Casalmaggiore plant. may 2013

Transcription

1 Casalmaggiore plant may 2013

2 we give shape to steel Marcegaglia is the leading industrial group worldwide in the steel processing sector, with a yearly output of 5 million tons. After first transformation, within its controlled value chain Marcegaglia develops the world s widest range of customer tailored steel semi-products and finished goods. 2

3 Steel coil processing is at the core of Marcegaglia activities. The complete range of first transformation processes is carried out within 50 facilities worldwide. Marcegaglia stands among the steel market s top independent players in the world. A worldwide network of partnership agreements provides reliable supply of raw materials of all grades to our facilities. 3

4 MARCEGAGLIA WORLDWIDE PRESENCE Antwerpen Bremen Düsseldorf Munhall Dublin Dudley Barcelona Praszka Timişoara Cluj Moscow Vladimir Yangzhou Calcutta Lyon Doha Kluczbork Headquarters Lima Garuva Casalmaggiore 6,000,000 sqm manufacturing areas 4

5 Casalmaggiore plant The Marcegaglia manufacturing unit of Casalmaggiore (Cremona, Italy) spreads over 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 processing of carbon steel hot rolled coils for the production of welded tubes and hollow sections, round, square, rectangular and of special shapes, with thickness ranging from 1,35 to 16 mm diameters from 17 to 406, in accordance to current norm requirements as well as to custom specifications. 5

6 Casalmaggiore plant The production surface and equipment additions were completed in 2011 and have allowed the plant to increase its manufacturing capacity up to over 700,000 tonnes/year. New additions include: 1 slitting line allowing to process up to 16 mm thickness coils 3 tube mills adding new dimensional range capacities up to 406,4 mm and 16 mm thickness 1 normalization furnace 1 new automated warehouse 6

7 Casalmaggiore plant The new area is covered with an integrated photovoltaic roofing employing Marcegaglia own produced panels, generating 2.1 MWh peak power, equal to 2,000,000 kwh/year electrical power. Other electrical installations increase efficiency with energy recovery systems, such as a 4-quadrant inverter connected to overhead cranes. 7

8 Casalmaggiore plant development 8

9 Casalmaggiore plant Manufacturing areas Slitting Tube mills 3 Heat treatments Straightening Tube cutting Warehouse 9

10 Main manufacturing standards EN Round and shaped precision tubes EN Tubes for pressure purposes, for use at room temperature EN Square and rectangular precision tubes EN Tubes for pressure purposes, for use at high temperatures EN Cold formed welded structural tubes (CE homologation) EN Steel pipes for pipelines for combustible fluids EN Structural hollow sections, hot finished or cold formed and heat treated EN Tubes for the conveyance of water and other aqueous liquids Upon request: supply of grades not included in the above mentioned standards EN Tubes suitable for welding and threading 10

11 Tubes for steel structural work Tubes for piling Typical applications The production program of Marcegaglia tubes from hot rolled strip covers a wide range of structural and mechanical applications, guaranteeing specific suitability for subsequent processing. 11

12 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 frameworks for traffic signs and lightings masts for data, tv and radio communication agricultural machinery, tractors, earthmovers vehicle cabs, frames, bodies, trailers, hitches railway cars warehousing 12

13 Tubes for automotive applications With a dedicated production for the automotive sector, Marcegaglia is the supplier of choice for carmakers and OEM manufacturers of structural parts, components and interior details. 13

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

15 Tubes for district heating Tubes for pressure purposes include applications for the heat exchanger industry, heating and ventilation, gas and water line pipes, district heating tubes. Tubes for heat exchangers Tubes for gas and water line pipes 15

16 Roller conveyor tubes Tubes for lifting equipment Tubes suitable for drawing Marcegaglia has developed a unique know-how in the manufacturing of precision tubes to meet the strict dimensional and surface specifications required by manufacturers in several mechanical engineering sectors. 16

17 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 17

18 Marcegaglia Casalmaggiore Tube mills lines 11 product type round, square, rectangular, special shaped tube manufacturing capacity (t/y) 700,000 wall thickness (mm) from 1.3 up to 16 diameter (mm) from up to length feasibility (mm) from 5,000 to 16,000 18

19 Production line TC011 (3 ) Welded tubes ex hot rolled strip (black or pickled), cold rolled strip, coated strip ROUNDS Min. thickness (mm) 1,35 Max. thickness (mm) 6,6 Min. diameter (mm) 21,25 Max. diameter (mm) 89 SQUARES AND RECTANGULARS Min. thickness (mm) 1,35 Max. thickness (mm) 6 Smallest square (mm) Largest square (mm) 20x20 75x75 and all rectangular derived 19

20 Production line TC011 (3 ) Mill lengths Length tolerance on demand Thickness range mm mm mm 1,35-6,6 mm TECHNICAL FEATURES Marking of strips prior to forming Weld seam removing Online laser gauge to control adherence to 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 20

21 Production line TC002 (8 ) Welded tubes from hot rolled black strips (upon mutual agreement we can possibly use pickled and coated strips) ROUNDS Min. thickness (mm) 3 Max. thickness (mm) 16 Min. diameter (mm) 114,3 Max. diameter (mm) 219,1 SQUARES AND RECTANGULARS Min. thickness (mm) 3,7 Max. thickness (mm) 16 Smallest square (mm) Largest square (mm) 90x90 180x180 and all rectangular derived 21

22 Production line TC002 (8 ) Length feasibility mm 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 diameter Reel mounted stamping Online cutting with coated saw blades Internal washing Deburred ends/bevel ends Dot matrix cast marking Length tolerance mm on request mm Thickness feasibility mm * on demand we can offer a : mm tolerancefor lengths 6.000, and mm NON DESTRUCTIVE TESTS Induced eddy currents online Eddy current + magnetic flux leakage (Rotomat) after bevelling 22

23 Production line TC001 (16 ) Welded tubes from hot rolled black strips (upon mutual agreement we can possibly use pickled and coated strips) ROUNDS Min. thickness (mm) 4 Max. thickness (mm) 16 Smallest square (mm) 244 Largest square (mm) 406 SQUARES AND RECTANGULARS Min. thickness (mm) 4 (3) Max. thickness (mm) 16 Min. diameter (mm) Max. diameter (mm) 200x x325 and all rectangular derived 23

24 Production line TC001 (16 ) Length feasibility Length tolerance on request mm mm mm 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 diameter Reel mounted stamping Online cutting with coated saw blades Internal washing Deburred ends/bevel ends Dot matrix cast marking Thickness feasibility 4-16 mm * on demand we can offer a : mm tolerancefor lengths 6.000, and mm NON DESTRUCTIVE TESTS Induced eddy currents online Rotomat after deburring 24

25 Marcegaglia Casalmaggiore Heat treatments furnaces 3 heat treatments: normalization annealing stress relieving manufacturing capacity (t/y) 200,000 wall thickness (mm) from 0.9 up to 16 diameter (mm) from 16 up to

26 Marcegaglia Casalmaggiore Straightening lines 4 manufacturing capacity (t/y) 80,000 wall thickness (mm) from 0.9 up to 14 diameter (mm) from 13 up to

27 Marcegaglia Casalmaggiore Tube cutting lines 6 length (mm) from 100 to 12,000 also in bundles manufacturing capacity (t/y) 50,000 wall thickness (mm) from 0.9 up to 16 diameter (mm) from up to

28 Marcegaglia Casalmaggiore Automated warehouse It allows the automated storage and preparation of bundles to ship, avoiding the operator s access to the loading bays. The storage area spreads over 14 hall aisles. 28

29 Marcegaglia Casalmaggiore Optional processing Suitability for subsequent galvanizing Complete normalization or weld area normalization Additional heat treatments Weld seam removing Special end finishing Cut to length Customer defined marking Restricted tolerances Welding position Specific corrosion protection Specific packaging method Hot galvanization 29

30 Marcegaglia Casalmaggiore Testing Chemical composition Tensile test Flattening test Expansion test Impact test Eddy current test Flux leakage test Ultrasonic test Visual test Hydraulic test Dimensional test Micrographic analysis Release of special certificates 30

31 Certification ISO 9001:2008 CERTIFICATO N. CERTIFICATE No. 505/96/S SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF MARCEGAGLIA S.p.a. VIA BRESCIANI, GAZOLDO DEGLI IPPOLITI (MN) ITALIA NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS SS 420 SABBIONETANA CASALMAGGIORE (CR) ITALIA SITI DI SUPPORTO / REMOTE LOCATIONS COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASING VIA BRESCIANI, GAZOLDO DEGLI IPPOLITI (MN) ITALIA COMMERCIALE / SALES VOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB DUSSELDORF GERMANIA È CONFORME ALLA NORMA / IS IN COMPLIANCE WITH THE STANDARD ISO 9001:2008 Per informazioni sulla validità del certificato, visitare il sito For information concerning validity of the certificate, you can visit the site The plant is certified according to ISO 9001:2008 with RINA (Registro Italiano Navale) PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES EA:17 PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDED LONGITUDINALLY Riferirsi al Manuale della Qualità per i dettagli delle esclusioni ai requisiti della norma Reference is to be made to the Quality Manual for details regarding the exemptions from the requirements of the standard La validità del presente certificato è subordinata a sorveglianza periodica annuale / semestrale ed al riesame completo del sistema di gestione con periodicità triennale The validity of this certificate is dependent on an annual / six monthly audit and on a complete review, every three years, of the management system L'uso e la validità del presente certificato sono soggetti al rispetto del documento RINA: Regolamento per la Certificazione di Sistemi di Gestione per la Qualità The use and validity of this certificate are subject to compliance with the RINA document : Rules for the certification of Quality Management Systems Prima emissione First Issue Emissione corrente Current Issue Data scadenza Expiry Date Dott. Roberto Cavanna (Managing Director) RINA Services S.p.A. Via Corsica Genova Italy CISQ è la Federazione Italiana di Organismi di Certificazione dei sistemi di gestione aziendale CISQ is the Italian Federation of management system Certification Bodies SGQ N 002 A SSI N 001 G SGA N 002 D DAP N 001 H PRD N 002 B PRS N 066 C SCR N 003 F LAB N 0832 Membro degli Accordi di Mutuo Riconoscimento EA, IAF e ILAC Signatory of EA, IAF and ILAC Mutual Recognition Agreements 31

32 Certification ISO/TS 16949:2009 CERTIFICATO N. CERTIFICATE No. TS/505/96 SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF MARCEGAGLIA S.p.a. VIA BRESCIANI, GAZOLDO DEGLI IPPOLITI (MN) ITALIA NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS SS 420 SABBIONETANA CASALMAGGIORE (CR) ITALIA SITI DI SUPPORTO / REMOTE LOCATIONS COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASING VIA BRESCIANI, GAZOLDO DEGLI IPPOLITI (MN) ITALIA COMMERCIALE / SALES VOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB DUSSELDORF GERMANIA È CONFORME ALLA NORMA E AI REQUISITI DELLO SCHEMA IS IN COMPLIANCE WITH THE STANDARD AND THE SCHEME REQUIREMENTS ISO/TS16949:2009 CISQ è la Federazione Italiana di Organismi di Certificazione dei sistemi di gestione aziendale. CISQ è membro di IQNET. CISQ is the Italian Federation of management system Certification Bodies. CISQ is a member of IQNET. The plant is certified according to ISO/TS 16949:2009 with RINA (Registro Italiano Navale) Requisiti particolari per l applicazione della ISO 9001:2008 per la produzione o serie e delle parti di ricambio nell industria automobilistica (Components for the automobile industry) PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES EA:17 PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE PER L'INDUSTRIA AUTOMOBILISTICA PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDED LONGITUDINALLY FOR THE AUTOMOTIVE INDUSTRY Riferirsi al Manuale della Qualità per i dettagli delle esclusioni ai requisiti della norma Per informazioni sulla validità del certificato, visitare il sito For information concerning validity of the certificate, you can visit the site Reference is to be made to the Quality Manual for details regarding the exemptions from the requirements of the standard Essendo stati valutati in accordo alle Regole per lo schema di certificazione ISO/TS 16949:2002 Terza Edizione Ottobre 2008 Having been assessed in accordance with "ISO/TS 16949:2002 certification scheme rules Third Edition October 2008" Prima emissione Dott. Roberto Cavanna La validità del presente certificato è subordinata a sorveglianza First Issue (Managing Director) periodica annuale / semestrale ed al riesame completo del sistema di gestione con periodicità triennale Emissione corrente Current Issue The validity of this certificate is dependent on an annual/six Data di scadenza monthly audit and on a complete review, every three years, of Expiry date the management system RINA Services S.p.A. Via Corsica Genova Italy CISQ AUTOMOTIVE - Via Quintiliano MILANO IL PRESENTE CERTIFICATO È EMESSO IN CONFORMITÀ ALLE REGOLE IATF THIS CERTIFICATE IS ISSUED IN CONFORMITY WITH THE IATF RULES Certificato IATF n. IATF Certificate n

33 Certification ISO/TS 29001:2011 The plant is certified according to ISO/TS 29001:2011 with RINA (Registro Italiano Navale) Petroleum, petrochemical and natural gas industries, requirements for product and service supply organizations 33

34 TÜV - PED Certifications Marcegaglia is qualified according to AD Merkblatt W0 (directive 97/23/EC) with TÜV Rheinland The qualification currently applies to norm EN /2, grades P235TR1, P235TR2 and P235GH The qualification allows Marcegaglia to supply certificates conform to W4 according to PED directive 34

35 Homologation CE Marcegaglia is qualified with RINA according to the European directive 89/106/EEC (CE marking) CE marking refers to Appendix ZA of norm EN Standard grades certified with CE marking: S235JRH, S275J0H, S275J2H, S355J0H, S355J2H Micro-alloyed grades certified with CE marking: S355MH, S420MH, S460MH 35

36 RINA approval Certificate of Approval of Manufacturers of Materials Tubes for naval constructions EN EN S235JR, S355J0, S303J2 P235 TR1 - TR2 - GH 36

37 thank you via Bresciani, Gazoldo Ippoliti, Mantova - Italy