PROJECT REPORT

Assessment of Environmental Aspects and Impacts of Karachi Steel

Industry, I-10/3, Islamabad

SUBMITTED BY:
 Ayesha Noor (1849-FBAS/BSES/F22)
 Arifa Batool (1851-FBAS/BSES/F22)
 Mahrukh Fatima (1852-FBAS/BSES/F22)
 Kubra Fatima (1866-FBAS/BSES/F22)
 Farah Noor-ul-ain (1883-FBAS/BSES/F22)
 Nabila Bibi (1887-FBAS/BSES/F22)
 Ayesha Tariq (1894-FBAS/BSES/F22)
 Maira Waseem (1898-FBA/BSES/F22)

SUBMITTED TO:
Dr. Sarah Amir (Lecturer)

INTERNATIONAL ISLAMIC UNIVERSITY ISLAMABAD

FACULTY OF BASIC AND APPLIED SCIENCES
DEPARTMENT OF ENVIRONMENTAL SCIENCES

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 CONTENTS
ACKNOWLEDGEMENT………………………………………………………..4
LIST OF ABBREVIATIONS…………………………………………................5
LIST OF FIGURES………………………………………………………………7
LIST OF TABLES………………………………………………………………..8
PROJECT SUMMARY………………………………………………………….9
1. Introduction………………………………………………………………….10
1.1 Description of Industry……………………………………………….10
1.2 Mission Statement…………………………………………………….11
1.3 Core Values…………………………………………………………....11
1.4 Organogram/Organization Hierarchy………………………………11
1.5Quality Management Policy…………………………………..………13
1.6 Products…………………………………………………….…………13
1.7 Clients…………………………………………………….…………...14
1.8 Industrial Operations and Processes……………………….……….14
2. Objectives of the Project…………………………………………………….15
3. Methodology………………………………………………………………….16
3.1 Study Area………………………………………………………….…16
3.2 Study Population……………………………………………….……..16
3.3 Data Collection…………………………………………………….….16
4. Assessment of Environmental Aspects/Impacts………………………….…17
5. Proposed Environmental Policy ………………………………………….....18
6. Proposed Environmental Objectives………………………………………..19
7. Applicable Environmental Legislations…………………………….…….…19
8.Recommendations……………………………………………………………..20
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9.Conclusion…………………………………………………………………..…20
References………………………………………………………………………...21
Annexure I: Photo Gallery……………………………………………….……...22

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 ACKNOWLEDGEMENT

All praise and thanks be to Almighty Allah, whose blessings and guidance enabled us to
successfully complete this project.
We would like to express our heartfelt gratitude to our respected project coordinator, Dr Sarah
Amir, Lecturer of Department of Environmental Sciences, International Islamic
University, Islamabad for assigning us this valuable project and guiding us throughout. Her
efforts in preparing us with the knowledge of what to observe were truly instrumental. This visit
marked our first exposure to an industrial environment and provided us with significant insight
into the production processes, and various other essential aspects of manufacturing.
We sincerely thank the Karachi Steel Industry, I-10/3, Islamabad staff for their cooperation
and sharing their time, which made our visit informative and insightful.
We appreciate the involvement and enthusiasm of all our group members, whose teamwork and
dedication made this visit both educational and enjoyable. Lastly, we are equally grateful to our
parents for their constant support and for allowing us to participate in this educational activity.

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LIST OF ABBREVIATIONS
EMS Environmental Management System
ISO International Organization for Standardization
PSQCA Pakistan Standards and Quality Control Authority
GM General Manager
CEO Chief Executive Officer
HSE (Health, Safety, and Environment) Officer
PWD Public Works Department
C&W Communication and Works Department
CDA Capital Development Authority
NESPAK National Engineering Services Pakistan
PPE Personal Protective Equipment
ISO International Organization for Standardization
IER Initial Environmental Review
GHG Greenhouse Gas
VOCs Volatile Organic Compounds
SOx Sulphur Oxides
CO Carbon Monoxide
NOx Nitrogen Oxides
NEQS National Environmental Quality Standards
EPA Environmental Protection Act
SMART Rules Specific, measurable, Achievable, Relevant, and Time-bound
ASTM American Society for Testing and Materials
BSI British Standard Institution
JIS Japanese Institute of Standards
CGGC China Gezhouba Group Cooperation
FFBL Fauji Fertilizer Bin Qasim Ltd

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MH Military Hospital
CO2 Carbon dioxide
PM Particulate Matter
CH4 Methane
PEPA Pakistan Environmental Protection Agency

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LIST OF FIGURES
Fig 1.1: Process of steel production
Fig 1.2: Main operations and processes at Karachi Steel

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LIST OF TABLES
Table 4.1 Environmental Aspects/Impacts of Karachi Steel Industry

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PROJECT SUMMARY
This project is based on a survey conducted at Karachi Steel Industry, located in Sector I-10/3 of
Islamabad — a designated industrial zone. Established in the mid-1980s, the company supplies
high-quality steel products primarily to the construction sector. The main goal was to study the
industry's operations, organizational structure, products, and environmental practices through
direct observation and data collection.
The objectives of the survey were to assess environmental aspects and impacts, identify risks,
and propose sustainable solutions and an environmental policy tailored to the industry.
The research methodology included field visits, informal interviews with staff and management,
check-list-based assessments, direct observation, photography, and videography. Occupational
safety measures were observed, including the use of PPE, safety signage, and emergency exits,
though improvements are needed.

The proposed environmental policy emphasizes reducing emissions (PM, SOx, NOx, CO),
implementing proper filtration systems, conducting regular health checks, and submitting
environmental reports to the EPA. Recommendations include adopting green technologies,
reducing waste, and setting SMART environmental goals to ensure sustainability and compliance
with regulatory standards. The study concludes that proactive environmental management is
essential to minimize the industry's ecological footprint.

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1. Introduction
The environment is a foundational pillar of sustainability, vital for the long-term well-being
of humanity and the planet. It is governed by a complex framework of laws, regulations, and
policies designed to address critical environmental issues, including pollution, habitat
destruction, and biodiversity conservation. Unfortunately, the environment has often been
overlooked, resulting in escalating ecological challenges. Among the most urgent is climate
change, driven by the unchecked rise of greenhouse gas emissions from industrial activities,
deforestation, and transportation. These emissions have caused widespread disruptions to
ecosystems, highlighting the critical need for stronger environmental stewardship.
Industries, as key contributors to environmental impacts, play a crucial role in driving
change. In response to growing environmental awareness, businesses are increasingly adopting
international standards to mitigate their ecological footprint and promote sustainability. ISO
standards, such as ISO 9001 (Quality Management) and ISO 14001 (Environmental
Management), serve as powerful tools for fostering sustainable practices. These certifications
provide structured frameworks to help organizations optimize processes, reduce waste, and
improve productivity while addressing environmental concerns.
By aligning with ISO standards, businesses not only enhance their operational efficiency but
also build consumer trust and meet regulatory requirements. Embracing ISO standards goes
beyond compliance-it represents a strategic commitment to sustainability. By integrating these
frameworks, industries can actively reduce their environmental impact, contribute to global
efforts in combating climate change, and support biodiversity preservation. More importantly,
adopting such measures strengthens the environment's role as a cornerstone of sustainability,
paving the way for a more resilient and sustainable future for all.
To evaluate the environmental impacts and practices of industries not certified under ISO
14001, we selected Karachi Steel Industry, based in Islamabad. This company is ISO 9001
certified.

1.1 Description of industry

The Karachi Steel is recognized as one of Pakistan’s most reputable business groups in
the steel sector. Established in 1950, just three years after Pakistan’s independence, it was
founded by visionary entrepreneur Mr. M. Muhammad Hussain. What began as a single-unit
steel plant in City Saddar Road, Rawalpindi, has since evolved into a major multi-steel
enterprise.
The company has significantly contributed to Pakistan’s industrial and commercial
development by launching key ventures in important sectors. From the outset, the founder
demonstrated foresight and dedication to advancing the steel industry. Thanks to relentless
efforts, Karachi Steel now produces top-grade structural reinforcement steel bars and continues
to play a vital role in national progress

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 Karachi Steel Industry, located in I-10/3, Islamabad, is certified under ISO 9001:2008. It
is recognized as one of the pioneers in Pakistan’s steel sector for introducing an anti-pollutant
system that reduces smoke emissions to nearly zero, in accordance with NEQS (National
Environmental Quality Standards). Additionally, the industry has installed a coal gasifier plant,
enabling it to produce its own natural gas required for reheating billets.
As one of the most integrated steel manufacturing units in Pakistan, Karachi Steel has the
capacity to produce over 70,000 tons of steel bars annually. Since its inception, the company has
built a solid reputation for maintaining high production levels with consistency and quality.
The organization continues to grow and evolve—pursuing new goals and directions—
while staying true to its original mission. Karachi Steel remains committed to expansion,
innovation, and excellence in steel production.

1.2 Mission:
We have established our presence in the steel industry by providing superior quality products and
reliable services, catering to the customers’ needs, at the best prices; transforming values, and
close partnerships. We plan to carry on that vision throughout the decades. We take pride in
providing an environment that heightens teamwork and leadership capabilities to manage our
company, following the highest standards of business ethics.

1.3 Core Values:

The Karachi Steel Industry is committed to environmental responsibility and quality assurance
through cleaner technologies and ISO-certified production. It prioritizes innovation and
sustainability, investing in methods like in-house gas production and pollution reduction. It
operates with integrity and accountability, ensuring transparency and responsible practices.

1.4 0rganogram/Organization Hierarchy:

Organizational Hierarchy:
Karachi Steel has established a clear reporting structure to ensure effective communication and
accountability within the organization. The following hierarchy outlines the defined roles and
responsibilities for managing environmental aspects and compliance across various operational
levels.

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 Finance Manager (1)

Quality Control Officer(1)

Administrative
Division (4)
Quality Assurance Officer (1)

Marketing Manager(1)

Electrical (3)
Middle
Management
Mechanical (3)
(20)
Furnace
Unit (8) Gasifier
Plant Safety
Officer (1)
Gasifier
Plant (2)
Gasifier Plant
Technical Supervisor
(1)
Top Division
Management (16)
Mechanical (3)
CEO (1) Rolling
Unit (6) Electrical (3)

Continual Casting Suprvisor (1)

Security Casting
Mold Maintenance
Services (3) Plant (2)
Technician (1)
Logistics Operator (1)
Logistics and
Low
Transport (2)
Management Driver (1)
(10)
Catering
Kitchen (2)
Services (2)

Sweepers(2), Waste
Sanitation (3)
Disposal Officer (1)

Figure 1: Hierarchy of Karachi Steel Mills

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1.5 Quality Management Policy:
Karachi Steel will strive to be a leading name in the manufacturing of all kinds of MS Bars
(Deformed Bars G-40/G-60) for use in various projects by national and international
organizations. We will ensure 100% product quality, all with the help of our dedicated trained
workforce, keeping our clients' interest and conducting business competitively and effectively.
The policy and objectives are communicated and understood within the company and are also
liable to be reviewed through management review and customer feedback for continual
improvement_Chief Executive, Karachi Steel.

1.6 Products:
Karachi Steel Industry offers a comprehensive range of flat and long steel products, ensuring
they can cater to customers' requirements wherever they may be. Their commitment lies in
providing top-quality structural reinforcement steel bars, accredited to meet international
standards.
The main products manufactured by Karachi Steel Industry include:
 Deformed Bars Grade- 40 & 60 10mm to 36mm
ASTM A615/A615M Grade 40 & 60
(American Standards Testing & Materials)
• BS1 4449 Grade 250 & 460
(British Standards Institute)
• ASTHOM31
JIS 311235/40
(Japanese Industrial Standards)
 Mild Steel Rods
 Iron Billets
 Hot Rolled Steel Products
 Structural Steel (I-beams, channels, angles)
These products are primarily used in the construction sector and industrial manufacturing.

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1.7 Clients
Karachi Steel sources its raw materials, including iron ore, from international suppliers in South
Africa, the U.K., and Dubai. These materials are then used in its production processes, which
supply both domestic and international markets. Karachi Steel serves a wide range of clients,
particularly in the construction sector, by providing high-quality steel products for major
infrastructure projects.
Some notable projects include:
• Pak-China Friendship Centre in Shakkar Parian, Islamabad, contracted by Shanghai
Construction.
• King Abdullah University in ChattarKalas, Muzaffarabad, contracted by SAMBU.
• Hydro Power Project in Neelum Jhelum, contracted by CGGC.
• Fauji Fertilizer Bin Qasim Ltd. (FFBL) in DHA Phase II, Rawalpindi, contracted by Izhar
Constructions (Pvt) Ltd.

In addition to supplying steel, Karachi Steel also exports iron oxide powder, a byproduct
from its smoke-free filter technology. This powder, formed through advanced filtration
processes, is purchased by China at a cost of 230 per kg for various industrial applications,
including in the production of pigments and other chemicals. This partnership highlights Karachi
Steel's global reach and its contribution to both the domestic and international markets.

1.8 Industrial Operations and Processes:

The steel production process begins in the furnace section, where crude steel or semifinished
products such as billets are produced. These billets are then transferred to the rolling section,
where they undergo further processing to be transformed into their final form, typically steel
bars. The furnace section involves melting raw materials, primarily iron ore, with additives such
as scrap steel and coke. Once the billets are formed, they are heated and passed through a series
of rollers in the rolling section, shaping them into the desired dimensions and forms, ready for
use in various industrial applications.
The industrial process for steel production at Karachi Steel includes the following stages:

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 Raw Material
Smelting/Refining Primary Steel
Collection (Iron ore,
(Blast Furnace or Making (Refining
coal, limstone,
Electric Arc molten iron or
recycled steel
Furnace) scrap steel)
scrap)

Continual Casting Secondary Steel

Rolling (Hot rolling
(Moldig into se,i- Making (Adjusting
or cold rolling)
finished form) composition)

Final Steel Products

Finished (Cutting,
(Bars, sheets,
surface treatment)
plates,etc)

Figure 2: Process of Steel Production

2. Objectives of the Project

The main objectives of this project are as follows:
 To examine the industrial operations and processes being carried out in the Karachi
Steel Mills.
 To evaluate the environmental impact of steel mills by assessing air quality, water
pollution, soil contamination, and waste management practices to determine the facility
overall ecological footprint.
 To examine the emissions produced during steel manufacturing and evaluate the
measures in place to control pollutants such as dust, gases, and particulate matter,
ensuring compliance with air quality standards.
 To identify methods for reducing the carbon footprint of steel production, exploring
innovative technologies and practices that minimize greenhouse gas emissions and work
toward carbon neutrality.
 To assess the noise pollution generated by steel mill operations, investigating the sources
and impact on local communities and exploring strategies to reduce noise levels.
 To explore opportunities for improving circular economic practices in steel production,
such as the reuse of materials, recycling of steel scrap, and reducing waste generation
throughout the production process.

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  To analyze energy and water consumption efficiency within the steel production process,
identifying opportunities to optimize resource utilization and reduce environmental
impacts.

3. Methodology:
The methodology for this research includes:
Field Visit: A direct visit to the industry for on-site observation.
Interviews: Informal interviews with staff and managers to understand operations and
environmental management.
Checklist Assessment: Use of a pre-designed checklist to observe pollution control equipment,
emissions, waste disposal, and safety measures.
Photography & Notes: Documentation through photographs and field notes.

3.1 Study Area:

The Karachi Steel Industry is located in Sector I-10/3, an industrial zone of Islamabad.
The area is designated for manufacturing industries and includes other steel, plastic, and
chemical factories. It is in proximity to residential sectors and experiences significant vehicle and
industrial traffic.

3.2 Study Population:

A total of 6 people were interviewed by the Karachi Steel industry.
Top management (CEO) pf the industry.
Two people were interviewed by middle management related to the administrative department.
Two people were interviewed by middle management related to the technical department.
One from lower management of the industry.

3.3 Data Collection:

Data was collected using:
Direct Observation: Assessing emissions, noise levels, storage of raw materials, and
cleanliness.

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Interviews: Verbal information from industry staff about operations, waste management, and
compliance with environmental laws.
Secondary Data: Reviewing any available records, permits, or environmental reports provided
by the industry.
Checklists: Covering air quality control, water use, wastewater disposal, noise control, and
worker safety.

4. Assessment of Environmental Aspects/Impacts of Steel Industry

Table 4.1 Environmental Aspects/Impacts of Karachi Steel Industry

Sr. Products, Activities and Environmental

Environmental Impacts
No Services Aspects

Dust generation, noise, Air pollution, noise pollution,

1 Scrap Collection and Sorting
metal particles soil contamination

Open stockpiles, runoff,

2 Scrap Storage Soil and water contamination
rusting

Energy consumption, Air pollution, GHG emissions,

3 Melting in Furnaces
emissions, slag solid waste

Thermal pollution, air quality

4 Ladle Handling and Pouring Heat radiation, emissions
degradation

Noise, vibration, high Noise pollution, energy resource

5 Rolling Mill Operation
energy usage depletion

Water consumption, steam Water resource strain, thermal

6 Steel Cooling Process
release water pollution

Dust, metal shavings, Air contamination, waste

7 Cutting and Shaping of Steel
energy use generation

Oil/fuel use, lubricant Soil/water pollution, noise

8 Heavy Machinery Operation
leakage, noise disturbance

9 Welding and Fabrication Fume generation, Indoor air quality issues, high

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Sr. Products, Activities and Environmental
Environmental Impacts
No Services Aspects

electricity use energy use

VOC emissions, chemical

10 Paint/Coating Application Air toxicity, worker health risks
use

Product Transportation Diesel use, emissions, road Air pollution, traffic congestion,
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(internal/external) wear carbon emissions

No use of PPEs like

Health and Safety Risk of injury, Burns, cuts,
12 (Safety glasses, Gloves,
Management punctures etc
safety shoes Jackets)

Installation of smoke free

13 Waste Management Prevention of air pollution
plant

Leak potential, improper Soil/water contamination, fire

14 Hazardous Material Storage
labeling hazards

Emergency Situations Reduce number of accidents and

15 Emergency kits, first Aid
(Fire/Spill/Explosion) injuries

5. Proposed Environmental Policy:

6. Proposed Environmental Objectives:

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The proposed environmental objectives are as follows,

 Reduce emissions of particulate matter, sulfur dioxide (SO₂), nitrogen oxides (NOx), and
carbon monoxide (CO) through proper filtration (e.g., bag filters, electrostatic
precipitators).
 Reduce water consumption through recycling and efficient use.
 Treat industrial wastewater before discharge to meet NEQS (National Environmental
Quality Standards).
 Prevent contamination of surface and groundwater sources.
 Reduce and manage slag and dust by-products through reuse or safe disposal.
 Promote recycling of scrap metal within operations.
 Properly dispose of hazardous waste materials such as oils, chemicals, or spent
refractory.
 Optimize energy consumption through modern, energy-efficient equipment and practices.
 Explore use of renewable energy sources where feasible.
 Implement noise control measures to ensure sound levels remain within acceptable limits,
especially for neighboring communities.
 Provide a safe working environment to minimize health risks from dust, fumes, and
noise.
 Use PPE (personal protective equipment) and regular health monitoring.
 Regularly submit environmental monitoring reports to the Environmental Protection
Agency (EPA).
 Increase awareness and training on environmental responsibility among employees and
contractors.

7. Applicable Environmental Legislations

The following are the applicable environmental legislations,
 The Factories Act, 1934
 Environmental Protection Act, 1997(EPA)
 Hazardous Waste (Management Handling and Trans-boundary Movement), 2008
 Hazardous Substances Rules, 2014
 NEQS for ambient air, drinking water and noise, 2010
 Environmental Sample Rules, 2014

8. Recommendations
The following are the recommendations given to the management of the industry:

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  Adopt environmentally friendly practices to reduce waste, conserve resources, and
minimize environmental impact.
 Invest in technologies that reduce environmental impact, such as renewable energy
systems and pollution control equipment.
 Establish a systematic approach to managing environmental impacts, including setting
goals, monitoring performance, and reporting progress.
 Conduct regular audits to identify areas for improvement, ensure compliance with
regulations, and assess the effectiveness of environmental management systems.
 Provide training to employees on environmental best practices, sustainability principles,
and the importance of environmental stewardship.
 Engage with stakeholders, including local communities, customers, and suppliers, to raise
awareness about environmental initiatives and promote sustainability.
 Set specific, measurable, achievable, relevant, and time-bound (SMART) goals and
targets for reducing environmental impact and improving sustainability performance.
 Implement programs to reduce waste generation, increase recycling rates, and promote
sustainable waste management practices.

9. Conclusion:
The Karachi Steel Industry located in Sector I-9, Islamabad, plays a significant role in supporting
Pakistan’s construction and infrastructure development through the production of steel products.
However, like many industrial operations, it presents notable environmental challenges that must
be addressed to ensure sustainable development. This report has highlighted the key
environmental impacts associated with the industry's operations, including air emissions, water
usage, solid waste generation, and noise pollution. In response, the industry has proposed a series
of environmental objectives aimed at reducing its ecological footprint. These include the
adoption of cleaner production techniques, efficient waste management practices, compliance
with national environmental regulations, and improvements in energy and water efficiency.
Continued efforts to implement and monitor these environmental objectives are crucial. By
integrating environmental considerations into its operational and decision-making processes, the
Karachi Steel Industry can enhance its environmental performance, ensure regulatory
compliance, and contribute to a healthier environment for surrounding communities. Sustainable
industrial growth is possible, and with commitment and collaboration between industry
stakeholders, regulatory bodies, and the community, the Karachi Steel Industry can serve as a
model for environmentally responsible manufacturing in Pakistan.

References:
https://www.karachisteel.com
https://www.epa.gov

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https://environment.gov.pk
https://www.epa.gov/laws-regulations
https://worldsteel.org

ANNEXURE 1-PHOTO GALLERY

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 Fig1. Karachi Steel Industry

Fig 2. Quality Policy

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Fig 3. Smoke Treatment Plant

Fig 4. Raw material (Scrap)

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Fig 5. Melting Area

Fig 6. CC Plant

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Fig 7. Electric Panel Room

Fig 8. Electric motors

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 Fig 9. Control room

Fig 10. Final Product (Structural Iron)

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 Fig 11. Material Handling Machine

Fig 12. Furnace Control Panels

Fig 13. Cooling bed

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 Fig 14. Scale

Fig 15. Operations room

Fig 16. Cylindrical Metal Samples

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Fig 17. Computer Numerical Control Machine

Fig 18. Certificates

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Fig 19. Tensile Testing Machine

Fig 20. Weighing Machine

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Group Visit

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