EMSTEEL’s rebar mill in Abu Dhabi has successfully completed the replacement of its entire twin channel system, originally supplied by Danieli in 2006. Danieli Service executed the full upgrade after a joint assessment in 2021 concluded that all 30 modules should be replaced in a single shutdown.
A twin channel system in a rebar mill is a safety mechanism that guides hot rebars from the shear to the cooling bed. It uses two parallel closed channels to securely contain the bars at high rolling speeds, reducing accident risks.
The project required extremely precise alignment, within 0.5 mm over a 90-meter length, and was carried out under a tightly coordinated 23-day schedule with continuous 24-hour shifts. The old system was dismantled in three days, followed by installation of the new modules in another three. On September 16, 2025, one day ahead of schedule, EMSTEEL rolled its first billet, with full production resuming on September 17.
The work was completed without incidents, reflecting the strong safety culture and close collaboration between EMSTEEL and Danieli Service.
Headquartered in Abu Dhabi, EMSTEEL has a production capacity of 3.5 mln tons of steel and 4.6 mln tons of cement annually. The group exports to over 70 markets, accounting for 30pct of its sales. The company offers a diverse range of steel products, including wire rod, rebar, heavy sections, and sheet piles.
