Essar Steel Heavy Plates for Speciality Applications

Essar Steel Heavy Plates
for Speciality Applications
Contents
3
Essar Group
5
Essar Steel
13
Plate Applications
7
• Shipbuilding
• Line Pipe
• Yellow Goods
• Boilers and Pressure Vessels
• Defence
• Wind Engineering
• General Engineering / Fabrication
• Construction
Heavy Plates
for Speciality
Applications
12
Salient Features
of Plate Products
32
8
International
Grades
Available
Essar Plate Mill
Process
34
36
Testing
Facilities
Contact Us
35
Ordering
Essar Group
The Essar group is a multi-national conglomerate and a leading global player
in the sectors of steel, energy, power, communications, BPO, shipping, ports
& logistics, and construction. With operations in more than 20 countries
across five continents, and over 60,000 employees, the group’s annual
revenues are over USD 15 billion. Essar began as a construction company
in 1969 and has now diversified into manufacturing, services and retail.
Over the last decade, it has captured new markets and discovered new
sources for raw materials either through strategic global acquisitions and
partnerships or through greenfield and brownfield development projects.
It is also building a strong presence in sectors like mining & minerals.
Today, the group continues to expand its global footprint by focussing on the
Asian, American, African and European markets. Essar invests significantly
in forward and backward integration of its businesses, and on leveraging
synergies between businesses. It also focuses on in-house research,
innovation and on embracing the latest technology to remain a low-cost
manufacturer with high quality products and innovative customer offerings.
Along with its ambitious business pursuits, Essar has ensured that it also
delivers on its social responsibility. The group runs community outreach
initiatives in all its plant locations with a focus on education, healthcare,
environment, agricultural development, and self-employment.
The Essar group is widely regarded as a responsible and conscientious
global employer. It has experience in managing businesses in different
geographies with a culturally diverse workforce. This is why its people
practices are sensitive to cross-cultural nuances. The group’s people
strategy is focussed on promoting a learning culture that continually
enhances the professional skills of its employees.
3
Essar Steel
Essar Steel is a global steel producer with a strong presence in intensive
steel consuming markets like Asia and North America. Its goal is to reach a
global production capacity of 20 – 25 million tonnes per annum (MTPA) by
augmenting its current capacity of 14 MTPA. Essar Steel is a fully-integrated
operation from mining to retail, with strong downstream capability and a
worldwide network of processing and distribution facilities, and distribution
outlets known as Hypermarts.
Global Operations
Essar Steel Algoma in Canada has a current capacity of 4 MTPA. Essar
Steel Minnesota USA (with iron ore reserves of over 1.4 billion tonnes) – is
developing a 6 MTPA pellet plant, an ore concentration plant and a direct
reduced iron plant. In Indonesia, Essar Steel is the largest private steel
processor and operates a 400,000 tonnes per annum (TPA) cold rolling
complex with a galvanising line of 150,000 TPA.
Essar Steel is the largest steel producer in western India, with a capacity
of 10 MTPA at Hazira, Gujarat. The steel plant is backed by an iron ore
beneficiation and a pellet unit that ensures supply of quality raw material.
The Essar Steel complex at Hazira has a complete infrastructure setup
including a captive port, and power, lime and oxygen plants.
It has set up a 1.5 MTPA plate mill and a 0.6 MTPA pipe mill at Hazira to make
further value-additions to its product portfolio. Essar Steel has the country’s
largest steel processing capacity of 2.7 MTPA at its seven processing and
distribution facilities, located at key automotive and industrial hubs. In India,
it has the distinction of being one of the largest galvanisers, as well as being
the largest producer of cold rolled and colour coated products. Additionally,
it is setting up a 12 MTPA pellet plant in Paradip, Orissa.
Products and Services
Essar Steel produces highly-customised products catering to a variety
of product segments. It is India’s largest exporter of flat products to the
highly demanding US and European markets, and to the growing markets
of South East Asia and the Middle East. It invests in world-class research
& development and has technology collaborations with global steel
majors to develop enhanced value-added products and grades that find
wide acceptance in sectors like automotive, white goods, construction,
engineering and shipbuilding. With investments in downstream capabilities,
Essar Steel has evolved from being a product-based company to a valueadded service provider with an extensive product portfolio.
5
Heavy Plates
for Speciality
Applications
Widening horizons of the future
The demand for thicker, wider and ultra high strength steel plates has
been increasing due to rapid industrialisation across the world. Key
industry players across different segments in India, have concurred
that availability of thicker and wider width plates will result in enormous
savings on fabrication and welding, and also lead to an improvement in
yield, quality and durability.
Recognising the growing needs and potential of the plate market in India,
Essar Steel has recently commissioned a state-of-the-art plate mill at
Hazira. The 4 Hi Rolling mill has a roll separating force of 10,000 metric
tonnes and can produce plates with a width of up to 5 metres. Other facilities
include Normalising, Accelerated Cooling / Direct Quenching, Hot and Cold
Levelling and Quenching and Tempering.
Coupled with advanced steel-making facilities, the mill can produce plates
with extremely low sulphur content and tramp elements which guarantee
extremely high toughness values of up to -80°C. The special feature of
Accelerated Direct Cooling (ADCO) enables designing of products for
specific wear resistance applications.
Essar plates are supported by the best manufacturing practices and testing
facilities including the Scanning Electron Microscope with EDAX, to ensure
clean steel with low inclusion. Essar plates conform to all international
standards including API, ASTM, EN, JIS and IS. They are also supplied in
customised grades as per client-specific requirements.
Plates undergo close process metallurgy and chemistry that is
customised to the specific requirements of different application segments.
The Essar Steel mill is capable of producing high strength and high
toughness plates that can cater to niche segments with an optimised
thickness-to-strength ratio resulting in weight reduction.
Essar’s quenched and tempered plates are designed to meet the demands
of strength, toughness and wear resistance for specialised applications –
earth moving machinery, heavy earth movers, submarines, shipbuilding,
anti-ballistic plates and extremely low temperature storage tanks. The
normalised plates are produced using cutting-edge technology suitable for
critical use in nuclear reactors, hydrogen reactors, supercritical boilers and
high pressure vessels for oil and gas.
Each final plate has a unique identification mark that ensures proper
traceability right from the stage of heat making to the final product. The
port location of the plant gives Essar Steel a logistical advantage thereby
ensuring timely production and delivery of orders across the world.
7
Essar Plate Mill
World-class Processes, Ultra-modern Facilities
Digital Reheating Furnaces
With a capacity of 1.5 MTPA, the plate mill is equipped to
produce steel plates with widths of up to 5 metres. Superlative
toughness, excellent weldability and perfect flatness make
these plates comparable to the best in the world.
The digital furnaces are equipped with side burners having an
independent on / off control for each burner, thus helping to
reduce excess scale formation. The furnace is split into different
control zones for uniform heat transfer through homogeneous
heat elimination of hot spots.
Plate Capacity
Thickness
Up to 150 mm
Width
1,100 to 4,950 mm (in mill edge condition)
900 to 4,850 mm (in trimmed condition)
Length
3,000 to 25,000 mm
Rolling Mill
The reversible rolling mill along with cross rolling facilities has a
roll separating force of 10,000 tonnes. This force helps in highshape factor rolling and thus reduces the internal discontinuities.
The rolling mill is supported by high-speed automatic gauge control
for accurate dimensions, plan view rolling for proper crosssection and shape, profile and flatness gauge for ensuring
premium quality in plates.
State-of-the-art Technology, World-renowned Suppliers
Equipment
Supplier
Rolling mills, ADCO facilities,
roller tables, cooling beds, hot
and cold levellers, including
automation and control systems
Siemens VAI, France
Extensive heat treatment
facilities covering austenitising
and normalising, quenching and
tempering furnaces
LOI, Germany
Digital reheating furnace
Stein-Heurtey, France
Shot blasting and painting
Wheelabrator, Germany
Roll grinder
Waldrich, Germany
Thermo-Mechanical Controlled Rolling (TMCR) and
Accelerated Direct Cooling (ADCO)
TMCR and ADCO facilities help in producing high-tensile steel
grades with lower carbon equivalent and high toughness, good
formability and better weldability. ADCO ensures controlled
cooling with edge masking facilities for achieving uniform
properties along the cross-section. It also has the capability of
direct quenching for achieving high strength and high hardness
grades. This process is used for producing high-tensile steel
plates with high toughness and good weldability for all major
structural applications.
4 HI MILL
Plate Process Flow
RECEIVING
SLAB
PRIMARY
DESCALER
ADCO
COOLING
SLAB
YARD
DOUBLE SIDE
TRIM SHEAR
CROP SHEAR
FULL BODY UST
QC LAB
8
SLAB RE-HEAT
FURNACES
SLITTING
SHEAR
CHAIN TRANSFER &
TURNOVER DEVICE
DIVIDING
SHEAR
Hot Leveller
Heat Treatment
The hot leveller, with a capacity of 4,000 tonnes, provides
excellent flatness and residual stress-free plates. A plastification
ratio of up to 80% can be offered depending on the tensile
strength and thickness. The unit has automatic gauge control
and shape system to ensure a high level of flatness.
The mill is equipped with heat treatment facility with
austentising and normalising, and quenching and tempering
furnaces for acheiving the desired texture of steel plates. The
plates are shot blasted and an inert atmosphere is maintained
in the furnaces with indirect radiant type heating to ensure that
no scales are formed on the surface of the plate.
Shearing Units
Marking and Traceability
The shearing units in the mill can cut plates of up to 50 mm
thick. The mill is equipped with heavy duty shearing units like
crop shear for cutting the improper shapes of as-rolled plates,
double side trim shear for cutting improper shapes into wider
sections, slitting shear for trimming and dividing shear for length
and width trimming.
In addition to a hot paint marker, a plate marker & stamper
are provided to mark or stamp each final plate with a unique
identification mark. This ensures proper traceability right from
the stage of heat making to the final product.
Logistics
Ultrasonic Testing
The ultrasonic testing unit is an on-line test equipment for
automatic inspection and evaluation of the full body of the
plates. A hundred probes ensure accurate examination of all
flaws. As a result, on-line inspection of up to 50 mm covering
100% of the plate body and edges is done. Indications are
recorded and evaluated to ensure precise monitoring of the
internal quality of heavy plates cut in the shear lines.
Essar has a captive port which can accommodate vessels of
up to 60,000 DWT, enabling Essar to ship customer orders
directly without multiple handling.
THICK PLATE PROCESSING
HOT
PAINT
MARKER
HOT
LEVELLER
COOLING BED-1 > 50 MM
DISPATCH
FINISHED
PLATES
Cooling Bed-2 < 50 mm
STOCK &
SHIPPING
YARDS
PLATE
MARKER
CROSS
TRANS #2
PLATE PILER
CROSS
TRANS #3
CROSS
TRANS #4
HEAT TREATMENT
(NORMALISING AND Q&T)
COLD LEVELLER
SHOT BLASTING
PAINTING
9
10
Metallurgy of Plate Rolling
The Thermo-Mechanical Control Process (TMCP)
• Shorter processing time as no heat treatment is required
Through TMCP, very fine and uniform ferrite microstructure
is obtained and results in higher strength and toughness.
The plate is also less susceptible to cold cracking and has
better weldability.
Normalising
The process of producing a stable microstructure by heating it
to the high temperature austenite and slowly cooling it.
Advantages
CONVENTIONAL
PROCESSING
THERMO-MECHANICAL
CONTROLLED PROCESSING (TMCP)
• Refines and ensures homogenous structure
HEAT TREATMENT
HOT
ROLLING
• Reduces residual stresses from rolling
ACCELERATED
ROLLING
• Reduces the risk of "banding”
QUENCHING & TEMPERING
SPRAY
WATER
AIR COOL
L
OOLED
AIR COO
C
WATER
AIR OR
OL
UENCH
AIR CO
OL
AIR CO
Q
WATER
TEMPERATURE,
NORMALISING
CONTROLLED
ROLLING
TEMPERATURE
Process for producing heavy plates
Quenching and Tempering
This is a conventional process used to harden or strengthen
steel. During the quenching step, the austenite is converted
to martensite. The quenched alloy is then tempered at an
intermediate temperature to transform the brittle martensite
into a very fine dispersion of cementite (iron carbide) phase in
an iron ferrite matrix.
AUSTENITE
PLATE ROLLING
STAGE I
POLYGONAL FERRITE
STAGE II
STAGE III
AI
R
AI
R
CO
OL
IN
G
AI
R
CO
OL
AI
R
CO
OL
IN
G
IN
G
TEMPERATURE,
DEFORMED ZONE
TEMPERING
QUENCHING
CO
OL
IN
G
FINELY DEFORMED
FERRITE
TIME
TIME
CONTROLLED-ROLLING
Concept of microstructure change during TMCP
Advantages
Quenching and Tempering process
Advantages
• Increases hardness for better wear and abrasion resistance
• Superior weldability due to lower carbon equivalent(Ceq)
• Improves ductility and toughness
• Better formability
• Reduces cracking
• Excellent mechanical properties (high strength and
toughness) attained through fine microstructure
• Increases impact resistance
Salient Features of Essar Steel Heavy Plate
Clean Steel
Plate Characteristics
Essar plates are supported by state-of-the-art technology and
the best manufacturing practices to ensure clean steel (with
low inclusion) contents and low sulphur to avoid any hydrogeninduced cracking, fatigue failures, lower toughness, etc.
• Better weldability even with higher strength plates
• Good cold formability due to good homogeneity and micro structural cleanliness
• Excellent hot forming characteristics due to normalising
Mechanical Properties
Mechanical properties of Essar plates conform to international
standards (ASTM, EN, JIS, and IS, etc.) and can be made to
any other mutually-agreed specifications.
• Improved toughness for high heat input welding at a lower
temperature of -60°C
• Free of residual stress
• High corrosion resistance due to micro addition of
special alloys
• Superior abrasion and wear resistance due to micro addition
of special alloys and the quenching & tempering process
• Shot blasted and painted for marine application
Unique Features
Facility
Product Quality
Edge masking for uniform cooling Consistent properties across the width and cross-section of the plate
12
ADCO cooling system
Superior hardness
Hot levelling (up to 100 mm)
Better flatness and residual-free plates
Cold levelling (for < 50 mm)
Acute dimensional accuracy, flatness and residual stress-free plates: minimal warpage
Shearing plate
Available for plates up to 50 mm
Shot blasting and painting
Biocompatible epoxy coating: both Sn and Pb based, suitable for marine application
Quenching and tempering
Ultra high strength and tough plates
Plan view rolling
Excellent shape and flatness
Plate Applications
Type
Application
Shipbuilding
Ultra high strength and tough steel plates
• Merchant ships, cargo, bulk carriers, submarine hulls
• Low-temperature applications
Line Pipe
High strength and ultra tough steel plates
• Line pipes carrying different fluids, gases (including sour-gas)
• Offshore structural application
Yellow Goods
Ultra high strength steel plates with superior toughness
Structures like
• Truck body
• Arm
• Support structures
High abrasion and wear resistant steel plates
Shovels, quarries & mines equipment crushers, buffer bins,
buckets, dump trucks
Boilers and Pressure Vessels
High strength alloyed steel plates
Sub-critical to super-critical boilers applications
High strength steel plates
High pressure applications
Normalised steel plates
Low-temperature applications
Defence
High strength, hardness, toughness and anti-ballistics
steel plates
Armour tanks, mine protective vehicles
Ultra high strength and toughness, bulletproofs steel
Personal and vehicle protection
Special alloy steel plates
Naval warships, submarines
Wind Engineering
Higher width high strength steel plates
Conical sections of long wind towers
General Engineering / Fabrication
High strength steel plates with excellent weldability
General engineering / fabrication
Construction
Ultra high strength and tough steel plates
Dams, bridges, buildings, power plant structures, penstock
Atmospheric corrosion resistant steel plates
Offshore platforms, bridges
Seawater corrosion resistant steel plates
Bridges, offshore platforms, structures
13
9
Shipbuilding
Propelling the future
Applications
Challenges During Usage
• Offshore structures
Plates for marine applications must endure adverse load
conditions like corrosion and large cyclical loads – wave
loading, sea slap and slamming thermal excursions in tropical
and arctic seas, vibration and cargo buoyancy. Thus, steel
plates require high strength coupled with good low-temperature
toughness, through thickness properties, corrosion and fatigue
resistance, and tight dimensional tolerances. One of the most
important requirements is toughness in the base plate and in
the HAZ regions.
• Bulk carriers
• Tankers
• Barges
Metallurgy
Composition / Treatment
Result
Proper alloy design having C, Mn, and other
micro-alloying elements
High strength and toughness
Addition of micro-alloying elements like Nb, V, and Ti
Improved strength and toughness
Clean steel, with very low S content
Avoid lamellar tearing
Addition of Cu and Cr
Improved all-weather resistance
Optimal carbon equivalent (Ceq) with low carbon
and micro-alloying elements
Good mechanical properties and good weldability
Normalisation of plates to remove secondary phases
Improved fatigue life and mechanical properties
Mechanical Properties
• High strength
• Good low-temperature toughness
Dimensions
Thickness
5 – 100 mm
Width
1,100 – 4,950 mm (mill edge)
900 – 4,850 (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per standard shipbuilding
norms
• High corrosion resistance
• Excellent high and low cycle fatigue properties
• Excellent weldability due to lower carbon equivalent and
HAZ toughness
Supply conditions
• As-rolled
• Thermo-mechanically processed
• Normalised rolling / Furnace normalised
• Shot blasted and painted with biocompatible epoxy coating: both Sn and Pb based, suitable for marine application
15
16
Line Pipe Steels
Fuelling the future
Applications
Challenges During Usage
• Transport of oil, gas, water
Pipes are required to withstand very high hoop / circumferential
stress generated due to the transport elements. These are built
across different geographies, and thus would require good
corrosive resistance to Sulphide Stress Corrosion Cracking
(SSCC) and Hydrogen Induced Cracking (HIC), a high Ductile
to Brittle Transition Temperature (DBTT) and a good DropWeight Tear Test (DWTT) value.
• Offshore structures
Metallurgy
Composition / Treatment
Result
Low C and very low S and P
High strength and toughness
Clean steel
Improved resistance to HIC and toughness
Addition of Micro-alloying elements like Nb, Ti, V Reduced DBTT and increased DWTT
Addition of molybdenum in Nb containing steels
Improves the impact toughness and DWTT
Addition of Ni, Cr, and Cu
Improved corrosion resistance to HIC and SSCC
TMCR
Improved strength and toughness
Mechanical Properties
Dimensions
• High strength
Thickness
From 5 – 50 mm for normal pipe
• Good low-temperature toughness
Width
1,100 – 4,950 mm (mill edge)
900 – 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per API standards
• High corrosion resistance to HIC and SSCC
• Good weldability
Supply Conditions
• As rolled
• Thermo-mechanically controlled
• Furnace normalised
18
Yellow Goods and Mining Equipment
Excavating the future
Applications
Challenges During Usage
• Mines and quarries
The plates used in yellow goods are subjected to land mines,
hard rocks, loading bulk material, shovels, crushing units, etc.
• Agriculture machinery
• Vehicle manufacturing
• Cement works
The plates are therefore required to have high strength and
toughness and excellent abrasion and wear resistance.
• Dump trucks
• Front loaders
• Crushers
Metallurgy
Composition / Treatment
Result
Low S, P and H
High toughness
Optimum alloy chemistry with C, Mn and other alloying elements
High strength and toughness
Alloying of special elements like Cr, Mo and Ni
Improved abrasion and wear resistance
Quenching and tempering
Desired mechanical properties
Mechanical Properties
• High strength
• High hardness
Dimensions
Thickness
5 – 150 mm (70 mm max for QT plates)
Width
1,100 – 4,950 mm (mill edge)
900 – 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per relevant international standards
• High abrasion and wear resistance
• Good weldability
Supply Conditions
• Thermo-mechanically controlled
• Furnace normalised
• Quenched and tempered
• Shot blasted and painted
20
Boilers and Pressure Vessels
Powering the future
Applications
Properties Required During Service
Boilers:
Generally, steel plates are hot / cold formed to desired shape
for major boilers to withstand high temperature and pressure,
and adverse corrosive environments. Since the boilers and
pressure vessels carry high pressure and temperature fluids,
hold low-temperature fluids, the steel plates are required to
have high strength, toughness and ductility, and corrosion
resistance. Due to high temperature applications, the steel
plates should have excellent creep resistant properties.
• Power plants
• Process industries
• Refineries
• Coal gasifiers
• Petrochemical exchangers
Pressure Vessels:
• Process industries
• Power plants
• Nuclear power plants
Metallurgy
Plate Metallurgy - Composition / Treatment
Result
Clean steel with low S and P
Improved strength and toughness
Addition of micro-alloying elements like Nb, Ti, V
Improved strength and toughness
TMCR
High strength coupled with low-temperature toughness
Special alloying elements like Ni, Cr, Mo
Strength, hardenability and creep resistance
Furnace normalisation
Improved mechanical properties and fatigue resistance
Mechanical Properties
• High strength
Dimensions
Thickness
5 – 150 mm (70 mm max in
furnace normalised condition)
Width
1,100 – 4,950 mm (mill edge)
900 – 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per relevant international
standards
• Good low-temperature toughness
• High corrosion resistance, high resistance to HIC, SSCC and embrittlement
• High creep resistance
Supply Conditions
• As-rolled
• Thermo-mechanically controlled
• Normalised rolled
• Furnace normalised
• Quenched and tempered
• Shot blasted and painted
21
22
Defence
Protecting the future
Applications
Challenges During Usage
• Armoured vehicles
The plates used for defence have to face battlefield
conditions like land mines, rockets, high momentum bullets
and other blast materials. They are therefore required to
have excellent toughness, high strength, high hardness and
good ballistic properties.
• Mine protective vehicles
• Protective buildings
• Security vehicles
Metallurgy
Composition / Treatment
Result
Proper alloy design having micro-alloys such as Mo, Cr, Ni, B
and others
Desired toughness, strength, hardness and ballistic properties
Mechanical Properties
• High strength, up to 1,500 MPa tensile strength
• Good low-temperature toughness
Dimensions
Thickness
5 – 70 mm (QT plates)
Width
1,100 – 4,950 mm (mill edge) 900
– 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per defence standards and
MIL specification
• High corrosion resistance
• Good weldability
• NIJ Level-III for anti-ballistic properties
Supply Conditions
• Thermo-mechanically controlled
• Quenched and tempered
• Shot blasted and painted
24
Wind Engineering
Harnessing the future
Application
Challenges During Usage
• Conical sub-sections of wind towers
The plates used in wind engineering are subjected to high
wind, tower and buckling loads due to rotation of blades. The
plates are required to have high strength and toughness, good
weldability and formability.
Metallurgy
Composition / Treatment
Result
Clean steel with low S and P
Improved toughness
Optimal alloy design containing C, Mn, and other micro-alloying
elements like Nb, V and Ti
High strength and toughness
TMCR
Desired mechanical properties
Mechanical Properties
Dimensions
• High strength, up to 690 MPa tensile strength
Thickness
5 – 70 mm
• Good weldability
Width
1,100 – 4,950 mm (mill edge) 900
– 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per relevant international
standards
• Good corrosion resistance
Supply Conditions
• As-rolled
• Thermo-mechanically processed
• Furnace normalised
• Shot blasted and painted
26
General Engineering / Fabrication
Designing the future
Applications
Challenges During Usage
• Equipment manufacturing
The plates are required to have high strength, toughness,
corrosion resistance and good weldability.
• Forging and industrial fabrication
• Kilns
• Gates for hydro projects
• Crane girders
• Turbine runners
Metallurgy
Composition / Treatment
Result
Optimum alloy design and TMCR
High strength, high toughness and good corrosion resistance
Mechanical Properties
Dimensions
• High strength
Thickness
5 – 150 mm
• High toughness
Width
1,100 – 4,950 mm (mill edge)
900 – 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per relevant international
standards
• Good weldability
• Good corrosion resistance
Supply Conditions
• As-rolled
• Thermo-mechanically controlled
• Furnace Normalised
• Shot blasted and painted
28
Construction
Building the future
Applications
Challenges During Usage
• Civil structures
Plates used for this segment are pre-fabricated structures and
range from low strength to high strength depending on the
application. The plates must have good corrosion resistance,
toughness, weldability and dimensional tolerances.
• Bridges
• Dams
• Highways
• Power projects
• Mega residential and commercial complexes
• Telecom towers
Metallurgy
Composition / Treatment
Result
Optimum alloy design and TMCR
High strength and toughness
Low levels of S and P
Improved toughness
Furnace normalisation
Uniform mechanical properties
Mechanical Properties
Dimensions
• High strength
Thickness
5 – 150 mm
• High corrosion resistance
Width
1,100 – 4,950 mm (mill edge) and
900 – 4,850 mm (trimmed edge)
Length
3,000 – 25,000 mm
Dimensional
tolerances
As per relevant international
standards
• Good weldability
Supply Conditions
• As-rolled
• Thermo-mechanically processed
• Furnace normalised
• Shot blasted and painted
30
Factory Welded Beams
Optimising Cost, Maximising Productivity
Applications
Key Benefits
• Power projects
• Shortens project time and maintains a clutterless project site
• Bridges
• Increases productivity due to zero rejection and zero scrap
• Civil construction
• Reduces capex, labour and working capital
• Improves quality with tighter design tolerances and
weld strength
• Eliminates pollution (no shot blasting, no painting,
no welding at site)
Facilities
High-quality steel from one of the largest plate mills in the world
at Hazira using the state-of-the-art Essar Steel processing and
distribution facility:
• Plasma cutting under water
• Web loading by magnetic tilting arms
• Tandem arc welding
• 4-edge welding for better results
• Shot blasting up to 250 Ra finish
• Beam auto-straightening
• Primer & final paint booth
• Oxy-plasma profile cutting up to 60 mm
• CNC drilling machine
Dimensions
Welded Beam Specifications
Web height
350 – 2,500 mm (flanges included)
Web thickness
10 – 40 mm
Flange width
250 – 1,000 mm
Flange thickness
8 – 63 mm
Max beam weight
1,500 kg / m
Beam length
6,000 – 18,000 mm
Conical beam
The difference in height between the two ends < 900 mm
Types of Beams
I / H beams
Wide flange beams
Non-symmetrical
L / Tapered beams Cross / Star
Custom-made, Ready-to-use Beams
Special beam shapes are available in an extensive range of
profiles, providing designers and construction engineers with
maximum flexibility in selecting the optimum structural steel
section for their specific application.
Asymmetrical C-shapes
Camber
T-shapes
Variable depth
Z-shapes
Symmetrical hybrid
Tapered
31
International Grades Available
Usage segment
Specifications
ASTM
Shipbuilding
JIS
KS
Others
ABS A, B, D,
NK
KR
NV, CR, BV, RINA, A, B, D,
AH32,
KA, KB, KD, KE,
RA, RB, RD, RE,
NV, RINA A27, D27, E27,
DH32,
Ka32, KD32,
RA32, RD32,
A32, D32, E32, A36, D36,
EH32,
KE32, KA36,
RE32, RA36,
E36, A40, D40, E40 CR, BV
Ah40
KD36, KE36,
RD36, RE36,
A, D, E32/36, A, D, E40,
KA40, KE40,
RA40, RD40,
KL24A,B, KL33, 37
KL24A, B,
RE40, RL24A,
LR Ah32, DH32, EH32,
Kl33, 37
B, Rl33, 37
AHS34, DHS34, Ah36,
DH36, EH36, Ah40 GL
A32, D32, E32, A36, D36, E36,
A40, D40, E40
Mechanical
A36(M)
JIS G 4051,
KS D 3752,
Structure
SAE1010
S10C~S58C,
SM10C~SM5
~SAE1060,
JIS G4105,
8C
SAE4150
SCM415~440
Boilers
A285 Gr A, B, C
JIS G 3103, SB410,
KS D 3560,
En10028
and Pressure
A515 GR 55, 60,
450, 480, SB450M,
SB 410, 450,
P265GH
Vessels
65, 70 A516
SGV410, 450, 480
480 KS D 3540
Gr 55, 60, 65, 70
JIS G 3115, SPV235,
SGV 420, 450, 480
A537 Class 1, 2
315, 355 SPV450, 490,
KS D 3521,
A387 Gr 11, 12
JIS G 3119, SBV 1A,
SPPV 235, 315,
SBV 1B, 2,
SPPV 450, 490
3 JIS G 4109,
KS D 3560
SCMV 1, 2, 3
SB 450M,SB 480M
Low-temperature
A662
JIS G 3126
KS
WDEhw 680
Pressure Vessels
Gr A, B, C
SLA235A, B
SLA235A, B
TTST41
A203
SLA325A, B
SLA325A, B
TTST45
Gr
SLA360
SLA360
BS1501-224
A, B, C, D, E, F
KS D 3586
KS D 3586
Gr 430A, B
A553-1
SL3N255,
SL3N255,
Gr 460A, B
SL3N275,
SL3N275,
SL3N440,
SL3N440,
SL9N590
SL3N590
SL9N590
32
Usage segment
Specifications
ASTM
JIS
KS
Line Pipes
Others
API 5L-A, B
X42, X46,
X52, X56,
––
––
––
X60, X65,
X70
Marine Structures
API-2H
––
––
––
Gr 42, 50
API-2W
Gr 42, 50, 60
Weathering &
A441
JIS G 3114
KS D 3529
Corrosion
A588
SMA400AW, AP
SMA41AW, AP
Resistant
Gr A, B, C, K
SMA400BW, BP
SMA41BW, BP
SMA400CW, CP
SMA41CW, CP
SMA490AW, AP
SMA50AW, AP
SMA490BW, BP
SMA50BW, BP
SMA490CW, CP
SMA50CW, CP
SMA570W,
SMA58W,
SMA570P
SMA58P
––
Structural
A283
JIS G 3101
KS D 3503
EN 10025
Applications
Gr A, B, C, D
SS330,
SS330,
S185
A36
SS400,
SS400, SS490
S235J2G3, 4
A572
SS490
KS D 3515
S275JR,
Gr 42, 50,
JIS G 3106
SM400A, B, C
J0, S355JO,
60, 65
SM400A, B, C
SM490A, B, C
J2G3, 4
A633
SM490A, B, C
SM490YA, YB
E295
Gr A, C, D, E
SM490 YA, YB
SM520 B, C A678
SM570
SM570
A656
JIS G 3136
A514B, F
SN400A, B, C
A573
SN490B, C
Gr 58, 65, 70
33
Testing Facilities
• Optical emission spectrometer
• Scanning electron microscope with EDAX analyser
• Universal testing machine with elevated temperature testing with a capacity of 1,200 KN
• Universal testing machine with a capacity of 2,000 KN
• Cold bend tester with a capacity of 1,000 KN
• Drop weight tear tester with a capacity of 80,000 J
• Impact tester with a capacity of 450 J
• Vicker hardness tester
• Rockwell cum Brinell hardness tester
• Metallurgical microscope with 1000 X Magnification
Typical microstructure of a normalised rolled plate
Marking
• Paint marking
• Mechanical stamping
• Bar coding
34
Ordering
Attributes
Details to be specified
Remarks
Plate dimensions required:
thickness width length
out of squareness
Refer capability matrix
Other requirements in dimension
would be subject of Minimum Order Quantity
(MOQ) on an individual case basis (ICB)
Prescribed or
equivalent specification
In case specification required is different
please mention the equivalent specification
Plate marking
Marking will be on plate top surface.
Specify additional requirements if any
On mutually agreed terms
Trimmed / Untrimmed
In case flame cut requirements,
the tolerance would be subject to
mutual agreement
Applicable in case of plate sizes
above 50 mm thickness
As-Rolled / Normalised / QT
Specify relevant heat treatment
Supply conditions
Tolerance (close / skewed)
• In case tolerance of required is closer than
the minimum mentioned, the same should
be mentioned against each attribute
and would be negotiable based on ICB
• Skewed tolerances to be mentioned clearly
On mutually agreed terms
Inspection by customer /
Third Party Inspection (TPI)
Kindly specify in case of inspection
requirement:
• Inspection agency
• Scope of inspection
• Inspection required during rolling
or finishing or at both stages
• Would be at an additional cost unless
man datory as per specification
• The scope of inspection should be defined
at negotiation stage
TPI with Indian Boiler Regulation
(IBR) certification
In case normalising is not mandatory
but IBR certification required
For non boiler applications including
pressure vessels
Ultrasonic testing – as per ASTM
ASTM A435
ASTM A578 Level A, B, C
As per ASTM A435 unless otherwise specified
(Other cases can be considered on mutually
agreed terms)
Impact proof certification
Please specify the temperature range
Z test
Sampling requirements if required
On mutually agreed terms
Flatness & waviness
As per ASTM – A6. Any closer tolerance
would be be possible subject to
confirmation from our end.
On mutually agreed terms
Dual certification
Certification specifications
On mutually agreed terms
Copper extra
Percentage of Copper in LSA
On mutually agreed terms
Low sulphur
Sulphur restriction
0.005% Max
On mutually agreed terms
Inclusion rating
Rating
On mutually agreed terms
Shot blasting and painting
Supply conditions
On mutually agreed terms
Delivery
• Lead time
• Ship to
• Sold to
On mutually agreed terms
35
Contact us
India Offices
India Offices
International Offices
Ahmedabad
Essar House,
Ellisbridge,
Ahmedabad - 380 006
Tel: +91 79 6608 6666
NCR
A-5, Sector-3,
Noida - 201 301
Tel: +91 120 6626 666
Indonesia
PT Essar Indonesia
BFI Estate, Inds 3 Kav B1,
Cibitung, Bekasi 17520,
West Java , Indonesia
Tel: +62 21 8980 152
Bengaluru
No. 2, 2nd Floor, RR Chambers,
11th Main, Vasanth Nagar,
Bengaluru - 560 052
Tel: +91 80 2220 2131
Chennai
Chennai House,
5th Floor, No. 7, Esplanade,
Chennai - 600 108
Tel: +91 44 2535 1271 / 73
Hyderabad
301, Sidhu Shree Vaishnavi Arcade,
Road No. 1, Banjara Hills,
Hyderabad - 500 034
Tel: +91 40 2337 0125 / 6677 0980
Indore
409, City Centre,
570 M.G. Road,
Indore - 452 001
Tel: +91 731 2538 825 / 2537 974
Kolkata
2nd Floor, Block: EP, Plot Y16,
Sector V, Saltlake City,
Kolkata - 700 091
Tel: +91 33 6612 6608
Essar House, 11 K. K. Marg,
Mahalaxmi, Mumbai - 400 034.
India
Tel: +91 22 6660 1100
Fax:+91 22 2353 2695
www.essarsteel.com
Mumbai
Essar Technopark,
# 2, L.B.S. Marg, Kurla (West),
Mumbai - 400 034
Tel: +91 22 6733 5000
Pune
408, City Tower,
17, Boat Club Road,
Pune - 411 001
Tel: +91 20 6620 9901 / 2
International Offices
Canada
Essar Steel Algoma Inc.
5515 North Service Road,
Burlington, Ontario,
L7L 6G4 , Canada
Tel: +1 905 331 3400
Dubai, U.A.E.
Emaar Business Park,
# 4, Sheikh Zayed Road,
P.O. Box 61078, Dubai, U.A.E.
Tel: +971 4364 9000 / 37
Give your business a
competitive edge.
Mail us at
[email protected]
Germany
Essar Steel Gmbh,
92 a, Konigsalee,
Dusseldorf 40489, Germany
Tel: +49 211 5403 9615
United Kingdom
Servo Steel
Pensnett Road, Dudley,
West Midlands DY1 2HA,
United Kingdom
Tel: +44 1384 471 371
Registered Office
27th KM, Surat Hazira Road,
Hazira - 394 270, India
Tel: +91 26 1668 2400
Corporate Office
Essar House,
11, K. K. Marg, Mahalaxmi,
Mumbai - 400 034, India
Tel: +91 22 6660 1100