Manufacturing
World-Class Facility
ADVANCED MANUFACTURING TECHNOLOGY FOR SUPERIOR QUALITY
Our leadership team brings together decades of experience in steel manufacturing, quality management, and business development — driving Gajkesari Steel towards greater heights every day.
Step by Step
MANUFACTURING PROCESS
Procurement of Raw Material
Iron Ore being the primary raw material, is procured from various parts of the country. We use only the highest grade iron ore and scrap metal, inspected rigorously for chemical composition and quality before entering production.
Steel Melting Shop Facility
At our SMS facility, we melt the raw material at 1600°C, and transform it into molten metal. Our state-of-the-art electric arc furnaces ensure consistent quality and precise control over the steel composition.
Steel Melting Shop Facility
At our SMS facility, we melt the raw material at 1600°C, and transform it into molten metal. Our state-of-the-art electric arc furnaces ensure consistent quality and precise control over the steel composition.
Spectrometer Testing
We then check the chemical composition of the molten metal. As per IS 1786 standards, we predominantly check for Carbon, Sulphur, Phosphorous & Manganese and other chemical elements to ensure optimal steel grades.
Re-Rolling Mill
The molten metal passes through various stands in the re-rolling mill to achieve desired sizes ranging from 8 to 40mm. Our precision rolling mills ensure exact dimensional tolerances and surface quality.
Re-Rolling Mill
The molten metal passes through various stands in the re-rolling mill to achieve desired sizes ranging from 8 to 40mm. Our precision rolling mills ensure exact dimensional tolerances and surface quality.
Thermax Process
For the quenching process, we utilize German-approved Thermex technology. This is done to maintain a soft inner core and a hardened exterior for better physical properties — giving superior earthquake resistance and weldability.
UTM Material Testing
At the Universal Testing Machine, we check the physical properties of TMT bars before dispatching them. These properties include grade, yield, ductility, and elongation to ensure every bar meets IS 1786:2008 standards.
UTM Material Testing
At the Universal Testing Machine, we check the physical properties of TMT bars before dispatching them. These properties include grade, yield, ductility, and elongation to ensure every bar meets IS 1786:2008 standards.
Our Commitment
QUALITY TESTING
Chemical Composition Analysis
Ensuring the correct composition of Carbon, Manganese, Sulfur, Phosphorous to meet IS standards.
Mechanical Testing
Tensile strength, yield strength testing and elongation testing to measure bar capacity.
Dimensional Inspection
Checking diameter, length, and straightness to ensure compliance with specified tolerances.
Bendability & Rebendability
Evaluating the ability to bend without breaking and return to original shape after bending.
Ultrasonic Testing (UT)
Detecting internal defects such as cracks, voids, or inclusions using ultrasonic waves.
Magnetic Particle Inspection
Identifying surface and near-surface defects like cracks or laps using magnetic field inspection.
Corrosion Resistance Testing
Assessing the resistance of TMT bars to corrosion through accelerated corrosion tests.
Macroscopic Examination
Visual inspection of the TMT bars for any surface irregularities or imperfections.
QUALITY ASSURANCE PLAN
- Raw Material Inspection
- Production Process Control
- Heat Treatment Control
- Dimensional Inspection
- Certifications & Compliance
- Traceability and Documentation
- Customer Feedback & Continuous Improvement
Quenching & Self-Tempering (TMT) Process
At Gajkesari Steels and Alloys Pvt. Ltd., we utilize the advanced Thermex TMT process to manufacture high-performance rebars with superior strength and durability. This process involves two critical phases of cooling that create a unique microstructure within the steel bar. As the bar exits the final rolling mill stand, it undergoes rapid quenching in the Thermex water cooling system, which hardens the outer surface while retaining a hot core. The core then cools gradually under controlled atmospheric conditions, forming a fine ferrite-pearlite structure, while the outer layer develops a tempered martensite structure. This combination results in TMT bars with excellent strength, flexibility, bendability, and elongation, ensuring long-lasting performance in construction applications.
Setting Industry Standards Through Advanced Technology
With the growing demand for high-performance construction materials, TMT rebars have become the preferred choice in the industry. At Gajkesari, we manufacture premium-grade TMT bars such as Fe 500 and Fe 550D, offering superior elongation, enhanced ductility, and improved strength compared to conventional steel grades. Our advanced manufacturing technology ensures that our products meet stringent national and international standards, making them ideal for modern infrastructure and high-rise construction. By combining cutting-edge processes with strict quality control, Gajkesari continues to deliver reliable, high-quality steel solutions trusted by engineers and structural designers.