Rebar Factory

 

Apart from trading of Steel products, we have a Rebar Factory to cater to the cut & bend requirements of our Clients as per their specifications.  We have fully automatic production lines from Italy/Europe which are advanced and computerized machineries capable of high rate production and performance of all required shapes according to standards that meet customer’s requirements. Further, for the smooth & efficient execution of manufacturing process, we are backed by a team Engineers, Supervisors, Foremen, Machine Operators & other technical staff who are qualified, well-trained & motivated.

 

1. Cutting Line

 

The fully automated cutting cycles are programmed, stored and controlled by a dedicated industrial computer which can be interfaced with remote PC’s. These Machines are manufactured by the best European manufacturers using the latest technology in Steel Cutting.

Cutting-Line2

 

2. Automatic Bending Machine

 

Mokasco is equipped with the latest bending machines capable of carrying out all forming operations on iron bars for reinforced concrete in fully automatic cycle. The working operation can be performed in automatic, semi-automatic or manually.

Bending-Machine2

 

3. Stirrup Machine

 

Automatic Stirrup Bender, bidirectional, electronically controlled for the Production of small medium sized stirrups, able to produce cut to length bars, as well as bent/shaped bars with bends on one side, up to a length of 12m.  The Straightening technology guarantees maximum flexibility and quality within specific requirements.

Strirup-machine2
 

4. Dextra Mechanical Rebar Splicing System

Mechanical rebar splices are devices used to connect steel bars in reinforced concrete construction. Compared to the conventional method of lap splicing, they not only save steel, but provide a stronger, faster and safer connection.
Bartec®, Griptec® & Repairgrip™ are "bar-break" systems, which means that under tensile loading, the failure occurs in the reinforcing bar, away from the coupler.
Avoiding a failure at the connection means that the ductility and the ultimate performance of the reinforcement as a whole is not affected by the mechanical splices.

5. Schnell Prima 16+3D System

6. Schnell Bar Wiser 28

 

 

1. Bartec®


bartec
 

Bartec®system is the best "pound for pound" mechanical splice on the market, with a guaranteed "bar-break" performance under full tensile load.
Bartec®offers the easiest way of connecting two bars that cannot be rotated thanks to its parallel thread that uses the same coupler for standard splices and position splices with a simple adjustment in the threading length on the reinforcing bar.

2. Griptec®

Griptec® system is the most accomplished mechanical splice on the market : its patented extrusion process includes a systematic, non-destructive tensile test that performs a 100% check on the bar end preparation.
Moreover, the extrusion machine automatically adjusts its processing parameters when switching from one bar size to another, thereby greatly improving the productivity and reducing the risk of human error.

3. Rolltec®

Rolltec® system is a type 2 rolled-thread splice requiring only one single machine and one operator for the bar-end preparation process.
Rolltec® offers the benefit of easily connecting two bars that cannot be rotated , by adjusting the threading length on the reinforcing bar and using the same coupler for standard splices and position splices.

4. Unitec®

Unitec® system is a universal on-site splicing system, that does not need any hydraulic power tool. A standard compressed air supply is sufficient to tighten the bolts and achieve the connection.
It is ideal in situations where there is no bar end preparation facility to thread the bars and where it would be too cumbersome to handle a mobile hydraulic press.

5. Repairgrip™

Repairgrip™ system is an on-site splicing method using a sleeve that is swaged onto the ribs of the reinforcing bar by means of a mobile hydraulic press.
It is ideal in situations where there is no bar end preparation facility to thread the bars.

6. END ANCHORS

End anchors are anchor plates that are fixed at the end of reinforcing bars by the same means as used for the mechanical splices.
They constitute a mechanical anchorage that is a convenient alternative to hooks in congested areas. They also save steel and, by avoiding the bending, they remove the risk of rebar embrittlement, especially on large diameters.
They are available within Bartec®, Griptec® and Rolltec® splice range.

 

 

 

 

 

 

 

 





Steel Supply, Cut and Bend.

For the aim of uniformity in the scheduling, dimension, cutting and bending of steel reinforcement, Mokasco follows the British Standard BS8666 and the American Standard ACI 318 as required.

MOKASCO EXPRESS REBAR FACTORY applies the following Standard Operation Procedures to make sure the quality aspect for our supply of reinforcing steel bars.

   I. Implementing Guidelines

I.I. Receiving the rebar from the Manufacturer


1.1.1.    Upon the receipt of the rebar bundles form the manufacturer, our staff visually inspects the bundles for straight alignment and proper tagging, and ensures that the required manufacturer's delivery notes and mill test certificates are provided and pertained to the same received rebar bundles.

1.1.2.    The rebar bundles will then be unloaded and stocked properly using power lift equipments in our stacking area keeping the bundles straight aligned.

1.1.3    The stocked reinforcing steel shall always be kept totally protected and covered by heavy duty water proof tarpaulin covers.

1.1.4    No tag is allowed to be removed from any bundles in the storage area


1.2 Fabrication of Rebar and Delivery :

Mokasco Express emphasizes the quality and accuracy of cutting and bending operations as vitals factors to the project progress and ensure proper fit on site and perfect matching to the required standards, thus, following quality procedures are followed in the production process.
1.2.1 All fabrication activities are carried out according to BS8666 : 2000 or to the specific project specification if exist. Lengths and shapes shall be as per the customer's approved order and BSS.  1.2.2. Bars are cut to the required length using the very accurate automated shear lines. Cast numbers for opened bundles arc immediately shifted to the cutting list for all cut bars.


1.2.3.    Cut bars are bent using either the automatic bending machines based on the length, shape and size

1.2.4.    Fabricated bars shall be group, bundled and properly tagged.

1.2.5.    Fabricated rebar bundles will eventually be loaded and delivered according to the customer's schedule. They are place on the trailer properly ease the unloading process and to satisfy the secure transport and traffic regulations.


1.3 Traceability:

Mokasco should make a tag every bundle of steel laid down in its yard and to be cross-referenced with the Qatar Steel original received tags. This process will ease the traceability of each single bar from which certificated has been used.

   2.    Loading and Transportation
    The responsibilities of this department are to coordinated with the Production department and customers in respect to the delivery schedule     submitted by the customers and organize the delivery of the processed steel to the site. Mokasco have their own trucks to be used for delivery     and employs rented trucks when needed to make sure the delivery is on time.

   3.    Rebar Site Fixing Service
    Our well experienced and trained steel fixing team that is reliable, communicative and industrious. This team is united, cooperative and working     harmoniously, with Project Managers and others people on the project in order to keep the schedule intact.

 

List of Machinery and Equipment

 

S. No Description Specification Unit(s)
 1.  Cutting Machine  OSCAM Computerized Hydraulic Shear Line T530 with mobile supporting frame  4
 2.  Cutting Machine  SHEAR Type 17000  6
 3.  Double Bending Machine  OSCAM Futura/2M Smart - Robot System 2  2
 4.  Automatic Bending Machine  OSCAM Automatic Bending Machine K1  24
 5.  Stirrup Machine  SCHNELL Computerized Stirrup Machine Prima Plus  3
 6.  Stirrup Machine  SCHNELL Prima 16+3D  2
 7.  Multi-Tasking Machine  SCHNELL Bar Wiser 28  1
 8.  Others  OSCAM Hoop - Spiral Machine  3
 9.  Threading Machine  DEXTRA Bartec Threading Machine  4
 10.  Cranes  Konecranes 10 Ton Double Girder Overhead Crane  9
 11.  Mobile Cranes  Tadano Crane TL300  2
 12  Forklift   CAT Forklift  8

 

 

SOFTWARE

Mokasco has implemented specialized Computer Software ARMAOR which has been developed by “ARIADIS” especially for cut and bend facilities.  This Software is widely used by Rebar Companies in the Middle East Region.  We also have CADS-RC Software for designing, drawing and automatic generation of Bar Bending Schedule which is further exported to ARMAOR.

 

ARMAOR Main Features

  • Bar Bending Schedules is generated according to British or American Standards
  • It optimized production, Off Cuts and Scrap Reduction
  • Prepares Invoices and delivery note.
  • Make cutting tags and loading check list for Production.

Our Engineering Department extensively applies the software for excellent results to serve well our clients;


The following procedures are outlined below.

  • The design drawing is translated to data
  • The Bar Bending Schedule is generated after Data is fed to the system
  • The BBS is submitted to the customer for approval
  • Production optimization should be done; lists and tags are printed out for production, After the approval of the customer.
  • Loading check list is printed out for production to load the processed steel
  • Delivery Note is issued