Marcegaglia CasalmaggioreEN_dic2012

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    Casalmaggiore plant

    december 2012

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    we give shape to steel

    Marcegaglia is the leading industrial groupworldwide in the steel processing sector,with a yearly output of 5 million tons.

    After first transformation,within its controlled value chainMarcegaglia develops the worlds widestrange of customer tailored steelsemi-products and finished goods.

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    Marcegaglia stands among the steel marketstop independent players in the world.A worldwide network of partnershipagreements provides reliable supplyof raw materials of all grades to our facilities.

    Steel coil processing is at the coreof Marcegaglia activities.The complete range of first

    transformation processes is carriedout within 50 facilities worldwide.

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    Antwerpen Bremen Dsseldorf

    Munhall

    Garuva

    Dublin

    Dudley

    Lyon

    Barcelona

    Doha

    Cluj

    MoscowPraszka

    Kluczbork

    Yangzhou

    Timioara

    CalcuttaIstanbul

    Lima

    Vladimir

    6,000,000 sqm manufacturingareas

    Casalmaggiore

    Headquarters

    MARCEGAGLIA WORLDWIDE PRESENCE

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    Casalmaggiore plant

    The Marcegaglia manufacturing unitof Casalmaggiore (Cremona, Italy) spreadsover a total surface of 320,000 square meters,of which 162,000 covered,currently employing about 460 employees.

    The plant is mainly dedicated to the processingof carbon steel hot rolled coils for theproduction ofwelded tubes and hollowsections, round, square, rectangularand of special shapes, with thickness rangingfrom 1,35 to 16 mm diameters from 17 to 406,in accordance to current norm requirements

    as well as to custom specifications.

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    Casalmaggiore plant

    The production surface and equipment additionswere completed in 2011 and have allowedthe plant to increase its manufacturing capacityup to over 700,000 tonnes/year.

    New additions include:

    a new slitting lineallowing it to processup to 16 mm thickness coils three new tube production linesadding new dimensional range capacitiesup to 406 mmdiameter and 16 mmthickness a new normalisation furnace a new automatedwarehouse

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    Casalmaggiore plant

    The new area is covered with an integratedphotovoltaic roofingemploying Marcegagliaown produced panels, generating 2.1 MWhpeak power, equal to 2,000,000 kWh/yearelectrical power.

    Other electrical installations increase efficiencywith energy recovery systems, such asa 4-quadrant inverter connectedto overhead cranes.

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    Casalmaggiore plant development

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    Casalmaggiore plantManufacturing areas

    Slitting

    Tube mills

    Heat treatments

    Straightening

    Tube cutting

    Warehouse

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    Main manufacturing standards

    EN 10305-3 Round and shapedprecision tubes

    EN 10305-5 Square and rectangularprecision tubes

    EN 10219 Cold formed weldedstructural tubes(CE homologation)

    EN 10210

    EN 10217-1

    Structural hollow sections,hot finished or cold formedand heat treated

    Tubes for pressure purposes,for use at room temperature

    Upon request: supply of grades not included in the above

    mentioned standards

    EN 10217-2 Tubes for pressure purposes,for use at high temperatures

    EN 10208-1 Steel pipes for pipelinesfor combustible fluids

    EN 10224 Tubes for the conveyance of waterand other aqueous liquids

    EN 10255 Tubes suitablefor welding and threading

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    The production program of Marcegaglia

    tubes from hot rolled strip coversa wide range of structuraland mechanical applications,guaranteeing specific suitabilityfor subsequent processing.

    Tubes for steelstructural work

    Tubes for piling

    Typical applications

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    Some applications:

    building frames (offices, residential, industrial buildings,

    sports venues, halls)

    bridges for pipelines and conveyors

    road and pedestrian bridges stairs, footbridges, railings

    machinery frames

    poles and frameworksfor traffic signs and lightings

    masts for data, tv and radio communication

    agricultural machinery, tractors, earthmovers vehicle cabs, frames, bodies, trailers, hitches

    railway cars

    warehousing

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    Tubes for automotive applications

    With a dedicated productionfor the automotive sector, Marcegagliais the supplier of choice for carmakersand OEM manufacturers of structural parts,components and interior details.

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    Major applications include:axles for vehicles and industrial vehicles,tubes for dump trucks, stabilizersand steering components.

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    Tubes for pressure purposes includeapplications for the heat exchanger industry,heating and ventilation, gas and water linepipes, district heating tubes.

    Tubes for heatexchangers

    Tubes for gasand water line pipes

    Tubes for districtheating

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    Tubes suitable for drawing

    Roller conveyor tubes Tubes for liftingequipment

    Marcegaglia has developed a unique

    know-how in the manufacturingof precision tubes to meet the strictdimensional and surface specificationsrequired by manufacturers in severalmechanical engineering sectors.

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    Marcegaglia Casalmaggiore

    Slitting lines

    lines 5

    manufacturing capacity (t/y) 700,000

    coil thickness (mm) from 1.3 up to 16

    coil width (mm) up to 2,000

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    product type round or shaped

    manufacturing capacity (t/y) 700,000

    wall thickness (mm) from 1.3 up to 16

    diameter (mm) from 16.75 up to 406.4length feasibility (mm) from 5,000 to 16,000

    Marcegaglia Casalmaggiore

    Tube mills

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    Production line

    TC011 (3)

    Welded tubes ex hot rolled strip (blackor pickled), cold rolled strip, coated strip

    ROUNDS

    SQUARES AND RECTANGULARS

    Min. thickness (mm) 1,35

    Max. thickness (mm) 6,6Min. diameter (mm) 21,25

    Max. diameter (mm) 89

    Min. thickness (mm) 1,35

    Max. thickness (mm) 6

    Smallest square (mm) 20x20

    Largest square (mm) 75x75

    and all rectangular derived

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    Production line

    TC011 (3)

    Mill lengths 5.000-14.000 mm

    Length tolerance -0+50 mm on demand -0+25 mm

    Thickness range 1,35 - 6,6 mm

    TECHNICAL FEATURES

    Marking of strips prior to forming

    Weld seam removing

    Online laser gauge to control adherenceto tolerances on 100% of the outside diameter

    Reel mounted stamping

    On demand,cold saw cutoff(no trimming but burr-free ends)

    Internal washing

    Bevel ends

    Dot matrix cast marking(on tubes for pressure applications)This may involve some speed reduction

    Air blowing of trimmings and swarf

    NON DESTRUCTIVE TESTS

    Induced eddy currents online

    Eddy current + magnetic flux leakage(Rotomat) after bevelling

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    Production line

    TC002 (8)

    ROUNDS

    SQUARES AND RECTANGULARS

    Min. thickness (mm) 3

    Max. thickness (mm) 16Min. diameter (mm) 114,3

    Max. diameter (mm) 219,1

    Min. thickness (mm) 3,7

    Max. thickness (mm) 16

    Smallest square (mm) 90x90

    Largest square (mm) 180x180

    and all rectangular derived

    Welded tubes from hot rolled black strips(upon mutual agreement we can possiblyuse pickled and coated strips)

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    Production line

    TC002 (8)

    NON DESTRUCTIVE TESTS

    Induced eddy currents online

    Eddy current + magnetic flux leakage(Rotomat) after bevelling

    TECHNICAL FEATURES

    Marking of strips prior to forming

    Trimming of strip edges before welding

    Weld flash trimming/removal

    Heat treatment (normalisation) of the welding area

    Online laser gauge to control adherence

    to tolerances on 100% of the outside diameterReel mounted stamping

    Online cutting with coated saw blades

    Internal washing

    Deburred ends/bevel ends

    Dot matrix cast marking

    Length feasibility 5.000-16.000 mm

    Length tolerance -0+50 mm on request -0+25 mm

    Thickness feasibility 13 - 16 mm

    * on demand we can offer a