Marcegaglia Casalmaggiore plant

Casalmaggiore plant
may 2013
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
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
MARCEGAGLIA WORLDWIDE PRESENCE
Antwerpen
Bremen
Düsseldorf
Praszka
Dublin
Timişoara
Dudley
Cluj
Moscow
Vladimir
Yangzhou
Munhall
Barcelona
Calcutta
Doha
Lyon
Kluczbork
Headquarters
Lima
Garuva
Casalmaggiore
6,000,000 sqm
manufacturing
areas
4
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
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
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
Casalmaggiore plant development
8
Casalmaggiore plant
Manufacturing areas
2
1
6
3
6
4
3
5
1
6
3
2
2
2
5
1
Slitting
2
Tube mills
3
Heat treatments
4
Straightening
5
Tube cutting
6
Warehouse
9
Main manufacturing standards
EN 10305-3
Round and shaped
precision tubes
EN 10217-1
Tubes for pressure purposes,
for use at room temperature
EN 10305-5
Square and rectangular
precision tubes
EN 10217-2
Tubes for pressure purposes,
for use at high temperatures
EN 10219
Cold formed welded
structural tubes
(CE homologation)
EN 10208-1
Steel pipes for pipelines
for combustible fluids
EN 10210
Structural hollow sections,
hot finished or cold formed
and heat treated
EN 10224
Tubes for the conveyance of water
and other aqueous liquids
EN 10255
Tubes suitable
for welding and threading
Upon request: supply of grades not included in the above
mentioned standards
10
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
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
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
Major applications include:
axles for vehicles and industrial vehicles,
tubes for dump trucks, stabilizers
and steering components.
Tubes for district
heating
Tubes for heat
exchangers
Tubes for pressure purposes include
applications for the heat exchanger industry,
heating and ventilation, gas and water line
pipes, district heating tubes.
Tubes for gas
and water line pipes
15
Tubes for lifting
equipment
Roller conveyor tubes
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
Marcegaglia Casalmaggiore
Slitting lines
lines 5
manufacturing capacity (t/y) coil thickness (mm) coil width (mm) 700,000
from 1.3 up to 16
up to 2,000
17
Marcegaglia Casalmaggiore
Tube mills
lines
product type
11
round, square,
rectangular,
special shaped tube
manufacturing capacity (t/y)700,000
wall thickness (mm)
diameter (mm)
length feasibility (mm)
from 1.3 up to 16
from 16.75 up to 406.4
from 5,000 to 16,000
18
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)
20x20
Largest square (mm)
75x75
and all rectangular derived
19
Production line
TC011 (3’’)
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
Mill lengths
5.000-14.000 mm
Length tolerance
on demand
-0+50 mm
-0+25 mm
Thickness range
1,35 - 6,6 mm
NON DESTRUCTIVE TESTS
Induced eddy currents online
Eddy current + magnetic flux leakage
(Rotomat) after bevelling
20
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)
90x90
Largest square (mm)
180x180
and all rectangular derived
21
Production line
TC002 (8’’)
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 feasibility
5.000-16.000 mm
Length tolerance
on request
-0+50 mm
-0+25 mm
Thickness feasibility
13 - 16 mm
* on demand we can offer a : -0+15 mm tolerancefor lengths 6.000, 12.000 and 16.000 mm
NON DESTRUCTIVE TESTS
Induced eddy currents online
Eddy current + magnetic flux leakage
(Rotomat) after bevelling
22
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)
200x200
Max. diameter (mm)
325x325
and all rectangular derived
23
Production line
TC001 (16’’)
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 feasibility
6.000-16.000 mm
Length tolerance
on request
-0+50 mm
-0+25 mm
Thickness feasibility
4 - 16 mm
* on demand we can offer a : -0+15 mm tolerancefor lengths 6.000, 12.000 and 16.000 mm
NON DESTRUCTIVE TESTS
Induced eddy currents online
Rotomat after deburring
24
Marcegaglia Casalmaggiore
Heat treatments
furnaces3
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 355
25
Marcegaglia Casalmaggiore
Straightening
4
lines manufacturing capacity (t/y) 80,000
wall thickness (mm) from 0.9 up to 14
diameter (mm) from 13 up to 219
26
Marcegaglia Casalmaggiore
Tube cutting
6
lines length (mm) from 100 to 12,000
also in bundles
manufacturing capacity (t/y) wall thickness (mm) diameter (mm) 50,000
from 0.9 up to 16
from 21.25 up to 406.4
27
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
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
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
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
Per informazioni sulla validità
del certificato, visitare il sito
www.rina.org
MARCEGAGLIA S.p.a.
For information concerning
validity of the certificate, you
can visit the site
www.rina.org
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
The plant is certified according to
ISO 9001:2008 with RINA
(Registro Italiano Navale)
SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIA
SITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASING
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALES
VOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
È CONFORME ALLA NORMA / IS IN COMPLIANCE WITH THE STANDARD
ISO 9001:2008
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
Riferirsi al Manuale della Qualità
per i dettagli delle esclusioni ai
requisiti della norma
PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDED
LONGITUDINALLY
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
30.12.1996
Emissione corrente
Current Issue
13.07.2012
Data scadenza
Expiry Date
12.07.2015
Dott. Roberto Cavanna
(Managing Director)
RINA Services S.p.A.
CISQ è la Federazione Italiana di
Organismi di Certificazione dei
sistemi di gestione aziendale
CISQ is the Italian
Federation of management
system Certification Bodies
Via Corsica 12 - 16128 Genova Italy
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
Certification
ISO/TS 16949:2009
CERTIFICATO N.
CERTIFICATE No.
TS/505/96
CISQ è la Federazione Italiana di
Organismi di Certificazione dei
sistemi di gestione aziendale.
CISQ è membro di IQNET.
SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
CISQ is the Italian Federation of
management system
Certification Bodies. CISQ is a
member of IQNET.
MARCEGAGLIA S.p.a.
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIA
SITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASING
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALES
VOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
È CONFORME ALLA NORMA E AI REQUISITI DELLO SCHEMA
IS IN COMPLIANCE WITH THE STANDARD AND THE SCHEME REQUIREMENTS
ISO/TS16949:2009
PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES
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)
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
Per informazioni sulla validità
del certificato, visitare il sito
www.rina.org
For information concerning
validity of the certificate, you
can visit the site
www.rina.org
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
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
First Issue
14.10.2002
Emissione corrente
Current Issue
13.07.2012
Data di scadenza
Expiry date
12.07.2015
Dott. Roberto Cavanna
(Managing Director)
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
RINA Services S.p.A.
Via Corsica 12 - 16128 Genova Italy
CISQ AUTOMOTIVE -
IL PRESENTE CERTIFICATO
È EMESSO IN CONFORMITÀ
ALLE REGOLE IATF
Certificato IATF n.
IATF Certificate n.
Via Quintiliano 41 – 20138 MILANO
THIS CERTIFICATE IS
ISSUED IN CONFORMITY
WITH THE IATF RULES
0143175
32
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
TÜV - PED
Certifications
• Marcegaglia is qualified according to
AD 2000 - Merkblatt W0
(directive 97/23/EC) with TÜV Rheinland
• The qualification currently applies to norm
EN 10217-1/2, grades P235TR1, P235TR2
and P235GH
• The qualification allows Marcegaglia
to supply certificates conform to W4
according to PED directive
34
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 10219-1
• Standard grades certified with CE marking:
S235JRH, S275J0H, S275J2H, S355J0H, S355J2H
• Micro-alloyed grades certified with CE marking:
S355MH, S420MH, S460MH
35
RINA approval
Certificate of Approval
of Manufacturers of Materials
Tubes for naval constructions
EN 10219
EN 10217
S235JR, S355J0, S303J2
P235 TR1 - TR2 - GH
36
thank you
via Bresciani, 16 • 46040 Gazoldo Ippoliti, Mantova - Italy
www.marcegaglia.com