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Grupo Alfonso Gallardo> Corrugados Getafe > Process

Production Process


For producing carbon steel or low alloy bars in an electric steel mill, the follow operations are followed:

Handling and storage of raw materials:

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The scrap metal is stored in the scrap yard where it is classified into different qualities according to its density and chemical composition. It is then loaded into baskets, mixed with lime which acts as a flux and is taken to the electric furnace.

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The scrap is melted with the electric heat along with natural gas burners with oxygen and carbon injections. The final product is molten steel, which passes on to the next stage.

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Induction Furnace: The molten steel is transported to the Ladle Furnace where, with the addition of ferroalloys and flux, the final composition is adjusted, eliminated the steel’s sulphur to form slag.

The solidifying of molten steel into a semi-product, a "billet", a square steel ingot with different lengths, is all done in the continuous casting process.


Corrugados GetafeContinuous casting: Continuous casting is a process that allows the casting of a series of ladles full of molten steel into lines of billets. The steel is poured in a controlled fashion into a regulating deposit, which is then poured into a hollow copper mould called a ingot mould, square in shape like the billet, is then abruptly cooled in water with the aim of starting solidification.

When the billet is removed from the ingot mould, water is sprayed on its surface to solidify the complete section before flame cutting it to the required length.

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After the first steel process and having created the billet, the process continues with the hot rolling to obtain rebars. Rolling consists of continuously reducing the cross-section of the billet by passing it through various rolling cylinders. The rolling stages are as follows:

Reheating Furnace: Its function is to heat the billet until reaching the rolling temperature. For this they burn natural gas.


Grinding mill: This consists of four horizontal-vertical columns where the square cross sections of the 140 x 140 billets are reduced, slowly becoming rectangular until rounded in the last reduction, with a diameter of approximately 85 mm.

Intermediate mill: These are the reductions made between the grinding and finishing mill. The bar passes through the continuous rolling boxes which continue reducing the cross-section and produces a second cropping of the billet.
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Finishing mill: This is what we call the last reduction. After having passed this, the product has the desired form and cross-section. Here the ribs are carved onto the rebar.
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Thermo-mechanical treatment: With the aim of increasing the ribbed steel’s resistance, the rebar is continuously thermo-mechanically treated. This treatment consists in hardening the bar’s surface upon finishing the last rolling process. For proper thermo-mechanical treatment, the bar’s temperatures, rolling speed, pressure and water pressure are controlled. The result is a product with surface resistance and a ductile core.
Finish and packaging: The finishing and packaging process depends on the way we supply the rebar. If it is supplied in bars, the product is evacuated in a toothed cooling sheet so that it cools uniformly throughout its complete diameter and length. Once cool, it is cut into bars at the established sales length and packaged.
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In this phase is where the final identification package label is placed, showing all of the information including cast number, product, quality, production date, quality certificates and manufacturer.


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