Forge welding projects

1.Introducing Sazeh Azmoun Foolad Engineering Company – Iran’s Pioneer in Rebar Forge Welding

Sazeh Azmoun Foolad Consulting Engineering Company (STS), established in 2006, is recognized as the founder and leading expert in rebar butt forge welding in Iran.

With nearly two decades of technical and practical experience, STS has earned a solid reputation for providing comprehensive solutions in this field. The company holds international quality certifications such as ISO 9001 and ISO 3834-4, and offers integrated services including:

Project execution
Supply and sales of forging equipment
Operator training (on-site and online)
Technical inspections and quality control

STS operates a fully equipped laboratory for destructive and non-destructive testing (UT, PT, MT, RT, bending, hardness, and impact), supported by a team of qualified engineers. This infrastructure enables STS to deliver complete forge welding services across Iran and meet the highest technical standards.

2.Importance and Technical Advantages of Rebar Forge Welding

Rebar butt forge welding is a solid-state joining process where two metal ends are joined by heating and applying pressure without melting. The process involves heating the rebar ends to 1200–1300°C using an oxyacetylene torch, followed by the application of high hydraulic pressure to create a strong, seamless molecular bond.

Key Advantages:

Preserves mechanical properties of the base metal
Stronger joints than conventional arc welding
Eliminates common arc welding defects (cracks, slag inclusions, etc.)
Fully compliant with:
Iranian national standards (ABA, Chapter 9 of the National Building Code)
International standards such as ISO and JIS

Due to its strength and reliability, this technology is ideal for seismic zones, high-rise buildings, and large infrastructure projects where structural integrity is critical.

3.Project Execution Process

Step 1: Assessment and Planning

Analyze project requirements and environmental conditions
Calculate optimal welding temperature and pressure
Develop WPS/PQR documentation in compliance with forging standards

Step 2: Rebar Preparation

Cold-cut rebar ends using high-precision tools to achieve clean, oxide-free surfaces
Align and fix rebars securely within the forge welding machine clamps

Step 3: Forging Operation

Heat rebar ends to ~1200–1300°C with an oxyacetylene torch
Apply controlled hydraulic pressure for molecular bonding
Monitor and document process parameters (temperature, pressure, duration) for quality assurance

Step 4: Testing and Quality Control

Perform non-destructive tests (UT, MT, PT, VT) at the site
Conduct destructive tests such as bend and tensile testing (as per code requirements)
Issue a Forging Weld Identification Certificate including test results and weld traceability

4.STS Forging Machines and Equipment

In addition to execution services, STS manufactures and supplies portable rebar forge welding machines, designed and engineered for optimal field performance.

Features:

Portable and user-friendly design (no need for three-phase power)
High-performance hydraulic pump and cutter system (Daya brand)
6-month warranty and access to spare parts
Free operator training and 24/7 technical support nationwide
After-sales services including part replacement and maintenance

STS also offers certified training courses (online and in-person) under official licenses from Iran’s Technical & Vocational Training Organization.

5.Track Record of Successful Forge Welding Projects

STS has achieved national recognition for executing large-scale, high-speed forge welding projects in Iran.

Major Accomplishments:

Over 100,000 welds completed in 2014 (Iran Mall Project)
Increased to 200,000 certified welds in the same year
Numerous projects across commercial, industrial, and infrastructure sectors
Full compliance with client specifications and international quality standards

These figures demonstrate STS's capacity and efficiency in delivering high-volume forge welding with consistent quality.

6.Certifications and Compliance

STS is certified and authorized by multiple national and international organizations, ensuring transparency and reliability across all operations.

Certificates and Accreditations:

ISO 9001:2008 – Quality Management
ISO 3834-4:2005 – Welding Quality Requirements
Official approvals from:
Ministry of Industry, Mine and Trade
Engineering System Organizations of Tehran and Isfahan
Member of specialized welding and inspection associations

7.Why Choose STS for Your Rebar Forge Welding Needs?

Here’s what sets STS apart in Iran’s welding industry:

Pioneer in rebar forge welding technology
Fully equipped laboratory with certified inspection personnel
High-quality equipment with full support and spare parts availability
Professional training programs for engineers and operators
Documented quality assurance for every weld
Proven experience with large-scale national infrastructure projects