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P R E S T R E S S E D S T E E L W I R E

PRESTRESSED STEEL WIRE

APPLICATIONS

Railway sleepers

High pressure pipes

Prestressed panels

Prestressed concrete beams

CONTENTS

- COMPAGNY PROFILE .......................................................................................02

- MAKLADA GOES GREEN ..................................................................................02

- A REPUTATION FOR QUALITY SINCE 1984 .......................................................02

- REFERENCES ......................................................................................................02

- SEVEN WIRE PRESTRESSED STRAND..................................................................02

- PRODUCTION RANGE ......................................................................................02

- TECHNICAL DATA ..............................................................................................02

- PACKAGING .....................................................................................................02

- INTERNATIONAL EXHIBITIONS AND EVENTS .....................................................02

01

BS 5896 Certificate No. CL12020163

ASTM A Certificate No. CL12020162

PRESTRESSED STEEL WIRE

03

COMPAGNY PROFILEMaklada i s part of a

Stunas Group, leader in s t e e l i n d u s t r i e s i n medi te r ranean a rea. Stunas Group includes a total of 13 companies, manufacturing 200.000 Mt of steel f rom sandwich panels, structures, modular buildings, wires, ropes, strands,... up to consulting services and real state. Maklada produces more than 100.000 Mt of drawn s t e e l w i r e s a n d h a s a worldwide customer portfolio among 35 countries.

Since its creation in 1984, with the Cooperation and Technical Assistance of Suzuki Metal Industry Japan, Maklada has reinforced its technical skills through benchmarkings with leading steel companies Arcelor Mittal, Lucchinni, Tatasteel,... and equipped our plants with the highest end technology and first class supplies for our Production Lines and Laboratories.

Our philosophy is to develop products according to our customers expectations and facilities, and to look after Excellence in Product Performance through our collaborations with Universities, Quality Organizations, Specialists, ....

Backed by 30 years of experience and his know-how, Maklada is specialized in the manufacturing of High Carbon Steel Wires and Strands according to international standards and / or client’s specifications. Today, we continue investing in Technology, in I+D for new products, in Environment Protection and in Customer Service.

MODERN TECHNOLOGIESOur plants are equipped with modern machinery and we are still heavily investing in new equipements and technologies in collaboration with worldwide leading companies and consultants. Our aim is to maintain high quality standard at all levels.

02

MAKLADA GOES GREENMaklada engages in environmental protection and energy management. Our new production site generates its own energy, with a full tri-generation plant, and is reducing also chemicals emissions by adding a mechanical shot blasting systemfor raw material cleaning.

OUR

ENVI

RONMENTAL

C O M MITM

EN

T

PRESTRESSED STEEL WIRE

05

Application :High Carbone steel wires are used for the production of high pressure pipes, beams and poles.

Standards :These steel wires are produced in conformity with more reputed standards :

• BS 5896 certified by Dubai Central Laboratory (DCL),• ASTMA421• EN 101382-,• UNE 36094,• Clients’s specifications.• Wire for prestressed pipes according to french standards and ASTM648

Relaxation :• Normal relaxation,• Low relaxation,• Very low relaxation with maximum relaxations losses of 2.5% after 1000 hours under initial load

70% of actual breaking load at 20%.

A REPUTATION FOR QUALITY SINCE 1984 PRESTRESSED STEEL WIREMaklada has a performing quality system allowing to control all its manufacturing process. The company is ISO 9001 : 2008 certified by TÜV and obtained the award of the presidential quality in 2010. The company is ISO9001 : 2008 certified by TUV and by UK Cares

Our range of steel strands (7 wires) for the prestressed concrete is certified in compliance with the standards BS 5896 and ASTM A416. The technical characteristics were checked and verified by the Dubai Central Laboratory (DCL). The technical

characteristics were checked by DCL and by UK CARES.

The prestressed armatures of our steel strands are certified in compliance with the technical specifications of ASQPE.

Our factories are equiped with PC Strand machines, chemical and mechanical cleaning installations, stress relieving lines to get all kind of relaxation (normal, low and very low), conditioning and wrapping shop, and a complete laboratory equipped with the most updated technology for mechanical and chemical tests (including relaxation test).

The properties of the strands are controlled during all stages of manufacturing according to a detailled quality control plan.

04

BS 5896 Certificate No. CL12020163

ASTM A Certificate No. CL12020162

The dimensions and properties of the wires are put across in the tables 1 and 2.

Chemical composition (%) :

Surface State :Smooth or intended

Specification of indentation :in 3 faces in conformity with EN10138 - 2 & BS5896

PRESTRESSED STEEL WIRE

07

1. Wire Rod Cleaning & Pre-coating :

All wire rod (raw material) must be de-scaled to remove the mill scale (iron oxides) present on the steel surface. This descaling process can be done chemically or mechanically using shotblasting line.

After the mill scale has been removed, the wire rod is then coated with a textured carrier coating that promotes lubricant adherence during the subsequent wire drawing process. The most commonly used carrier coating is Zinc Phosphate (ZnPO4) but other coatings are sometimes used (borax, lime, etc.).

2- Drawing :

The wire rod is drawn through a series of normally 7 dies but might be up to 9 dies for smaller sizes, to achieve the desired mechanical properties.

This is a cold-working process ; therefore the wire drawing practices are tightly controlled to prevent premature die wear or damage to the steel wire.

In PCWire drawing, the wire rod cross –sectional area is educed up to 85% when comparing the finished wire area to the area of the original wire rod.

The tensile strength of the wire rod is normally ~1.250 - 1.300 MPa. After the wire drawing process, the wire tensile strength is >1.6002.000- MPa; therefore the tensile gain is >50% due to work hardening.

3- Stabilization :

Once wire is produced, it is loaded into pay-off of the treatment line.

The wire is subjected to a thermo-mechanical process in which the wire is continuously heated to ~380ºC +/- 25ºC while under tension at ~40 - 50% of the minimum ultimate tensile strength of the wire. This process acts to relieve the residual wire drawing stresses, permanently elongate the wire, increase the yield strength and reduce relaxation losses. This combination of factors gives the wire a very consistent modulus of elasticity up to and exceeding 80% of the wire’s ultimate strength.

Before the wire is wound back into a coil , it is quenched in a water bath to freeze the steel in the permanently elongated condition and to rinse residual drawing lubricants from the wire surface.

MANUFACTURING PROCESS PRODUCTION RANGE AND TECHNICAL DATA

06

C Mn Si P S

0,70 - 0,50 - 0,30 0,035 0,035

0.85 0,90 Max. Max. Max.

Smooth

intended

Ø a l p

min max tol.

≤ 5 0.06 0.13 ±0.03 3.5 ± 0.5 5.5 ± 0.5

5.5 - 8 0.09 0.16 ±0.04 5.0 ± 0.5 8.0 ± 0.5

mm in. mm mm² in.² g/m lb/1000ft N/mm² Ksi Ksi N/mm² %

BA 4,98 0,196 +/- 0,05 19,50 0,03 152 102,0 1655 240 204,00 1407 4

BA 6,35 0,250 +/- 0,05 31,70 0,049 247 165,5 1725 240 204,00 1407 4

BA 7,01 0,276 +/- 0,05 38,60 0,06 301 202,0 1725 235 199,75 1377 4

WA 4,88 0,192 +/- 0,05 18,70 0,029 146 97,8 1725 250 212,50 1465 4

WA 4,98 0,196 +/- 0,05 19,50 0,03 152 102,0 1725 250 212,50 1465 4

WA 6,35 0,250 +/-0,05 31,70 0,049 247 165,5 1860 240 204,00 1407 4

WA 7,01 0,276 +/-0,05 38,60 0,06 301 202,0 1860 235 199,75 1377 4

No

t sp

ecifi

ed

NominalDiameterType

Diameter Tolerance

Out of round

Steelarea of strand

NominalWeight GradeTensile

Strength

Minimumstress at 1%extension

Min.Elong.

Curvativeof wire

Table 1 : ASTM A421

Max. relaxation loss after 1000 Hrs ≤ 2,5% when initial load at 70% of specified breaking Load

PRESTRESSED STEEL WIRE

INTERNATIONAL EXHIBITIONS AND EVENTS

Presidentiel award of quality - 2010

Interwire- Atlanta 2013

Big Five – Dubai 2012

World of concrete - Las Vegas 2014 Batimat - Casablanca 2012

Wire- Dusseldorf 2014

Table 2 : EN 10138 -2 & BS 5896

mm N/mm² g/m mm² % KN KN KN % of wire

4 1860 98,4 12,60 ± 2 23,40 26,90 20,80 3,5

5 1860 153,1 19,60 ± 2 36,50 42,00 32,50 3,5

6 1770 221 28,30 ± 2 50,10 57,60 44,10 3,5

7 1770 300,7 38,50 ± 2 68,10 78,30 59,90 3,5

8 1670 392,8 50,30 ± 2 84,00 96,60 73,90 3,5

max

25

mm

/ 1

met

er

Tensilestrength

Diameter,d

Mass permeter

Crosssectional

area

Toleranceon mass per

meter

Max.Breaking

load

Min.Breaking

load

Yield strength at0,1% elongation Min. Elong. Curvative

of wire

Max. relaxation loss after 1000 Hrs ≤ 2,5% when initial load at 70% of specified breaking Load.

Type #1 #2 #3

Inner diameter (mm) ~1000 ~1500 ~1800

Outer diameter (mm) ~1450 ~1900 ~2200

Coil weight (Kg) 200 to 500 500 to 1500 1000 to 2500

Conditioning and protection :• Coils : There are 3 types

Nominal Maximum Tolerance Maximum Diameter length on length curvature in Conditioning

7,00 or 8,00 6000 ± 1 8 mm /2 m

in bundle of 1000kg

• Bars : Straightened & cut to length for railway sleepers

Protection :Wrapping by PE plastic film or crepe paper (on request).

08

www.maklada.com

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BirEl Bey-TunisieTel. : +216 79 412 488 / +216 79 412 495

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Venus Steel TradingPO Box 391165 - Dubai

Tel. : +971 (0) 48 808 431Gsm : +971 (0) 505 571 055

Fax : +971 (0) 48 808 432Email : angeles.hidalgo@maklada.com