We’re pleased to share a complete high-performance rebar rolling line designed for stable, efficient, and cost-effective steel bar production. With an annual capacity of 100,000 tons, this line is engineered to produce hot-rolled ribbed bars and round bars ranging from Φ8mm to Φ40mm, with the main products focused on Φ8–16mm to meet mainstream market demand. It is built to support manufacturers in expanding production scale, optimizing product structure, and enhancing long-term market competitiveness.
This rolling line follows the design philosophy of advanced, reliable, economical, and practical, with fully reserved space for future capacity expansion and equipment upgrades, without additional initial investment. It balances high automation level, stable production rhythm, low operating cost, and easy maintenance, making it a cost-effective solution for medium-scale steel bar production. Every component and process is carefully selected to ensure consistent performance, long service life, and easy daily operation.
Full Production Process Flow
The production line adopts a mature continuous rolling process with fully coordinated speed and stable rhythm:
Hot billet → Φ520 three-high roughing mill (5 passes) → 1# cropping shear → (Φ365×4 + Φ325×4) intermediate rolling → 2# flying shear (head/tail cutting) → (Φ280×8) finishing rolling → TMT cooling system → 3# flying shear (multi-length cutting) → cooling bed feeding → step rack cooling bed → cold shearing to fixed length → shaping & automatic packing → finished product collection & storage
Core Equipment & Technical Advantages
1. Roughing & Intermediate/Finishing Mills
The line adopts a Φ520 three-high open‑type rolling mill with simple structure, convenient roll change, and stable rolling force. Roll gap adjustment is modular and quick to replace, supporting high precision and low downtime. Roll material is Cr‑Ni infinite cold hardened cast iron, with four‑row cylindrical roller bearings for radial support and four‑point contact ball bearings for axial support, ensuring strong rigidity and long service life.
Intermediate mills (Φ365/Φ325) and finishing mills (Φ280) feature open‑type upper adjustment structure, with hardened gear transmission and carburized grinding process, reaching grade 6 precision, ensuring stable size and high surface quality of finished bars. The mill stands are made of cast steel ZG270‑500, providing high strength and stability under heavy load.
2. High-Speed Flying Shear System
Three sets of flying shears are arranged at key process nodes to achieve accurate head/tail cutting, accident breaking, and fixed‑length cutting. Shearing speed is matched with rolling speed to avoid bending or deformation. Cutting accuracy is controlled within ±20–40mm, supporting adjustable cutting length to meet different customer requirements.
The 2# emergency shear adopts a rotary double‑blade structure with start‑stop working system, ensuring reliable cutting even in high‑temperature conditions above 850℃. The 3# flying shear provides high‑precision multi‑length cutting up to 48 meters, greatly improving logistics efficiency and finished product utilization.
3. TMT Cooling & Cooling Bed System
Equipped with a professional TMT cooling system to optimize metallographic structure and improve mechanical properties. The step‑rack cooling bed (width 8m, length 54m) ensures uniform cooling and straightness of bars, especially for Φ8–16mm small‑size rebar, greatly reducing bending and improving appearance quality. The stepping mechanism ensures stable bar movement without collision or scratch, effectively improving straightness and surface quality.
4. Pinch Roll, Shaping & Automatic Packing
Pinch rolls before and after flying shears ensure stable high‑speed delivery. The shaping device arranges bars neatly, and the automatic packing system completes tension, locking, and cutting in one step, improving packing efficiency and reducing labor intensity. The pneumatic combination strapping machine provides stable and reliable bundling with high tensile force, suitable for various bar diameters and bundle sizes.
5. Lubrication & Motor Control System
Centralized thin‑oil circulation lubrication ensures stable operation of gearboxes and bearings. The main motor adopts DC drive with F‑class insulation, IP44 protection, and air‑water cooling, supporting strong overload capacity and reliable long‑term operation. Precise encoder control ensures speed synchronization and process stability. The lubrication system provides constant temperature, pressure, and flow, effectively reducing wear and extending equipment life.
Raw Material & Product Structure
The production line uses continuous casting billets 120mm×120mm×3000mm as raw material, fully compliant with standard requirements. The product mix covers Φ8, Φ10, Φ12, Φ16, Φ20, Φ25, Φ32, Φ36, Φ40mm, with flexible ratio adjustment according to market demand.
Each specification is produced with stable dimensional accuracy, uniform mechanical properties, and excellent weldability and workability, widely used in construction, bridges, infrastructure, and industrial engineering.
Workshop Layout & Operational Advantages
The main workshop adopts a parallel layout of rolling span, raw material span, and finished product span, with auxiliary areas including roll shop, guide and guard shop, and main power room. This layout optimizes material flow, shortens transportation distance, reduces energy consumption, and improves overall production efficiency.
The rolling line is set at an elevation of +1000mm for convenient operation and maintenance. Water treatment, air compressor station, and other auxiliary facilities are reasonably arranged to support stable and continuous production.
Operational Stability & Long-Term Value
This line is designed with strong durability and low failure rate to ensure long‑term stable operation. All key equipment is equipped with reliable protection and monitoring functions, which can quickly alarm and respond in case of abnormality, reducing unexpected downtime.
At the same time, the line has good compatibility and scalability. It can adapt to different raw material conditions and product requirements through simple adjustment of rolls and process parameters. The reserved installation space also lays a foundation for future intelligent upgrading and capacity expansion.
Application & Market Value
This production line is suitable for producing deformed steel bars and round bars for construction, engineering, and infrastructure. With flexible specification adjustment, it can quickly respond to market changes. The compact workshop layout reduces land occupation and optimizes logistics.
It is an ideal solution for manufacturers aiming to:
- Expand annual output to 100,000‑ton level
- Stabilize product quality and improve qualification rate
- Reduce energy consumption and maintenance cost
- Realize semi‑automatic / automatic production
- Reserve upgrade space for future development
- Improve product competitiveness in domestic and overseas markets
