Rebar Production Line and Factory Setup

A rebar production line is a complete industrial system designed to transform steel scrap, sponge iron or billets into finished reinforcing bars under controlled process conditions. The line produces deformed and plain bars ready for construction use.

From an industrial perspective, rebar manufacturing is important because it combines melting, continuous casting of billets, hot rolling through a series of stands, controlled cooling and cutting into a continuous process. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary raw materials typically include steel billets, sponge iron, scrap, alloying elements and packaging materials. The core machinery set consists of melting furnaces, continuous casting machines, hot rolling mills, cooling beds, shears and bundling systems.

The Industrial Department supports investors who want to establish a new rebar plant as well as existing plant owners who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The rebar production line is engineered as an integrated process system covering melting, casting, hot rolling, cooling, cutting and bundling. Design capacity is determined during the engineering phase and can typically range from medium to large industrial throughputs, depending on final product mix and market requirements.

Product types include deformed and plain reinforcing bars of various diameters. The overall process flow follows a defined sequence: melting and casting of billets, reheating, hot rolling through successive stands, controlled cooling, cutting to length and bundling.

Main machinery groups include melting furnaces, continuous casting machines, reheating furnaces, hot rolling stands, cooling beds, shears and bundling equipment. Supporting infrastructure covers electrical power (500–1500 kW range), process gas (2000–5000 m³/h) and water (50–200 m³/day).

Manpower requirements depend on the degree of automation (typically 30–60 persons per shift). Quality control covers chemical composition, yield strength, tensile strength, elongation and surface quality. Finished bars are stored under ambient conditions before distribution.

Technical Specifications

Specification	Description
Product	Reinforcing steel bars (deformed and plain – depending on rolling configuration)
Production Capacity	Depending on project capacity and selected equipment sizing (to be determined during engineering phase)
Required Area	5000–15 000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 500–1500 kW
Gas Consumption	2000–5000 m³/h
Water Consumption	50–200 m³/day
Manpower	30–60 persons per shift
Main Machines	Melting furnace, continuous casting, reheating furnace, hot rolling mill, cooling bed, shear, bundling system
Packaging	Bundles according to selected equipment
Storage	Ambient storage (final design defined in engineering)

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial rebar production line can manufacture deformed and plain bars of various diameters and grades depending on billet chemistry and rolling parameters. Packaging formats (bundles) are selected according to target markets.

Raw Materials for Rebar Factory

Raw material selection and quality control are critical for chemical composition, mechanical properties and process stability. The main materials are steel billets, sponge iron, scrap and alloying elements.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by rebar factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Rebar
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial rebar projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

Melting and Casting – Scrap, sponge iron or other inputs are melted and cast into billets.
Reheating – Billets are reheated to rolling temperature.
Hot Rolling – Billets pass through successive rolling stands to achieve the final bar diameter and deformation pattern.
Cooling – Bars are cooled under controlled conditions on a cooling bed.
Cutting and Bundling – Bars are cut to length and bundled for dispatch.

Machinery & Equipment

Melting Furnace and Continuous Casting – Produce billets of controlled chemistry and size. Position: upstream. Importance: foundation of steel quality. Quality impact: composition and billet soundness affect final properties. Maintenance: refractory, electrodes and mould systems. Sahi Rasa Support: design, manufacturing/procurement, installation, repair, overhaul and spare parts.
Hot Rolling Mill – Reduces billets to final bar size and applies deformation pattern. Position: core of the process. Importance: determines capacity and dimensional accuracy. Quality impact: reduction schedule and temperature control strength and surface quality. Maintenance: stands, rolls, drives and guides. Sahi Rasa Support: design, manufacturing/procurement, installation, repair, overhaul and automation.
Cooling Bed – Cools bars under controlled conditions. Position: after rolling. Quality impact: residual stress and microstructure. Maintenance: transfer mechanisms and drives. Sahi Rasa Support: installation, repair and spare parts.
Shear and Bundling System – Cuts and packages bars. Position: end of line. Quality impact: length accuracy and bundle integrity. Maintenance: blades and strapping systems. Sahi Rasa Support: installation, repair and spare parts.

Factory Layout & Building Requirements

Typical functional areas include raw-material storage, melting and casting, reheating, rolling mill, cooling bed, finishing and bundling, utility rooms, maintenance workshop, staff facilities and loading docks. Layout must respect material flow, heat management and safety. Exact area allocation is determined during the engineering phase according to capacity.

Utilities

Electricity: 380 V three-phase, typically 500–1500 kW
Gas: 2000–5000 m³/h
Water: 50–200 m³/day
Environmental controls according to local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC or PMC approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing rebar plants can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for furnaces, rolling mills, cooling beds and shears.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn parts, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines (rolling stands, furnace capacity), improving finishing rate or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature and speed loops, automatic length control, HMI, data logging and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for rebar projects.

Packaging

Cutting, bundling, labeling, coding and loading are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for rebar projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new rebar factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a rebar production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Rebar

FAQ

What is the typical cost of setting up a rebar plant?
Cost depends on capacity, product range, automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Melting furnace, continuous casting, reheating furnace, hot rolling mill, cooling bed, shear and bundling system.
What production capacity can be designed?
Capacity is determined during the engineering phase according to market demand and investment criteria.
How much space is needed?
Typical process area ranges from approximately 5000 to 15 000 m², subject to final layout.
What are the main raw materials?
Steel billets, sponge iron, scrap and alloying elements.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.