Long Product Hot Rolling Mills

Services & Products

www.steelws.com

Bar & Rebar Mill

Steel Worldwide Services Ltd

Long Product Hot Rolling Mills

Services & Products

Wire Rod Mill

Small Section & Profile Mill

Engineering & Design Services

Our 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:

Used/2nd Hand Refurbished Mill/Equipment

Due 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:

Supply of New Equipment

We are able to design, manufacture and supply the following new equipment for:

Billet Handling & Reheating Furnaces

Billet 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:

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.

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.

Reconfiguration of the mill to meet the new owner requirements. Reconditioning & Refurbishing Services. Dismantling & Reinstallation at new site.

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.

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.

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

Rolls for Rolling Mills

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

Advanced Water Quenching Line (AQL) Systems

AQL 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 of Parts covers:

Spare Parts & Consumables

Our Spare Parts Department, with the collaboration of Our Long Product Rolling Division is able to provide various types of spare parts for long product hot rolling mills.

TYPES

Cast Steel Alloy Cast Steel Rolls

Adamite (steel base) Adamite Rolls

Cast Iron SGP Rolls

Diameter available:
200mm - 1300mm

70Mn2 Rolls

SGA Rolls Indenite Chilled Rolls

SGP : Spheroidal Graphite Pearlite SGA : Spheroidal Graphite Acicular

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.

Centrifugal Casting

Rolls for Guides

SWS Guiding Equipment & Systems

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

On-Site Customer Technical Assistance

As 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:

TYPES

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.

Static Guides

Entry Roller Guides

Slitting Guides

Prole Guides

Exit Twisting Guides

Wire Rod Block Guides

Two-Roller Roller Guides Model: ER

Torsion Roller Guides Model: ETR

Three-Roller Roller Guides Model: 3EPR

Our Guides are designed for being: Stout, Compact & Practical
Four-Roller Roller Guides Model: 4EPR Slitting/Cutting Guides Model: 2CUT & 4CUT

Steel Worldwide Services Ltd

Rolling Mills Guiding System

For Long Products Hot Rolling Mills
A Unique & Complete Solution for Rolling Mill Guiding Requirements.

Rolls for Guides

SWS Guiding Systems & Equipment

TYPES

SWS Roller Guides Technological 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;

Static Guides

Entry Roller Guides

Slitting Guides

Prole Guides

Exit Twisting Guides

Wire Rod Block Guides

entry and exit static guides

ER01- ER06 4ER01-4ER04 ERF05-ERF06

2CUT01-2CUT02 4CUT01

3EPR01-3EPR05 4EPR01-4EPR02

ETR01-ETR06

ERB01-ERB03

Two-Roller Roller Guides Model: ER

Torsion Roller Guides Model: ETR

Three-Roller Roller Guides Model: 3EPR

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.

Our Guides are designed for being: Stout, Compact & Practical
Four-Roller Roller Guides Model: 4EPR Slitting/Cutting Guides Model: 2CUT & 4CUT

Wire Rod Block Guides

ERB Series

ER Series

Two Roller Guides

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.

Size of Products:

Technical Description:

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.

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.

Dimensions:
TYPE ERB-01 ERB-02 ERB-03 A 167 167 167 B 35 35 35 C 99 99 99 Dmax 56 58 58 H 20 25 29.5 Imax 65 65 65 Imin 47 47 47 U 49 49 49 L 110 110 110

Two Roller Guides

ER Series

4ER Series

Four Roller Guides

Dimensions:
TYPE ER-01 ER-02 ER-03 ER-04 ER-05 ER-06 A 167 190 220 267 325 380 B 31 38 48 57 75 100 C 110 133 177 208 278 350 Dmax 60 70 85 108 140 180 H 25 35 55 80 120 170 Imax 65 78 108 125 170 225 Imin 47 56 70 90 120 170 U 46 60 80 95 130 165 L 115 127 170 205 280 365

Size of Products:

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.
H 25 35 55 80 35 35 Imax 65 78 108 125 103 128 Imin 47 56 70 90 81 106 U 75 80 100 115 80 80 L 148 180 230 280 205 230

Dimensions:
TYPE 4ER-01 4ER-02 4ER-03 4ER-04 4ER02.1 4ER02.2 A 210 225 255 305 225 225 B 75 85 110 140 85 85 C 150 165 205 245 165 165 Dmax 60 70 85 108 70 70

Fixed Roller Guides

ERF Series

2CUT & 4CUT Series

Cutting Guides

Technical Description:

Technical Description:

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.

There are 2 sizes in the ERF Series (ERF05 - ERF06); They are used in the roughing mill; The Guides can be set manually.

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;

Dimensions:
TYPE ERF-05 ERF-06 A 445 445 B 52.5 52.5 C 305 355 D MAX 122 142 H 120 170 U 152.5 177.5

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 & 4CUT Series

3EPR Series

Cutting Guides

Three Roller Guides

Dimensions:
2CUT
TYPE 2CUT-01 2CUT-02 A 188 213 B 60 60 C 180 205 U 90 102.5 L 150 180

Technical Description:

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)

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;

TYPE 4CUT-01

A 250

B 60

C 205

U 102.5

L 205

4CUT
TYPE 2CUT-01 2CUT-02 A 188 213 B 60 60 C 180 205 U 90 102.5 L 150 180

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 TYPE

TYPE 4CUT-01

A 250

B 60

C 205

U 102.5

L 205

Three Roller Guides

3EPR Series

4EPR Series

Four Roller Guides

Dimensions:
TYPE 3EPR-01 3EPR-02 3EPR-03 3EPR-04 3EPR-05 A 257 280 335 415 415 B 145 170 222 300 350 C 125 140 175 215 215 D1max 120 128 160 205 205 D2max 105 120 150 195 195 U 115 115 145 180 180 L 235 250 300 360 360

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);

Static Guides
Technical Description:

There are 2 Series of static guides: ES and US. ES are the Entry Static Guides. US are the Exit Static Guides.

Torsion Roller Guides

ETR Series

ETR Series

Torsion Roller Guides

Technical Description:

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.

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;

Dimensions: ETR01 & ETR02

TYPE ETR-01 ETR-02 A 175 190 B 108 123 C 135 165 U 67.5 82.5 L 90 110

Dimensions: ETR03, ETR04, ETR05 & ETR06

TYPE A B C ETR-01 175 108 135 ETR-02 190 123 165 TYPE ETR-03 ETR-04 ETR-05 ETR-06 A 340 420 520 550 C 300 355 470 500 U 150 177.5 235 250 L1 75 100 130 155

U 67.5 82.5

L 90 110

L2 122 150 198 218

L 197 250 326 373

TYPE ETR-03 ETR-04 ETR-05 ETR-06

A 340 420 520 550

C 300 355 470 500

U 150 177.5 235 250

L1 75 100 130 155

L2 122 150 198 218

L 197 250 326 373

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.

Various Heat Treatment Processes

Precision Casting of Parts

CNC Precision Machining Centres

Rolls for Roller Guides

SWS has developed its own technology to manufacture high quality rolls for the roller guides. Guide rolls are exposed to extremely high temperatures of almost 1000C (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.

Our Manufacturing Facilites

Our Partners Workshops have the following production facilities:

Quality Assurance Equipment:

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.

Basic physical properties testing equipment. 3-D Dimensional Measuring Equipment. Spectro Laboratory.

SWS Roller Guides A Complete Solution

SWS 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:

All Products are supplied under SWS Warranty.

Raw Casting of Parts

Final Machining of Parts

Guides Assembled & Ready to be Delivered

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.
High Inventories of Consumables for Roller Guides in most Rolling Mills

Consistent Monthly Supply of Consumables such as rolls, funnels, half guides and strippers

Packing

Sea Worthy Packing for Guides, Consumables & Spare Parts

SWS 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.

Rolling Rolls Guiding System

For Long Products Hot Rolling Mills

On-Site Customer Technical Assistance

As 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.

Porosity at Rolls

Advantages of Sws Rolling Rolls

SWS, with its 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:

Rolls for Rolling Mills

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

SWS Rolls General Specifications

Diameter available:
200mm - 1300mm
Chemical Composition
70Mn2

C 0.65-0.7 1 C 3.00-3.6 0 3.00-3.6 0

Si 0.20-0.4 5 Si 1.60-2.4 0 1.60-2.4 0

Mn 1.40-1.8 0 Mn 0.40-0.7 0 0.30-0.8 0

P < 0.035 Ni 2.00-3.0 0 3.51-4.5 0

S < 0.030 Cr 0.10-0.5 0 0.20-0.5 0 Mo 0.20-0.6 0 0.40-0.9 0 Mg 0.04 0.04 P 0.10 0.10
Hardness of Roll Neck 50-73 HSD 60-80 HSD Hardness of Roll Body 35-45 HSD 35-45 HSD

Chemical Composition
SGP

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.

Cast Steel Alloy Cast Steel Rolls

Adamite (steel base) Adamite Rolls

Cast Iron
SGA

SGP Rolls
Chemical Composition
Indenite Chill Adamite Hardness of Roll Neck 50-73 HSD 60-80 HSD Hardness of Roll Body 55-85 HSD 35-45 HSD

70Mn2 Rolls

SGA Rolls Indenite Chilled Rolls

SGP: Spheroidal Graphite Pearlite SGA: Spheroidal Graphite Acicular

C 2.90-3.6 0 1.30-2.1 0

Si 0.60-1.5 0 0.30-0.8 0

Mn 0.40-1.2 0 0.70-1.4 0

Ni 0.50-4.8 0 0.20-2.5 0

Cr 0.70-2.0 0 0.80-3.5 0

Mo 0.20-2. 00 0.20-0. 60

0.25 0.035

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 .

All our rolls are produced through Centrifugal Casting method

Vertical Furnace with Ladles

Product Marking at Rolls

Centrifugal Casting Machine

Pouring of Hot Metal for Casting

Sea Worth Packing for Rolls

Plain Rolls without Grooves

Our Manufacturing Facilites

Our 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.

Packing & Marking

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.

Quality Assurance Equipment:

Hardness Test Ultrasonic Test Metallograpgy Test Spectro Laboratory

Casting of Rolls

On-Site Customer Technical Assistance

As 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.
Proper Water Cooling for the Rolls Customer Assistance on Site

Machining of Rolls

Fire Cracks at the Grooves of the Rolls

Incorrect Water Cooling for the Rolls that will shorten the life-span of the rolls

Anomalous Wear at the Grooves of the Rolls

Steel Worldwide Services Ltd

Shear Blades
For Iron & Steel Industry

Precision Machining of Blades

Vacuum Hardening & Tempering Furnace

Advantages of Sws Shear Blades

SWS, with its 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:

Types of Shear Blades

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

Our Manufacturing Facility

Our 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

TYPES

Continuous Casting Machine

Billet Shearing Machine

Bar/Wire Rod/Prole Rolling Mill

Crop Shear Cut to Length Shear Cold Cutting to Length Shear

Hot Strip Mill / Plate Mill

Crop Shear

Cold Rolling Mill

Crop Shear

Excellent Quality of Shear Blades.

Quality Control for manufacturing

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).

Packing & Marking

SWS 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.

Sea Worthy Packing for Shear Blades

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.

Steel Worldwide Services Ltd

Shear Blades with Inserts

Typical Wear of Shear Blade of a Bar Mill

Steel Worldwide Services Ltd

Africa, America, Europe & Russia:

Corporate Headquarters
International House, 1 St. Katharines Way London E1W 1UN - United Kingdom Phone: +44 20 76804023 Fax: +44 20 76804021 E-mail: sws@steelws.com

Asia Pacific & Middle East:

1st Floor, Unit 7, Jalan Tengku Ampuan Zabedah B, 9/B Seksyen 9, 40100 Shah Alam, Selangor D.E. Malaysia Phone: +60 3 55118689 Fax: +60 3 55118690 E-mail: swsfareast@steelws.com