bundle:Size 8mm,10mm & 12mm = -0 +3Size 14mm,16mm & 18mm = -0 +2Size 20mm = -0 +1For above 20mm sizes , no deviations are permittedBar Length Tolerance +100mm & -0mm or as agreed. Minimum 4 strabs per bundleThe two ends straps are 0. 5M from the ends

2.2 Technical Specification

2.2.1 Straight Rebar

2 Product Specification

2.1 Rebar, Wire Rod & Rebar in Coil

Qualities & Grades

3URGXFW 6SHFLFDWLRQ *UDGH 6L]HVPPRebar BS 4449 / 97 460B 8 / 10 / 12 / 14 / 16 / 18 / 20 / 22 / 25 / 28 / 29 / 32 / 36 / 40 BS 4449 / 05 B 500B 8 / 10 / 12 / 14 / 16 / 18 / 20 / 22 / 25 / 28 / 29 / 32 / 36 / 40 ASTM A615 Grade 60 8 / 10 / 12 / 14 / 16 / 18 / 20 / 22 / 25 / 28 / 29 / 32 / 36 / 40Rebar in Coil BS 4449 / 97 460 B 8 / 10 / 12 / 14 / 16 BS 4449 / 05 B 500B 8 / 10 / 12 / 14 / 16Plain Wire Rod AISI 1005 - 1038 5.5 to 16 AISI 1045 - ER 7056

Standard Bar Count and Bar Length Tolerance.

D8 0.395 844 779 723 675 633 596 563 533 506 482 460 440 422D10 0.616 540 499 463 432 404 382 360 341 324 309 295 282 270D12 0.888 375 347 322 300 282 265 250 237 225 215 205 196 188D14 1.208 276 255 237 221 207 195 184 174 166 158 151 144 138D16 1.579 211 195 181 169 158 149 141 133 127 121 115 110 106D18 1.998 167 154 143 133 125 118 111 105 100 95 91 87 84D20 2.466 135 125 116 108 101 95 90 85 81 77 74 71 68D22 2.984 112 103 96 89 84 79 74 71 67 64 61 58 56D25 3.854 86 80 74 69 65 61 58 55 52 49 47 45 44D28 4.834 68 63 59 55 51 48 46 43 41 39 38 36 34D32 6.313 52 48 45 -- 39 37 35 33 32 30 29 28 26D36 7.99 42 39 36 33 31 29 28 26 25 24 23 22 21D40 9.864 34 31 29 27 25 24 23 21 20 19 18 18 17

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Steel

Other Characteristics

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We produce high yield deformed steel bars for concrete reinforcement (Rebar), in sizes 8-40 mm and 12 m long.The quenching process we use allows for superior mechanical properties to specication ASTM A615 GR 60, BS4449/97 GR 460B and BS 4449/05 GR B500B.

Emirates Steel is the only steelmaker in the ME1A region qualied to supply Q-class (nuclear quality) reinforcing steel to the UAE nuclear energy program and the fourth company in the world to be qualied by the American Society of Mechanical Engineers (ASME) to produce 1uclear Qualied reinforcing rebar.Rebar / ASTM A615 GR 60

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Steel

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We produce Plain Wire Rod coils according to steel grades AISI 1005 to 1045 ER 7056

Two heat resistant tags are attached to each coil (one at each end) with details of cast number, size, grade, specication, coil number etc.

2.2.2 Wire Rod

6L]HWROHUDQFH 2YDOLW\Sizes 5.5 - 6.5mm + / - 0.25mm 0.40mm MaxSizes 7 - 14mm + / - 0.30mm 0.48mm Max

We produce Rebar coils according to specications BS 4449/97, Grade 460B and BS 4449/2005, Grade

Two heat resistant tags are attached to each coil (one at each end) with details of cast number, size, grade, specication, coil number etc.

2.2.3 Rebar in Coil

6L]HWROHUDQFH 2YDOLW\Sizes 5.5 - 6.5mm + / - 0.25mm 0.40mm MaxSizes 7 - 14mm + / - 0.30mm 0.48mm Max

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2.2.4 Chemical Composition

Emirates

Steel

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2.3.1 Section Families

2.3 Heavy Sections

BS StandardUC 203x203UC 254x254UC 305x305UC 356x368UC 356x406UB 254x146UB 305x127UB 305x165UB 356x127UB 356x171UB 406x140UB 406x178UB 457x152UB 457x191UB 533x210

UB 610x229UB 610x305UB 686x254UB 762x267UB 838x292UB 914x305UB 914x419UB 1016x305PFC 200x75PFC 200x90PFC 300x90PFC 300x100PFC 380x100PFC 430x100

(XURSHDQ6WDQGDUGHE 200HE 220HE 240HE 260HE 280HE 300HE 320HE 340HE 360HE 400HE 450HE 500HE 550HE 600HE 650

HE 700HE 800HE 900HE 1000IPE 270IPE 300IPE 330IPE 360IPE 400IPE 450IPE 500IPE 550IPE 600IPE 750

GradesEN 10025 S235JR, S235JO, S235J2EN 10025 S275JR, S275JO, S275J2EN 10025 S355JR, S355JO, S355J2ASTM A36, A572 Grade 50, A992

ASTM StandardW 8x8W 10x10W 10x5-3/4W 10x8W 12x12W 12x10W 12x6-1/2W 12x8W 14x8W 14x10W 14x14-1/2W14x16W14x5W14x6-3/4W16x5-1/2W16x7W16x10-1/4W18x6

W18x7-1/2W18x11W21x6-1/2W21x8-1/4W21x12-1/4W24x7W24x9W24x12-3/4W27x10W27x14W30x10-1/2W30x15W33x11-1/2W33x15-3/4W36x12W36x16-1/2W40x12

Sheet PilesZ-Sheet Piles630 mm wide range under development

600 mm wide range under development

U- Sheet Piles

Bearing PilesBS Standard203X203254X254305X305356X368

HP 8X8HP 10X10HP 12X12HP 14X14 - 1/2

ASTM Standard

UB BS4 - Universal BeamsUC BS4 - Universal ColumnsPFC Parallel Flange ChannelsUBP Universal Bearing PilesHE European Wide Flange BeamsIPE European Narrow Flange BeamsW American Wide Flange Beams

Structural Steel Products to International Standards

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Emirates

Steel

Emirates Steel products have obtained the certicates that enable them to score all the related points possible for steel in the Estidama pearl system, SM9 & SM10.

The HYL process uses desulphurized heated natural gas to reduce the iron pellets. The steam used in the process is condensed and reused.

CO2 emissions are minimized by using a dedicated CO2 absorption system. CO2 is a by-product from the DRI production process. The CO2 capture system will capture up to 1 million tons of CO2 per annum from both DRI Plants. This will reduce the embedded CO2 content in ES steel to approximately 800 kg/ton liquid steel, this is important for construction grades (rebar and sections) which are used in LEED / Estidama building projects.

The CO2 is compressed and transported via a high pressure pipeline to oil elds. The CO2 is used to pressurise the oil reservoirs to enhance the recovery of oil from the reservoir. The CO2 returns to the surface with the oil, which is then scrubbed to separate the oil and CO2 which is then re-injected in the reservoir and permanently sequestered.

Emirates Steel is now the rst steel company in the world outside North America to capture CO2 on this scale. The plants environmental emissions (noise, gas, liquids, solid) by the strict environment rules as applied worldwide.

3. Quality

3.2.1 Quality Control

3.2.2 Quality Assurance

3.2.3 Environmental Aspects

To ensure our product quality, Emirates Steel has: A quality inspection plan to control incoming material, products in process and nal products Laboratory equipped with the latest testing instruments such as spectrometer, tensile and bend testing machines and rib area measurement device

To ensure the accuracy of testing and measuring instruments, Emirates Steel applies a calibrationplan for all instruments that may affect the quality of our products. Inspection and testing are conducted as per International Standards.

Emirates Steel operates a comprehensive Integrated Management System (IMS) with strong commitment to Quality, Environment, Health & Safety and sustainability based on the requirements of ISO 9001, ISO 14001, OH-SAS 18001, UK CARES, Dubai Central Laboratory, Emirates Authority for Standardization and Metrology (ESMA), Regulatory Authority and excellence award.

A detailed QEHS (Quality, Environment, Health and Safety) policy is deployed throughout the organization to ensure consistent product compliance to international standards, as well as to meet customer requirements.

We are committed to our Integrated Management System through: Identication and evaluation of environment aspects / hazards related to our activities Compliance with applicable regulatory requirements Dened objectives, targets and programs for continuous improvement We monitor and measure the performance of our IMS and take the necessary corrective and preventive actions in case of any deviation.

Emirates

Steel

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3.3 Contact us

)RUVDOHVHQTXLULHVRUIRUGLVFXVVLRQNLQGO\FRQWDFWSales DepartmentTel. +971 2 507 2144, Fax +971 2 551 5113Email: sales@emiratessteel.com, hsmsales@emiratessteel.comWebsite: www.emiratessteel.com

In our steel making process, the waste generated (tons per annum) is recycled as follows:

DRI Direct Reduced iron

DRI Sludge 70,000 Used in cement industryIron oxide nes 80,000 Used in cement industryCold DRI nes 6,000 Used in cement industrySteel Melt Shop

Slag 460,000 Used in road worksFume treatment plant dust/nes 72,000 Used in cement industry / land llingConcast scales 30,000 Used in cement industry

Rolling Mill

Billet Reheating dry scales 26,250 Used in cement industrySteel Scrap generated -2.50% Reused in the EAF

At Emirates Steel, we take pride in creating world standard products. In acknowledgement of our commitment, we have been awarded some of top industry certications.

Sheikh Khalifa Excellence Award (SKEA 2012).QSC Certication from the American Society of Mechanical Engineers (ASME) for the manufacture of concrete reinforcing bar.CE Marking for the Heavy Section Mill from UK CARES.Grade B500B rebar and coil Certication from UK CARES.The prestigious Emirates Quality Mark from ESMA.Saudi Quality Mark from SASO.GCCs rst sustainable reinforcing steel certication from UK CARES.Accreditation by the Dubai Central Laboratory Department (DCLD) of the Dubai Municipality.

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Emirates

Steel

4 Organizational Charts

4.1 Emirates Steel Organization Chart

Emirates

Steel

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4.2 Quality Assurance Department Organization Chart

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Emirates

Steel

4.3 Technical Services Department Organization Chart

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Images ofEmirates Steel

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Emirates

Steel

5.1 Aerial Images of the Plants

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5.2 Outside Images of the Plants

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5.2 Outside Images of the Plants

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5.3 Direct from the Mines

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5.3 Melting Steel

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5.3 Steel Casting

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5.4 Rebar and Wire Rod Making

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5.4 Rebar and Wire Rod Making

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Steel

5.5 Structural Steel for Architectural Creativity

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Emirates

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5.5 Structural Steel for Architectural Creativity

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Steel

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5.6 Best Quality Control

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5.6 Best Quality Control

Emirates

Steel

1 Certificates

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35

Emirates

Steel

1

1 Certificates

1.1 Commercial License

2 Emirates

Steel

1.2 Industrial License

Emirates

Steel

3

1.3 ADCCI Membership

4 Emirates

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5 Emirates

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7 Emirates

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1.10 Certificate of Factory Production Control

Emirates

Steel

11

1.11 DCL Certificate Of Product Conformity BS 4449:1997 with Amd1

12

Emirates

Steel

1.12 DCL Product Conformity Certification Scheme - Emirates Steel Industries

Emirates

Steel

13

1.13 DCL Bar Marking Emirates Steel Industries

14

Emirates

Steel

1.14 DCL Certificate Of Product Conformity BS 4449:2005

Emirates

Steel

15

1.15 DCL Product Conformity Certification Scheme - Emirates Steel Industries

16

Emirates

Steel

1.16 DCL Bar Marking Emirates Steel Industries

Emirates

Steel

17

1.17 DCL Certificate Of Product Conformity BS 4449:1997 with Amd1 EISC

18

Emirates

Steel

1.18 DCL Product Conformity Certification Scheme EISC

Emirates

Steel

19

1.19 DCL Bar Marking EISC

Emirates

Steel

1.20 DCL Certificate Of Product Conformity BS 4449:2005 EISC

Emirates

Steel

21

1.21 DCL Product Conformity Certification Scheme EISC

22

Emirates

Steel

1.22 DCL Bar Marking EISC

Emirates

Steel

23

1.23 ESMA certificate of conformity -BS4449:2005 & BS4449:1997

24

Emirates

Steel

1.24 ESMA -License of the use of the emirates mark of Conformity

Emirates

Steel

25

1.25 Management System-BS OHSAS 18001:2007

26

Emirates

Steel

1.26 Management System DIN EN ISO 14001:2009

Emirates

Steel

27

1.27 Estidama Compliance

28

Emirates

Steel

1.28 Saudi Arabian Standards Organization Certificate (SASO)

Emirates

Steel

29

1.29 Abu Dhabi Environment, Health & Safety Management System Certificate

Emirates

Steel

1.30 Abu Dhabi Environment, Health & Safety Management System Certificate

Emirates

Steel

31

1.31 SIRIM Product Certification License Structure Steel

32

Emirates

Steel

1.32 SIRIM Product Certification License WIRE ROD

Emirates

Steel

33

1.33 SIRIM Product Certification License REBAR

34

Emirates

Steel

1.34 ASME Quality System Certificate

Test Reports

37

Emirates

Steel

2 Test Reports

2.1 Tensile Testing of Steel Products

Emirates

Steel

38

2.2 Chemical Analysis of steel

39

Emirates

Steel

2.3 Tensile Testing of Steel Products

Emirates

Steel

2.4 Chemical Analysis of steel

41

Emirates

Steel

2.5 Tensile Testing of Steel Products

Emirates

Steel

42

2.6 Chemical Analysis of steel

43

Emirates

Steel

2.7 Tensile Testing of Steel Products

Emirates

Steel

44

2.8 Chemical Analysis of steel

45

Emirates

Steel

2.9 Tensile Testing of Steel Products

Emirates

Steel

46

2.10 Chemical Analysis of steel

47

Emirates

Steel

2.11 Tensile Testing of Steel Products

Emirates

Steel

48

2.12 Chemical Analysis of steel

49

Emirates

Steel

2.13 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

2.14 Tensile / Rebend & Chemical Tests of Steel Rebars

51

Emirates

Steel

2.15 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

52

2.16 Tensile / Rebend & Chemical Tests of Steel Rebars

53

Emirates

Steel

2.17 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

54

2.18 Tensile / Rebend & Chemical Tests of Steel Rebars

55

Emirates

Steel

2.19 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

56

2.20 Tensile / Rebend & Chemical Tests of Steel Rebars

57

Emirates

Steel

2.21 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

58

2.22 Tensile / Rebend & Chemical Tests of Steel Rebars

59

Emirates

Steel

2.23 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

2.24 Tensile / Rebend & Chemical Tests of Steel Rebars

61

Emirates

Steel

2..25 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

62

2.26 Tensile / Rebend & Chemical Tests of Steel Rebars

63

Emirates

Steel

2.27 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

64

2.28 Tensile / Rebend & Chemical Tests of Steel Rebars

65

Emirates

Steel

2.29 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

66

2.30 Tensile / Rebend & Chemical Tests of Steel Rebars

67

Emirates

Steel

2.31 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

68

2.32 Tensile / Rebend & Chemical Tests of Steel Rebars

69

Emirates

Steel

2.33 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

2.34 Tensile / Rebend & Chemical Tests of Steel Rebars

71

Emirates

Steel

2.35 Tensile / Rebend & Chemical Tests of Steel Rebars

Emirates

Steel

72

2.36 Tensile / Rebend & Chemical Tests of Steel Rebars

73

Emirates

Steel

2.37 Test Certificate Emirates Steel Industries

Emirates

Steel

74

2.38 Test Certificate Emirates Steel Industries

75

Emirates

Steel

2.39 Test Certificate Emirates Steel Industries

76

Emirates

Steel

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