Synergy Steels is Truly Raising Stainless Steel Standards

• May 31, 2024
• By: Yukti Kasera
• NEWS

Steel is one of the world’s most essential materials, isn't it quite evident in terms of the rising construction? It is fundamental to every aspect of our lives, including construction, transportation, machinery and appliances. Definitely, the steel industry plays a vital role in the global economy and significantly impacts employment, trade and infrastructure development. In this article, BMR deliberates about Synergy Steels, India’s leading stainless steel manufacturing company. 

The company specialises in the production of long steel products, including TMT bars, wire rods, and structural steel. Synergy Steels Ltd. uses the latest technology and equipment to ensure consistent quality and high production efficiency. The company's production processes are environmentally friendly, with a focus on minimising waste and reducing emissions. Here are a few answers to questions by Mr. Anubhav Kathuria, Director of Synergy Steels Ltd., discussing about the position of stainless steel rebars in the industry.  

How is stainless steel rebars segment progressing in India?

While the core industry data is lacking, there have been estimates that the demand for SS rebars is expected to go to US$600 million in the coming five years.

Market trends suggest that while the demand for SS rebars has remained rather low in the past, with less than 1.5% of the total stainless steel product market globally, the market is expected to continue to bolster in the coming years, owing to the Indian Government’s thrust towards utilizing stainless steel rebars- particularly in coastal and extreme environmental exposure areas)- for railways, high-elevated bridges, and superstructures/infrastructure projects. Since its standardization in 2017, the rebars segment has exhibited a consistent upward trajectory; marking significant progress as a viable alternative to carbon steel.

Simultaneously, the Government’s significant allocation towards infrastructure in the Interim Budget for FY2024-25 could further expedite the popularity of SS rebars in the near future. With this in mind, the industry is keen on expecting further investments towards large scale infrastructure in the Union Budget post-elections which may bolster the demand for SS rebars.  

What are the key challenges faced by the stainless-steel rebar industry today?

The optimal quality of the SS rebars, owing to their durability and resistance against corrosion and fire make them a rather popular product. While most of the utilization is seen in large-scale infrastructure projects of the Government, the segment is yet to expand to its full potential. There is still considerable headroom for awareness regarding the lifecycle cost among end users. The industry confronts the imperative need for the integration of design software to ensure optimal installation practices. Ongoing efforts towards standardizing codes across different grades of stainless steel are still underway. A significant challenge lies in bridging the gap in construction knowledge among industry professionals.

Lastly, there is a need to increase knowledge dissemination within the industry, with a limited number of players in the rebar sector and few dedicated forums for sharing best practices and fostering collaboration to engage with government and private entities for project opportunities.

What are the products offered by your company when it comes to rebars?

At Synergy Steels, we prioritize continual advancement and the introduction of novel products. Consistent with our commitment to a high-calibre and comprehensive product portfolio, we launched our ‘Stainless Steel Rebars/Reinforcement Bars’ last year (in 2023). They are available in sizes ranging from 8- 20 mm and in the grade AISI 410L. Specialized grades of, 304, 316, and 1.4362 are also available based on customer requirements.

These rebars boast exceptional resistance to both corrosion and fire, making them a prime selection for various construction endeavours. Through the introduction of these rebars, we equip our clientele with dependable, long-lasting, and cost-effective solutions that augment the longevity and fortitude of concrete structures, particularly in coastal environments.

How are different grades of rebar determined, and what influences the choice of grade for construction projects?

The grades of rebars are determined by factors like composition and mechanical properties. The chemical composition (comprising chromium, nickel, and molybdenum) primarily determines the grades of rebars as they influence the strength and corrosion resistivity of the stainless steel.

Currently, there are seven grades of stainless steel in India, distinguished by their corrosive resistance properties. However, the major determinant in selecting the grade for a construction project should revolve around the anticipated lifespan of the structure and its geographical context. Mechanical factors also determine the grades of rebars. The higher the yield strength, tensile strength, and elongation, the higher the grade. 

The choice of grade depends on the application and type of construction project– for projects located in coastal areas, for example, the temperature and humidity of the location, along with the weight/stress on the structure would determine the grade of the rebars to be used.

How does the production and use of rebar align with sustainable practices, and what efforts are made to minimize its environmental impact?

Stainless steel is renowned for its sustainability, particularly owing to its infinite recyclability. Stainless steel rebars stand out as a sustainable choice in construction materials due to several key factors. Their 100% recyclability ensures that they can be reused indefinitely hence, stainless steel rebars are almost completely produced out of recycled material and reduce the need for virgin resource extraction.

Simultaneously, the use of SS rebars not only perfectly aligns with today’s emphasis on sustainable practices, but its production methods have also seen remarkable progress in reducing the environmental impact in the recent years.

On the one hand, construction, real estate, and infrastructure segments are known for being one of the heaviest contributors to increasing carbon footprint. Hence, there are increasing discussions to introduce/utilise cleaner materials for our infrastructure projects, whether that is green cement or green metals. In such a scenario, stainless steel, being one of the most recycled materials on the planet- ahead of even glass, plastic, and paper– and the stainless steel rebars present themselves as promising solutions for enhancing sustainability in infrastructure projects.

On the other hand, efforts including carbon capture Utilization and Storage, as well as leveraging green hydrogen in powering the manufacturing processes are coming ahead as solutions to make the final product even ‘greener’ and minimize their environmental impact.

At Synergy Steels, we are committed to responsible manufacturing practices and have implemented cutting-edge carbon capture technology with top gas recycling technology, which can recycle as much as 90% of the furnace exhaust gas, demonstrably reducing our environmental footprint.

What are some of the challenges or risks associated with improper placement or installation of rebar in concrete?

Just like any other component, precision is a definite factor to ensure the structural integrity of an architecture.

Firstly, proper, accurate placement is vital when installing rebar in concrete to ensure structural integrity. With this in mind, it is pivotal to ensure that the installation at designated locations is devoid of errors with precise installation to avoid impacting structural integrity and in alignment to structural norms.

The second challenge lies in the inadequate provision of concrete cover over the rebars, which is vital for providing a protective layer for the rebars to safeguard them from corrosion and offer fire resistance. Insufficient cover could lead to premature deterioration and, over time, potential structural failure.

Thirdly, while installing rebars, proper spacing and alignment are crucial: insufficient spacing could hamper the overall strength of the structure, while improper alignment may congest the process of concrete pouring and further compromise the strength between the two elements.

Improper placement and inadequate installation of stainless steel in concrete can lead to corrosion and damage. It is important to note that while stainless steel is resistant to staining, it is not completely stain-free. Misplacing electrodes during concrete work can lead to issues. It is vital to utilize proper tools such as stainless wires, and ensure correct placement. Matching grades for couplers is essential to minimize waste and prevent corrosion. Incorrect installation methods can exacerbate corrosion risks. Thus, adhering to proper procedures and employing suitable tools are critical aspects of working with stainless steel.

How is the demand trend for your stainless steel rebars?

Introduced in 2023, our stainless-steel rebars have seen a continuous rise in demand due to their exceptional durability, resistance to corrosion, and environmental benefits. Especially in coastal regions which require anti-corrosive surfaces and materials owing to high humidity. Aligned with the government's focus on infrastructure development, and the consequent growth in construction projects nationwide, we anticipate these rebars to become the desired choice for their superior structural integrity and extended service life.

About the Company

Synergy Steels Ltd. products are used in a wide range of applications, including construction, infrastructure, energy, and manufacturing. The company has a diverse customer base, including major contractors, builders, and manufacturers across India and overseas. Synergy Steels is committed to providing its customers with the best possible products and services and has a dedicated team of professionals to ensure customer satisfaction. The company is also committed to social responsibility and sustainable development. 

The company has implemented various initiatives to improve the lives of local communities, including education, healthcare, and environmental programs. The company also strives to minimise its environmental impact through resource conservation, waste reduction, and pollution control measures. Synergy Steels vision is to be the leading steel manufacturer in India, known for its quality products, reliable service, and commitment to social responsibility. The company's mission is to deliver value to all stakeholders, including customers, employees, shareholders, and the community, through continuous improvement and innovation.

Mr. Kathuria is a dynamic and forward-looking leader who is credited with reshaping Synergy Steels into a contemporary and innovative enterprise. His most significant endeavour involved reshaping the company's conventional mindset and fostering a culture of innovation and technology adoption among its employees. He firmly believes that embracing innovation and technology is imperative for the company's current achievements. Under his guidance, the company has broadened its product portfolio and enhanced production capacity.

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