Long Product Hot Rolling Mills Services & Products

www.steelws.com

Long Product HotRolling MillsServices & Products

Bar & Rebar Mill

Wire Rod Mill

Small Section & Profile Mill

SteelWorldwideServices Ltd

Supply ofNew EquipmentWe are able to design, manufacture and supply the following new equipment for:

Pinch Rolls.

Cropping Shears (flying, crank, fly & crank combination).

2 Hi Rolling Stands (housingless, cantilever & convertible).

3 Hi Reversible Rolling Stands.

Pendulum Shears, Cold Cutting Shears & Cooling Bed Services.

Bar Counter, Tying & Bundling Machineries.

Laying Head for Coil Formation.

Coil Cooling Systems & Related Machineries.

Coil Compactor (Vertical & Horizontal).

Straighteners, Profile Stacking Machines.

Workshop Equipment (Robot Changing Device, Cartridge Tilting, etc)

Billet Handling & Reheating FurnacesBillet Reheating (pusher, walking hearth & walking beam furnaces) has focused mainly on maintaining the quality of the billets while reducing the operational cost, mainly on energy consumption.

Our Engineering Services & Supply of Parts covers:

Complete New Supply of Furnace

Changing from Pusher to Walking Hearth/ Beam Furnaces

Converting Fuel Oil to Natural Gas as energy supply

Better Efficiency Burners for optimized energy consumption

Increasing Productivity (t/h)

Revamping of Automation & Control Systems.

Engineering &Design ServicesOur Long Product Rolling Mill Division comprises experts who has more than 40 years of experience in design, manufacturing, & installation of various types of long product rolling mills.

Our Engineering & Design Services cover:

Roll Pass Design, Rolling Machinery Configuration & Product Development.

Re-layout for Existing Mills for product mix change & new equipment.

Overall Mill Productivity Improvement Feasibility Study.

Turnkey Engineering for Complete New Mill, inclusive of Civil, Auxiliary Plants, Workshops, etc.

Increasing the size of Roughing Mills for bigger & heavier billets.

Reconfiguration of Finishing Area for the mill for improved productivity.

Used/2nd Hand RefurbishedMill/EquipmentDue to our long presence in the long product market, our company has wide sourcing capability for Used/2nd Hand Refurbished complete mill or individual equipment.

Our Engineering & Design Services cover:

Reconfiguration of the mill to meet the new owner requirements.

Reconditioning & Refurbishing Services.

Dismantling & Reinstallation at new site.

Replacing New Structural & Fabrication parts.

Complete Engineering Services for piping, wiring and other basic requirements for the newly refurbished mill.

Erection & Commissioning of the newly refurbished mill or equipment.

Advanced Water Quenching Line(AQL) SystemsAQL Systems has been designed and engineered by our Long Product Rolling Division to provide customers to improve drastically the mechanical (esp. yield strength), using very poor chemical analysis in the billets.

Our Engineering Services & Supply ofParts covers:

Complete New Engineering & Metallurgical Process Design for AQL system for current production sizes.

Supply of Cooling Elements, i.e. Strippers, Coolers & Dryers.

Water Pumping Station Supply & Configuration for Optimum Water Consumption.

Detail Engineering & Local Fabrication Services for Structural Parts.

Spare Parts & ConsumablesOur Spare Parts Department, with the collaboration of Our Long Product Rolling Division is able to provide various typesof spare parts for long product hotrolling mills.

Rolls for Rolling MillsIn co-operation with our Rolls Manufacturing Partners, we are able to supply to long product rolling mills the following grades of rolls:

Cast Steel Adamite (steel base) Cast Iron

Alloy Cast Steel Rolls Adamite Rolls

70Mn2 Rolls

SGP Rolls

SGA Rolls

Indefinite ChilledRolls

TYPES

SGP : Spheroidal Graphite PearliteSGA : Spheroidal Graphite Acicular

Diameter available:Ø 200mm - Ø 1300mm

Centrifugal Casting

On-Site Customer Technical AssistanceAs a fundamental founding principals of our company, S.W.S. obtained its customers confidence through providing on-site technical assistance that solves operational and maintenance issues for the plant.

Our area of services cover:

Mechanical technicians for emergency repair and intervention on-site.

On-site Maintenance or Maintenance Supervision for critical equipment.

Erection of New Equipment.

Commissioning of New Equipment or Reconditioned Components.

On-site Training for operators & supervisors.

On-Site Feasibility Study for productivity improvement & revamping purposes.

SWS Guiding Equipment & SystemsSWS has designed, engineered & manufactured one of the world’s best guiding equipment for long products. Our expertise has stretched more than 40 years in design and engineering the guiding equipment & systems.

TYPES

Static Guides Entry Roller Guides

Slitting Guides Profile Guides Wire Rod Block

Guides Exit Twisting

Guides

Rolls forGuides

Two-Roller Roller Guides Model: ER

Four-Roller Roller Guides Model: 4EPR

Torsion Roller Guides Model: ETR

Slitting/Cutting Guides Model: 2CUT & 4CUT

Three-Roller Roller Guides Model: 3EPR

Our Guides are designed for being:Stout, Compact& Practical

Rolling MillsGuiding SystemFor Long ProductsHot Rolling MillsA Unique & Complete Solutionfor Rolling Mill GuidingRequirements.

SteelWorldwideServices Ltd

SWS Roller GuidesTechnological Features

The guides are designed to be COMPACT & LIGHT, yet ROBUST for practical application in the mill; certain ranges of guides can be hand carried or maneuvered;

All guides on line adjustments, from Roughing to Finishing Mill, are made with only a 24mm wrench;

Single Operation for Roll Symmetric opening & closing;

No External Hoses for Oil, Grease and Water which are vulnerable during cobble in the rolling mill thus reducing delays in plant downtime; all hoses are fitted with quick coupling for faster connection & disconnection;

Special Heat Treated Guide Rolls that can last 3 times longer without having to regroove the rolls (hardness of HRC 65) thus reducing servicing of the rolls;

Common sizes of consumables and spare parts for certain ranges of guides;

Guiding System Optimization for the Roll Pass, thus, reducing types of guides to be used;

Key Designers have more than 40 years of design, manufacture and on-site application experience solely on guiding system for long product rolling mill;

Small guides have a support, rather than a base, enabling for the quick substitution of the guides.

SWS Guiding Systems & Equipment

TYPES

Static Guides Entry Roller Guides

Slitting Guides Profile Guides Wire Rod Block

Guides Exit Twisting

Guides

Rolls for Guides

Two-Roller Roller Guides Model: ER

Four-Roller Roller Guides Model: 4EPR

Torsion Roller Guides Model: ETR

Slitting/Cutting Guides Model: 2CUT & 4CUT

Three-Roller Roller Guides Model: 3EPR

Our Guides are designed for being:Stout, Compact& Practical

entRy and exit statiC guides

eRB01-eRB03eR01- eR064eR01-4eR04eRF05-eRF06

2Cut01-2Cut024Cut01

3ePR01-3ePR054ePR01-4ePR02

etR01-etR06

Technical Description: There are 6 sizes in the ER Series (ER01-ER06), covering all ranges of products and sizes for long products rolling mills (flat, round, and square);

ER01, ER02, ER03 - light but robust - they are able to be hand maneuvered which allows for quick on line replacement in the intermediate and finishing mill;

The Guides can be set manually or through an optical bench;

Water Cooling Consumption : 25 – 90 l/min with 3 – 5 bar pressure (depending on the sizes of the guides);

Grease Lubrication: 2 x 5.5 cm2 every 2 working hours.

ER SeriesTwo Roller Guides

Size of Products:To cover the indicated range of rounds, squares and flats, we have developed six guide sizes. The diagrams below clearly show the applicable range for each guide size.

Guides size 01, 02 and 03 have been designed to be hand manoeuvrable in order to permit particularly quick on line replacements.

Technical Description: There are 3 sizes in the ERB Series (ERB01 - ERB03) They are normally used in the fast finishing blocks; The Guides can be set through an optical bench.

ERB SeriesWire Rod Block Guides

TYPE A B C Dmax H Imax Imin U L

ERB-01 167 35 99 56 20 65 47 49 110

ERB-02 167 35 99 58 25 65 47 49 110

ERB-03 167 35 99 58 29.5 65 47 49 110

Size of Products:

Dimensions:

Dimensions:

Technical Description: There are 4 sizes in the 4ER Series (4ER01-4ER04), covering all ranges of products and sizes for long products rolling mills (rounds and squares);

Light but robust – they are able to be hand maneuvered which allows for quick on line replacement in the intermediate and finishing mill;

They are used for quality products as they have a better guide with respect to the two roller guide.

4ER SeriesFour Roller Guides

TYPE A B C Dmax H Imax Imin U L

4ER-01 210 75 150 60 25 65 47 75 148

4ER-02 225 85 165 70 35 78 56 80 180

4ER-03 255 110 205 85 55 108 70 100 230

4ER-04 305 140 245 108 80 125 90 115 280

4ER02.1 225 85 165 70 35 103 81 80 205

4ER02.2 225 85 165 70 35 128 106 80 230

Size of Products:Dimensions:

ER SeriesTwo Roller Guides

TYPE A B C Dmax H Imax Imin U L

ER-01 167 31 110 60 25 65 47 46 115

ER-02 190 38 133 70 35 78 56 60 127

ER-03 220 48 177 85 55 108 70 80 170

ER-04 267 57 208 108 80 125 90 95 205

ER-05 325 75 278 140 120 170 120 130 280

ER-06 380 100 350 180 170 225 170 165 365

Technical Description: There are 2 sizes of the 2CUT Series (2CUT01 & 2CUT02), able to make 2 and 3 strands slitting;

The 4CUT type is used for 4 strands slitting;

The slitting process reduces the number of rolling stands as well as reduction of operating cost;

A good, robust & precise guiding system is important to ensure equal & balance strands;

Water Cooling Consumption: 60 - 100 l/min with 3 - 5 bar pressure (depending on the sizes of the guides).

2CUT & 4CUTSeriesCutting Guides

Size of Products:Designed to carry out online splitting of the bar in two, three or four strands. The cutting guide design allows for fast roll change and fast clearance of eventual cobbles.

Technical Description: There are 2 sizes in the ERF Series (ERF05 - ERF06);

They are used in the roughing mill;

The Guides can be set manually.

ERF SeriesFixed Roller Guides

TYPE A B C D MAX H U

ERF-05 445 52.5 305 122 120 152.5

ERF-06 445 52.5 355 142 170 177.5

Dimensions:

Technical Description: There are 5 sizes in the 3EPR Series (3EPR01- 3EPR05), covering all the ranges of angles and profiles (equal angle, sharp corned angle, unequal angle, and channel);

Height adjustment of the bottom rollers is possible, for the correct setting against pass line;

Single point top roller adjustment is also possible;

Water Cooling Consumption: 60 - 100 l/ min with 3 – 5 bar pressure (depending on the sizes of the guides);

Grease Lubrication: 3 x 8 cm2 every 2 working hours.

3EPR SeriesThree Roller Guides

Size of Products:Designed to guide angle profiles and usually positioned at the entry of the finishing stands.

Guarantee a correct guiding in order to achieve a very good precision on the angles dimension.

angLe(mm)

3ePR tyPe

2CUT & 4CUTSeries

Cutting Guides

TYPE A B C U L

2CUT-01 188 60 180 90 150

2CUT-02 213 60 205 102.5 180

TYPE A B C U L

4CUT-01 250 60 205 102.5 205

TYPE A B C U L

2CUT-01 188 60 180 90 150

2CUT-02 213 60 205 102.5 180

TYPE A B C U L

4CUT-01 250 60 205 102.5 205

Dimensions:2CUT

4CUT

Technical Description: There are 2 sizes in the 4EPR Series 4EPR01 and 4EPR02, covering all ranges of products and sizes for long products rolling mills profiles (flat and square);

Technical Description: There are 2 Series of static guides: ES and US.

ES are the Entry Static Guides.

US are the Exit Static Guides.

4EPR SeriesFour Roller Guides

Static Guides

3EPR SeriesThree Roller Guides

TYPE A B C D1max D2max U L

3EPR-01 257 145 125 120 105 115 235

3EPR-02 280 170 140 128 120 115 250

3EPR-03 335 222 175 160 150 145 300

3EPR-04 415 300 215 205 195 180 360

3EPR-05 415 350 215 205 195 180 360

Dimensions:

Dimensions:ETR01 & ETR02

ETR SeriesTorsion Roller Guides

Dimensions:ETR03, ETR04,ETR05 & ETR06

TYPE A B C U L

ETR-01 175 108 135 67.5 90

ETR-02 190 123 165 82.5 110

TYPE A C U L1 L2 L

ETR-03 340 300 150 75 122 197

ETR-04 420 355 177.5 100 150 250

ETR-05 520 470 235 130 198 326

ETR-06 550 500 250 155 218 373

TYPE A B C U L

ETR-01 175 108 135 67.5 90

ETR-02 190 123 165 82.5 110

TYPE A C U L1 L2 L

ETR-03 340 300 150 75 122 197

ETR-04 420 355 177.5 100 150 250

ETR-05 520 470 235 130 198 326

ETR-06 550 500 250 155 218 373

Technical Description: There are 6 sizes of ETR Series (ETR01-ETR06), covering all ranges of products and sizes for long products rolling mills that requires torsion rolling;

ETR01 & ETR02 – are light yet sturdy – they are able to be hand maneuvered;

The twisting angle can be set by adjusting the two screws on the top of the guide and locking them in place;

Water Cooling Consumption: 55 - 150 l/min with 3-5 bar pressure (depending on the sizes of the guides);

Grease Lubrication: 2 x 5.5 cm2 every 2 working hours.

ETR SeriesTorsion Roller Guides

Size of Products:We have designed two types of torsion roller guides to cover the whole range of products.

Guides size 01 and 02 are hand manoeuvrable and designed to allow particularly quick on line replacements. Torsion occurs by turning of rolls holder.

Guides size 03, 04, 05 and 06 are designed for the bigger sizes of products, in this case torsion occurs according to the shape of the guiding rolls and the adjustment of their distance between centres.

Our Manufacturing Facilites Our Partners’ Workshops have the following production facilities:

Precision Casting using Lost Wax or Silicasol; Various Heat Treatment Facilities, Precision Machining using CNC Machining. Our workshops are certified with ISO 9001: 2000 Standard.

All Products are supplied under SWS Warranty.

Quality Assurance Equipment: Basic physical properties testing equipment.

3-D Dimensional Measuring Equipment.

Spectro Laboratory.

Precision Casting of Parts CnC Precision Machining Centres

Various Heat treatment Processes

Raw Casting of Parts Final Machining of Parts Guides Assembled & Ready to be Delivered

Rolls for Roller GuidesSWS has developed its own technology to manufacture high quality rolls for the roller guides. Guide rolls are exposed to extremely high temperatures of almost 1000°C (due to its direct contact with the steel), scale contaminated water and extreme abrasive conditions.Adopting vacuum fusion technology, SWS is able to produce rolls that are highly resistant to high temperature, extreme abrasion and fatigue operation conditions. The compound layer has wear resistance of a hardness of up to HRC 65.In normal operating conditions, these rolls will last 3- 5 times its life span and without the hassle of redressing or regrooving of the rolls.

SWS Roller GuidesA Complete SolutionSWS has designed, engineered & manufactured a unique and complete solution for guiding equipment for long products. Our expertise has stretched more than 40 years in design and engineering the guiding equipment & systems.

Advantages of Our Products are:

Technological Advanced & Practical Roller Guides.

Short Lead Time in Delivery as there are inventories for semi-finished roller guides in SWS warehouse.

Competitive Prices with High & Consistent Quality of Products.

After Sales Site Technical Supervision and Assistance. Consistent Monthly Supply of Consumables such as rolls, funnels, half guides and strippers

High Inventories of Consumables for Roller Guides in most Rolling Mills

Rolling RollsGuiding SystemFor Long ProductsHot Rolling Mills

PackingSWS puts emphasize on the importance of proper and safe packing of the guides and components for sea transportation.The guides have to be protected packed with proper material for sea-worthy transportation. The use of supports for safe keeping in the boxes during shipment is foreseen.

On-Site Customer Technical AssistanceAs a fundamental founding principal of our company, SWS is able to provide the customer with on-site technical assistance & support in optimizing the usage of the roller guides in the rolling process.This will further enhance the life-span of the roller guides and its consumables in the rolling mills.

Incorrect Water Cooling for the roller guides that will shorten the life-span of the rolls & possibly the guides..

Overused Roller Guides that may cause cobble in the rolling process.

Guides in Operation in the Rolling Mill.

Sea Worthy Packing for Guides,Consumables & Spare Parts

SWS is able to produce the rolls for the customers based on the technical drawings provided.

SWS Rolling Rolls Technical Section is able to advise the customers on the materials to be used based on the roll pass design, products & steel grades to be rolled in the rolling mill .

Chemical Composition C Si Mn P S

70Mn2 0.65-0.71

0.20-0.45

1.40-1.80 < 0.035 < 0.030

Chemical Composition C Si Mn Ni Cr Mo Mg P

Hardness of Roll Neck

Hardness of Roll Body

SGP 3.00-3.60

1.60-2.40

0.40-0.70

2.00-3.00

0.10-0.50

0.20-0.60 0.04 0.10 50-73

HSD 35-45 HSD

SGA 3.00-3.60

1.60-2.40

0.30-0.80

3.51-4.50

0.20-0.50

0.40-0.90 0.04 0.10 60-80

HSD 35-45 HSD

Chemical Composition C Si Mn Ni Cr Mo P

Hardness of Roll Neck

Hardness of Roll Body

Indefinite Chill 2.90-3.60

0.60-1.50

0.40-1.20

0.50-4.80

0.70-2.00

0.20-2.00 0.25 50-73

HSD 55-85 HSD

Adamite 1.30-2.10

0.30-0.80

0.70-1.40

0.20-2.50

0.80-3.50

0.20-0.60 0.035 60-80

HSD 35-45 HSD

SWS Rolls General SpecificationsAdvantages ofSWS Rolling RollsSWS, with it’s long years of experience in mill design for hot long product rolling mills, has started in 2005, to manufacture rolling rolls that is able to cope with the new challenges of the modern rolling mills.

Our Supply Advantages to the Rolling Mills cover from:

Excellent Control of Casting of Rolls that has minimum Internal Defects such as porosity & unwanted chemical elements.

Precision in Machining due to Skilled & Trained Manpower and High Technology CNC Machining Centres.

Short Lead Time in Delivery.

Competitive Prices with High & Consistent Quality of Products.

After Sales Site Technical Supervision and Assistance (methods to increase the life-span of the rolls).

Consistent Monthly Supply of Rolls to reduce High Inventory of Rolls in Rolling Mills.

Porosity at Rolls

Rolls for Rolling MillsSWS, with the co-operation of our Partner Workshop is producing rolling rolls for Long Product Hot Rolling Mills with 3 different types of materials.

Cast Steel Adamite (steel base) Cast Iron

Alloy Cast Steel Rolls Adamite Rolls

70Mn2 Rolls

SGP Rolls

SGA Rolls

Indefinite ChilledRolls

TYPES

Diameter available:Ø 200mm - Ø 1300mm

SGP: Spheroidal Graphite PearliteSGA: Spheroidal Graphite Acicular

All our rolls are produced through CentrifugalCasting method

Plain Rolls without grooves

anomalous Wear at the grooves of the Rollsincorrect Water Cooling for the Rolls that will shorten the life-span of the rolls

Proper Water Cooling for the Rolls

sea Worth Packing for Rolls

Customer assistance on site

Fire Cracks at the grooves of the Rolls

Product Marking at Rolls

SWS has emphasized on the importance of proper and safe packing of the rolls for sea transportation to the eventual customers. All the rolls are protected with anti-rust coating and packed with special material for sea-worth transportation. They also have special support for handling and safe keeping in containers for sea-shipment.

Packing & Marking

On-Site Customer Technical AssistanceAs a fundamental founding principals of our company, SWS is able to provide customer with the on-site technical assistance & support in optimizing the usage of the rolls with the rolling process. This will further enhance the life-span of the rolls used in the rolling mills.

Our Manufacturing FacilitesOur Partner Workshop is having the following Production Facilities:

Vertical Furnaces, Induction Furnaces, Car Bottom Hearth Furnaces, Centrifugal Casting Machine, Horizontal Lathe, Lathe with Boring Capability, Gantry Milling Machine.

Our workshops are certified with ISO 9001: 2000 Standard.

Quality Assurance Equipment: Hardness Test Ultrasonic Test Metallograpgy Test Spectro Laboratory

Pouring of Hot Metal for CastingCentrifugal Casting Machine

Vertical Furnace with Ladles

Casting of Rolls

Machining of Rolls

shear BladesFor Iron &Steel Industry

SteelWorldwideServices Ltd

Our Manufacturing FacilityOur Partner Workshop has the strong know-how and expertise in metallurgy to ensure good raw material for the blades. The workshop has vacuum hardening & tempering furnaces to heat treat the blades to achieve its required mechanical properties. There are many CNC precision machining center to machine to final dimensions.

Our workshop is certified with EN ISO 9001: 2000 Standard

Quality Control formanufacturing

Vacuum Hardening & tempering Furnace

Precision Machining of Blades

sea Worthy Packing for shear Blades

Packing & MarkingSWS has emphasized on the importance of proper and safe packing of the shear blades for sea transportation to the eventual customers. All the shear blades are protected with anti-rust coating and packed with special material for sea-worthy transportation. They also have special support for handling and safe keeping in containers for sea-shipment.

Advantages ofSWS Shear BladesSWS, with it’s long years of experience in mill design for hot long product rolling mills, has started in 2005, to manufacture shear blades that is able to cope with the new challenges of the modern rolling mills.

Our Supply Advantages to the Rolling Mills cover from:

Excellent Quality of Shear Blades. Technical Know-how in selecting the most suitable and optimum types of blades according to the specific application.

Short Lead Time in Delivery

Competitive Prices with High & Consistent Quality of Products.

After Sales Site Technical Supervision and Assistance (methods to increase the life-span of the shear blades).

Types of Shear BladesSWS, is producing various types of shear blades for different type of hot long product rolling mills

TYPES

Continuous Casting Machine

Bar/Wire Rod/Profile Rolling Mill

Hot Strip Mill / Plate Mill

Cold Rolling Mill

• Billet Shearing Machine

• Crop Shear

• Cut to Length Shear

• Cold Cutting to Length Shear

• Crop Shear • Crop Shear

SteelWorldwideServices Ltd

Continuous Development

SWS, co-operating with the workshop, has developed the insert type of blades in order to reduce the wastage of the complete shear blade. The insert is made with an even better quality of tool steel, as it is small in piece and weight, compared to the entire blade. The entire blade becomes a holder eventually.

shear Blades with inserts typical Wear of shear Blade of a Bar Mill

SteelWorldwideServices Ltd

Asia Pacific & Middle East:1st Floor, Unit 7, Jalan Tengku Ampuan Zabedah B, 9/BSeksyen 9, 40100 Shah Alam, Selangor D.E.MalaysiaPhone: +60 3 55118689Fax: +60 3 55118690E-mail: swsfareast@steelws.com

Africa, America, Europe & Russia:Corporate Headquarters

International House, 1 St. Katharine’s WayLondon E1W 1UN - United KingdomPhone: +44 20 76804023Fax: +44 20 76804021E-mail: sws@steelws.com