Overall view of the 1.6Mtpa high-speed rebar mill in operation at Abul Khair Steel, BangladeshAbul Khair Steel Limited (BWRM), a subsidiary of the
Abul Khair Group, has commenced production at its newly commissioned high-capacity rolling mill in Sitakunda, Chattogram, Bangladesh. Built by
SMS group, the facility is engineered to produce 1.6 million tonnes of deformed bars annually, directly addressing the rising demand for premium construction steel in Bangladesh’s rapidly expanding infrastructure sector.
The new rebar mill, supplied entirely by SMS group, has already set a global benchmark for speed. During its initial operational phase, the mill achieved a production speed of 52.5m/sec, later reaching a record-breaking 55.04m/sec while rolling 2 x 10mm deformed bars. The plant is capable of manufacturing deformed bars ranging from 8 to 40mm in diameter.
SMS group delivered the entire rolling mill from a single source, integrating a suite of advanced technologies aimed at maximising efficiency and sustainability. Among these is the SMS ECOFlame+ burner, installed in the re-heating furnace to reduce energy consumption and fossil fuel usage through low NOx emissions. An Elotherm induction furnace is positioned at the entry side of stand 1 to recover billet heat losses after welding, enhancing thermal efficiency.
The mill also features the EBROS endless bar rolling system, which enables uninterrupted billet-to-billet welding. This system has already welded over 10 million billets and has demonstrated a productivity increase of up to 8% over a one-hour production period, along with a 2% improvement in material yield. Operational efficiency has also seen a marked improvement
Operational flexibility and consistency
MEERdrive blocks have been installed to provide high operational flexibility and consistent product quality across all bar sizes. The individual drive technology — one motor per pass — reduces wear and maintenance requirements, typically cutting roll-ring stock by around 60% compared to conventional block systems.
The HSD (High-Speed Delivery) system ensures precise and high-speed delivery of rebar, with over 8 million tonnes produced using HSD drums that require no maintenance. These innovations have enabled Abul Khair Steel to significantly reduce both capital expenditure (CAPEX) and operational expenditure (OPEX), making its production processes more competitive and environmentally responsible.
Bernhard Steenken, CSO, APAC & MEA, SMS group, commented: “This project shows SMS group’s expertise in delivering innovative rolling mill technology that combines speed, efficiency, and sustainability. By achieving record-breaking speeds and ensuring reliable operations, we are helping Abul Khair Steel serve its customers more effectively and contribute to Bangladesh’s infrastructure growth.”