EXCELLENCE IN
SUSTAINABLE
STEEL PROCESSING

INTRODUCTION

The Melt Shop, located in Johannesburg, is a steel mill specializing in the production of billets. These billets serve as raw material for major metal processors producing bars, rods, and wire. With cutting-edge technology, a skilled workforce, and a strong commitment to environmental and operational excellence.

RECEIVING & PRE-PROCESSING

The production process at The Melt Shop begins with the receipt of scrap metal. We have developed a robust system capable of charging scrap in various forms, such as industrial or production waste, obsolete plant and machinery, and various obsolete scrap metal. Upon arrival, materials are offloaded into designated receiving bays equipped with overhead cranes and heavy equipment, ensuring efficient handling of these materials. These bays are organized to maintain a steady supply for subsequent production stages.

Pre-processing involves an initial inspection to remove non-ferrous contaminants, tramp elements and oversized items, optimizing material flow and preparing the scrap for charging into the melting furnace.

RAW MATERIALS

We utilize scrap steel raw material in our process, sourced from South Africa and neighboring countries. With an established procurement and infeed capacity, we ensure a steady supply of high-quality materials to support our production demands.

SORTING AND PREPARATION

After receipt, the scrap undergoes detailed sorting and preparation to ensure a consistent feed for our furnaces. We utilize a combination of manual and automated techniques to segregate scrap based on grade, size, and composition.

Advanced magnetic separators eliminate residual non-ferrous materials, while trained personnel perform quality checks to meet furnace requirements.

The careful preparation and sorting of scrap enhance melting efficiency, ensuring that our state-of-the art furnaces receive an optimized charge. This process minimizes energy

consumption while maximizing molten metal yield, a crucial step in maintaining high production quality.

 

SMELTING AND CASTING

The heart of our operation lies in smelting and casting, where scrap is converted into billets.

The Melt Shop is equipped with multiple advanced electric furnaces that melt scrap at temperatures exceeding 1,600°C, producing molten steel with precise chemical composition.

These furnaces are paired with ladle metallurgy stations, where alloys are added, and impurities are removed, refining the steel to meet exacting standards. The molten steel is then transferred to our continuous casting system, which operates at a high rate to produce billets without interruption. This caster uses sophisticated mold oscillation and cooling techniques to ensure uniform billet structure and surface quality, adhering to client specifications.

After casting, billets are cut to length, inspected for defects using automated ultrasonic testing, and spectrum analysis and bundled for dispatch – available in bulk or containerised – ready to meet customer needs efficiently.

MAINTENANCE AND CONTINGENCY

Operational reliability is a priority at The Melt Shop. We emphasize regular maintenance of our furnaces,

casters, and auxiliary equipment, using predictive tools like vibration analysis and thermal imaging to anticipate and prevent issues.

Our adoption of energy-saving technologies, such as regenerative burners and variable frequency drives, boosts production efficiency while lowering environmental impact. Recognizing the importance of contingency planning, we maintain backup systems, including power generators and water reservoirs, to address potential power outages or water supply disruptions. These measures ensure uninterrupted production, safeguarding our ability to meet delivery schedules and maintain client confidence.

 
Certifications

Compliance with regulatory and industry standards is essential to our operations. The Melt Shop holds certifications including ISO 14001 (Environmental Management), ISO 45001 (Occupational Health and Safety), and adheres to the OSHAS Act, among others.

These accreditations affirm our commitment to operational excellence, worker safety, and environmental responsibility.

Through regular audits and ongoing improvement efforts, we ensure that we meet and exceed these standards, building trust with clients and stakeholders.

MAINTENANCE AND CONTINGENCY

The Melt Shop represents a modern, scrap-based steel mill, integrating advanced technology, a skilled workforce, and sustainable practices to produce high-quality long billets.

From receiving and sorting scrap to smelting, casting, and delivery, our processes are designed for efficiency, reliability, and excellence.

Our focus on maintenance, contingency planning, and certifications reinforces our dedication to consistent performance.

By transforming scrap metal into valuable billets for bars, rods, and wire, we play a key role in the steel supply chain, delivering products that meet the highest standards while promoting environmental and economic sustainability. We welcome collaboration with partners and clients, confident in our ability to fulfil their requirements with precision and integrity.

 

The Melt Shop

263 Oxford Rd, Illovo
Sandton, Gauteng, South Africa
+27 11 880 6410
info@reclam.co.za