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Widest range of world class Furnace
Normalised, Quenched & Tempered,
Line Pipe and As Rolled plates
W HAT M AKES O UR P LATES U NIQUE
MTCPL
Metallurgical Process:
Employing the best steel making technology and processes, Essar Steel plates contain low levels of sulphur,
phosphorous and gaseous content. Calcium treatment and inclusion shape control reduces internal discontinuities
giving plates improved toughness, enhanced fatigue life, better weldability and excellent shape properties.
TMCP- ADCO/DQ
Thermo Mechanical Controlled Processed (TMCP) with Accelerated Direct Cooling (ADCO) and Direct Quenching
(DQ) facilities offer Steel plates with improved abrasion resistance and wear performance, good formability and high
Customised Plate:
Equipped with advanced Hydraulic Automatic Gauge Control (HAGC), online Gamma Thickness Gauge and L-2
Automation, Essar Steel can supply steel plates as per actual thickness, width, length and profiles, required for
ASTM:
L-2 automation with no manual intervention and a walking beam furnace with a powerful de-scaler ensures that the
steel plates are precision manufactured to be supplied with consistency and maintains ASTM tolerances.
Product Range:
Essar Steel offers one of the widest ranges of plate qualities, sizes and grades available anywhere in the world.
As Rolled 5-150
requirement. This is specific for any project that requires LEED compliance as a prerequisite condition for the usage
of plates.
C ONTENT
5 ESSAR STEEL
11 PLATE APPLICATIONS
17 LINE PIPE
19 DEFENCE
21 SHIP BUILDING
25 CONSTRUCTION
27 WIND ENGINEERING
31 CERTIFICATES
35 TESTING FACILITIES
36 ORDERING
E SSAR S TEEL M ETALLURGY OF P LATE R OLLING
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
The Thermo-Mechanical Control Process (TMCP) Normalising
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 retail facilities, and distribution outlets Through TMCP, very fine and uniform ferrite The process of producing a stable microstructure by
known as Hypermarts.
microstructure is obtained and results in higher strength heating it to the high temperature austenite and
Global Operations and toughness. The plate is also less susceptible to cold slowly cooling it.
Essar Steel Algoma in Canada has a current capacity of 4 MTPA. Essar Steel Minnesota, USA (with iron ore cracking and has better weldability.
reserves of over 1.4 billion tonnes) is developing a 7 MTPA pellet plant and an ore concentration plant. In Advantages
Indonesia, Essar Steel is the largest private steel processor and operates a 400,000 tonnes per annum (TPA)
Process for producing heavy plates - Refines and ensures homogenous structure
cold rolling complex with a galvanising line of 150,000 TPA.
CONVENTIONAL THERMO-MECHANICAL - Reduces residual stresses from rolling
Essar Steel is the largest steel producer in western India, with a capacity of 10 MTPA at Hazira, Gujarat. The steel PROCESSING CONTROLLED PROCESSING (TMCP)
plant is backed by an iron ore beneficiation and a pelletization unit that ensures supply of quality raw material. HOT
HEAT TREATMENT
CONTROLLED ACCELERATED - Reduces the risk of "banding
ROLLING ROLLING ROLLING
The Essar Steel complex at Hazira has a complete infrastructure setup including a captive port, and power, lime NORMALISING QUENCHING & TEMPERING
WATER
and oxygen plants.
TEMPERATURE,
Quenching and Tempering
AIR OR
RAYSP
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
WATER
WATER
This is a conventional process used to harden or
AIR CO
AIR CO
AIR COOL
AIR COOL
product portfolio. Essar Steel has the countrys largest steel processing capacity of 4 MTPA at its seven
QUEN
CO
OL
OL
OLED
CH
processing and distribution facilities, located at key automotive and industrial hubs. In India, it has the distinction strengthen steel. During quenching, the austenite is
of being one of the largest galvanisers, as well as being the largest producer of cold rolled and colour coated converted to martensite. The quenched alloy is then
products. Additionally, a 6 MTPA pellet plant is located at Paradip, Orissa and will be increased to 12 MTPA by
Concept of microstructure change during TMCP tempered at an intermediate temperature to
the next financial year.
transform the brittle martensite into a very fine
TEMPERATURE
AUSTENITE
Essar Steel produces highly-customised products catering to a variety of product segments. It is Indias largest
STAGE I
iron ferrite matrix.
exporter of flat products to the highly demanding US and European markets, and to the growing markets of
POLYGONAL FERRITE
STAGE II
STAGE III
South East Asia and the Middle East. It invests in world-class research & development and has technology
AI AI AI AI
R R R R
CO CO
collaborations with global steel majors to develop enhanced value-added products and grades that find wide
CO CO
OL OL OL OL
IN IN IN IN FINELY DEFORMED PLATE ROLLING
G G G G
FERRITE
acceptance in sectors like automotive, white goods, construction, engineering and shipbuilding. With TIME CONTROLLED-ROLLING
TEMPERATURE,
TEMPERING
investments in downstream capabilities, Essar Steel has evolved from being a product-based company to a QUENCHING
Advantages
TIME
6
W ORLD C LASS P LATE M ILL F ACILITIES
Rolling Mill
High roll separating force of 10,000 tonnes, almost double compared to some of the other plate mills - generates
extremely fine grain properties on plates. The mill is supported by a fully automatic gauge controller, plan view rolling
and flatness gauge to achieve a high degree of profile, even for very thick plates.
High-tech plate mill features with world class processes and ultra modern facilities:
10,000 tonnes of roll separating force Thermo-Mechanical Controlled Rolling (TMCR) and Accelerated Direct Cooling (ADCO)
Thermo Mechanical Controlled Process with Accelerated Direct Cooling Thermo mechanical rolling and DQ (direct quenching) equipped with ADCO facility for high strength plates - can be
4,000 tonnes of hot leveller capacity used in demanding applications for the oil & gas sector and other segments.
Equipment Supplier
Heat Treatment
Rolling mills, ADCO facilities, Siemens VAI, France
roller tables, cooling beds, hot Heat treatment facility with austentising, normalizing, quenching and tempering to provide desired properties of steel
and cold levellers, including plates. Furnace normalization is done in an inert atmosphere with indirect radiant type heating to ensure no scales are
automation and control systems
formed on the surface of the plates, leading to a better yield. Quenched & Tempered facilities spray the plates with
Digital reheating furnace Fives Stein, France
Heat treatment facilities covering LOI, Germany more than 10,000 cubic metres of water in two minutes.
austenitising and normalising,
quenching and tempering
Ultrasonic Testing
furnaces
Auto UT testing NDT, Germany 100% ultrasonic testing is performed for plates up to 50 mm thickness using an image comparator and without any
Shot blasting and painting Wheelabrator, Germany manual intervention. To keep it perfectly aligned the testing unit is recalibrated every day. Testing of plates above
Roll grinders Waldrich, Germany 60mm thickness is done manually by an international third party inspection agency.
4 HI MILL
RECEIVING
SLAB RE-HEAT PRIMARY ADCO HOT HOT
LEVELLER PAINT COOLING BED-1 > 50 MM
SLAB DISPATCH
FINISHED
14
DIVIDING STOCK &
DOUBLE SIDE SLITTING CHAIN TRANSFER &
CROP SHEAR SHIPPING
TURNOVER DEVICE PLATE
FULL BODY UST
PLATE PILER
CROSS CROSS
CROSS
COLD LEVELLER
QC LAB
HEAT TREATMENT
SHOT BLASTING PAINTING
7 8
W HY B U Y P LA TE S FR OM E SSAR S TEEL
Clean Steel
Essar Steel plates are backed by the latest steel making technology to ensure clean steel with low inclusion
contents and low sulphur to improve plate suitability and avoid Hydrogen Induced Cracking (HIC test is in
Great Quality
Essar Steel plates conform to international standards including ASTM, EN, JIS and IS. We have also gained
quality approvals for plate supply from Det Norske Veritas, Germanischer Lloyd, American Bureau of Shipping,
American Petroleum Institute, NEEPCO, Nippon Kaiji Kyokai and Indian Navy.
Essar Steel plates can be supplied under As rolled, Normalised rolled, TMCR (thermo-mechanical
controlled rolled), Furnace normalised, quenched and tempered conditions. Plate sizes range from 5mm
to 150mm thickness, with widths up to 5m and lengths up to 25m. Plates with ultra high strength steel
Application engineering
Application engineering and product development in Essar Steel is the corner stone of the successful
integration of deep insight and understanding of the customers current and evolving needs with a meaningful
product development solution. The new product development efforts of the application engineering team
delivers sustained value-creation for customers right from conceptual design to ready for service value
10
P LATE A PPLICATIONS
Type Application
Boilers and Pressure Vessels ESSAR THERMOR
Yellow Goods & Mining Equipment ESSAR ROCKSTAR & ESSAR BOOMOR
Ultra high strength steel plates with superior toughness Structures like
- Truck body
- Arm
- Support structures
Defence
High strength, hardness, toughness and anti-ballistics Armour tanks, mine protective vehicles
steel plates
Ultra high strength and toughness, bulletproofs steel Personal and vehicle protection
Special alloy steel plates Naval warships, submarines
High strength steel plates with excellent weldability General engineering / fabrication
Ultra high strength and tough steel plates - Merchant ships, cargo, bulk carriers, submarine hulls
- Low-temperature applications
Ultra high strength and tough steel plates Dams, bridges, buildings, power plant structures, penstock
Atmospheric corrosion resistant steel plates Offshore platforms, bridges, building structure
Seawater corrosion resistant steel plates Bridges, offshore platforms, structures
Higher width high strength steel plates Conical sections of long wind towers
11
E SSAR T HERMOR P LATES F OR B OILERS
A ND P RESSURE V ESSELS
Applications steel plates are required to have high strength,
toughness, ductility and corrosion resistance. Due to
Boilers: high temperature applications, the steel plates should
- Power plants have excellent creep resistant properties.
Metallurgy
Marquee Customer:
- Mines and quarries The plates used in yellow goods are subjected to
land mines, hard rocks, loading bulk material,
- Agricultural machinery
shovels, crushing units, etc.
- Vehicle manufacturing
The plates are therefore required to have high
- Cement works
strength and toughness and excellent abrasion
- Dump trucks
and wear resistance.
- Front loaders
Mechanical Properties
- Crushers
- High strength
- Booms
- High hardness
- Good weldability
Metallurgy
Alloying of special elements like Cr, Mo and Ni Improved abrasion and wear resistance
Thickness 5 - 70 mm Thickness 5 - 70 mm
Width 900 4850 mm (trimmed edge) Width 900 - 4350 mm (trimmed edge)
Supply Condition Quenched & Tempered Yield Strength 500 / 600 / 620 / 650 / 690 MPa
Marquee Customer:
15
E SSAR A CIDOR & E SSAR F LUIDOR P LATES
F OR L INE P IPE
Applications Corrosion Cracking (SSCC) and Hydrogen Induced
Cracking (HIC), a high Ductile to Brittle Transition
- Transport of oil, gas, water
Temperature (DBTT) and a good Drop- Weight
- Offshore structures Tear Test (DWTT) value.
Metallurgy
Addition of Micro-alloying elements like Nb, Ti, V Reduced DBTT and increased DWTT
Marquee Customer:
21
D EFENCE
Applications are therefore required to have excellent
toughness, high strength, high hardness and good
- Armoured vehicles
ballistic properties.
- Mine protective vehicles
Mechanical Properties
- Protective buildings
- High strength, up to 1,500 MPa tensile strength
- Security vehicles
- Good low-temperature toughness
Challenges During Usage - High corrosion resistance
Metallurgy
Dimensions
Marquee Customer:
Metallurgy
Composition / Treatment Result
Clean steel, with very low S content Avoid lamellar tearing
Optimal carbon equivalent (Ceq) with low carbon Good mechanical properties and good weldability
and micro-alloying elements
Mechanical Properties
- High strength
ESSAR SHIPOR
Thickness 5 - 100 mm
Width 1100 - 4950 mm (mill edge)
900 - 4850 mm (trimmed edge)
Length 3000 - 25000 mm
Supply Condition As Rolled, TMCP, Normalised &
Shot Blasted & Painted
Standard All SBP grades -
ABS, DNV, NKK, LRS, RINA &
other relevant grades
Marquee Customer:
21
ESSAR STRUCTOR & ESSAR FANOR PLATES
FOR GENERAL ENGINEERING / FABRICATION
Applications Challenges During Usage
- Equipment manufacturing The plates are required to have high strength,
- Forging and industrial fabrication toughness, corrosion resistance and good weldability.
- Kilns
Mechanical Properties
- Gates for hydro projects
- High strength
- Crane girders
- High toughness
- Turbine runners
- Good weldability
- Good corrosion resistance
Metallurgy
Width 1100 - 4950 mm (mill edge) Supply Condition TMCP & Q&T
900 - 4850 mm (trimmed edge)
Yield Strength 600 /650 / 690 MPa
Length 3000 - 25000 mm
Standard EN 10025
Supply Condition As Rolled, Normalised & Q&T
Yield Strength 350 / 410 / 450 / 500 / 600 /
650 / 690 MPa
Standard BIS, EN 10025, ASTM, JIS &
other relevant grades
Marquee Customer:
Metallurgy
Metallurgy
Optimal alloy design containing C, Mn, and High strength and toughness
other micro-alloying elements like Nb, V and Ti
Marquee Customer:
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:
- 4-edge welding for better results - Tandem arc welding
- Beam auto-straightening - Shot blasting up to 250 Ra finish
- Oxy-plasma profile cutting up to 60 mm - Primer & final paint booth
- Plasma cutting under water - CNC drilling machine
- Web loading by magnetic tilting arms
Dimensions
Web thickness 10 40 mm
Flange thickness 8 63 mm
Types of Beams
T-shapes
Camber
Z-shapes Tapered
Marquee Customer:
29
C ERTIFICATES C ERTIFICATES
ISO 9001:2008 ISO 14001:2004 BIS certificate Boiler Quality & NEEPCO Approval for
Pressure Vessels IBR Quench and Temper
NKK Certificate RDSO
ABS Certification
Indian Navy approval
31 32
P LATE M ILL P RODUCT S IZE R ANGE P LATE M ILL P RODUCT S IZE R ANGE
Table-3.2 Best possible thickness tolerance
Table-1 Thickness x Width x Length combination
Width Range
Maximum Daughter Plate Length
Thickness Range 1501 - 2500 2501 - 3000 3001 - 3500 3501 - 4000
THICKNESS WIDTH
Thk Tol. Thk Tol. Thk Tol. Thk Tol.
2000 2500 3000 3500 4000 4500 6.0 12.0 +/- 0.3 +/- 0.3 +/- 0.3 +/- 0.3
6-20 12.1 - 16 +/- 0.3 +/- 0.3 +/- 0.4 +/- 0.4
20 24500 16.1 - 20 +/- 0.4 +/- 0.4 +/- 0.4 +/- 0.4
25 22000 19500 20.1 - 25 +/- 0.4 +/- 0.4 +/- 0.5 +/- 0.5
30 24500 21000 18500 16000 25.1 - 40 +/- 0.5 +/- 0.5 +/- 0.5 +/- 0.5
35 21000 18126 15861 14000 40.1 - 60 +/- 0.6 +/- 0.6 +/- 0.6 +/- 0.6
40 22000 18500 15800 13800 12000 60.1 - 80 +/- 0.8 +/- 0.8 +/- 1.0 +/- 1.0
50 22000 17500 14800 12500 11000 9800 80.1 - 100 +/- 1.0 +/- 1.0 +/- 1.2 +/- 1.2
70 15800 12500 10500 9000 7900 7000 Note 1: As symmetric thickness tolerance can also be acceptable within the above given total thickness tolerance.
Note 2: Best tolerance can be offered to customers who are willing to compensate for higher level of process control.
80 13800 11000 9200 7900 6900
Thickness 1501 - 2500 2501 - 3000 3001 - 3500 3501 - 4000 4001 - 4500
Class A: For minus thickness tolerance depending on the nominal thickness. No length restriction Width Tol. Width Tol. Width Tol. Width Tol. Width Tol.
Class B: Foe a fixed minus tolerance of 0.3 mm;
Class C: Foe a fixed minus tolerance of 0.0 mm; 6.0 - >100 + 60/0 + 80/0 + 90/0 + 110/0 + 130/0
Class D: for symmetrical tolerance.
*All dimensions in mm
33 34
T ESTING F ACILITIES O RDERING
- Optical emission spectrometer
Attributes Details to be specified
- Universal testing machine with elevated temperature
Plate dimensions required: Refer capability matrix
testing with a capacity of 1,200 KN
thickness width length out of squareness
- Universal testing machine with a capacity of 2,000 KN
Prescribed or equivalent specification In case specification required is different please
- Cold bend tester with a capacity of 1,000 KN mention the equivalent specification
- Drop weight tear tester with a capacity of 80,000 J Plate marking Marking will be on plate top surface. Specify
additional requirements if any
- Impact tester with a capacity of 450 J
Trimmed / Untrimmed In case of flame cut requirements, the tolerance
- Vicker hardness tester Typical microstructure of a normalised rolled plate
would be subject to mutual agreement
M ARKING
- Paint marking
- Mechanical stamping
- Bar coding
R & D F ACILITIES
- SME with EADX and EDSD
- Micro hardness
- Optical microscopy
35
O RDERING C ONTACT U S
Supply conditions
India Offices: Marketing Offices India Offices: Marketing Offices Italy
Attributes Details to be specified Essar Steel Processing &
Ahmedabad Gurgaon Distribution Italia S.R.L.
Essar House Essar Steel India Ltd. Via G. Boccaccio 4, 20123
Tolerance (close / skewed) In case tolerance of required is closer than Ellisbridge 1st Floor, AEGIS Bldg, 247 Udyog Milano, Italy
Ahmedabad - 380 006 Vihar, Phase-IV,Gurgaon-122 016 Tel: 39 02 4980402
the minimum mentioned, the same should be Tel: +91 79 6608 6666 Haryana, India Fax: 39 02 4986434
Tel: +91 124 6796666
mentioned against each attribute and would
Kolkata Canada
be negotiable based on ICB 2nd Floor, Block: EP, Plot Y16, Faridabad Essar Steel Algoma Inc.
Sector V, Saltlake City, Essar Steel India Ltd. 105 West Street
Kolkata - 700 091 33-A, Industrial Area, Sault Ste. Marie
Skewed tolerances to be mentioned clearly Tel: +91 33 6612 6608 NIT, Faridabad-201301 ON Canada P6A 7B4
Haryana, India Tel: 1 905 331 3400
Bengaluru Tel: +91 129 4163915
Inspection by customer / Third Party Kindly specify in case of inspection requirement:
No. 2, 2nd Floor, RR Chambers, United Kingdom
Inspection (TPI) Inspection agency 11th Main, Vasanth Nagar, Essar Steel Processing &
Bengaluru - 560 052 International Offices Distribution UK Ltd
Tel: +91 80 2220 2131 Pensnett Road, Dudley
Scope of inspection UAE West Midlands, England - DY12HA
NCR Essar Steel Middle East FZE, United Kingdom
Inspection required during rolling or finishing A-5, Sector-3, (Middle-East Asia Regional Office) Tel: 44 7538 092676
Noida - 201 301 S 40402, JAFZA South,
or at both stages Tel: +91 120 6626 666 Dubai, UAE - 261754 Corporate Offices
Tel: +971 48998500
Chennai
TPI with Indian Boiler In case normalising is not mandatory but IBR Mumbai
Chennai House, China Essar Steel Limited
5th Floor, No. 7, Esplanade, Essar Steel Limited
Regulation (IBR) certification certification required Essar House
Chennai - 600 108 Essar - Beijing Representative Office 11, Keshavrao Khadye Marg
Tel: +91 44 2535 1271 / 73 Unit 1509, China World Tower 1 Mahalaxmi, Mumbai - 400 034
Ultrasonic testing ASTM A435 China World Trade Centre Phone: +91 (22) 2495 0606 /
Mumbai No 1 Jian Guo Men Wai Avenue
ASTM A578 Level A, B, C 6660 1100
Essar Technopark, Beijing 100004 Fax: +91 (22) 2492 8896
# 2, L.B.S. Marg, Kurla (West), PR CHINA
EN 10160 Mumbai - 400 034 Tel: +86 (10) 5866 9923
Tel: +91 22 6733 5000 Fax: +86 (10) 5866 9924
Registered Offices
Impact proof certification Please specify the temperature + energy level
Hyderabad Spain
values required 301, Sidhu Shree Vaishnavi Arcade, Hazira (Registered Office)
Essar Steel Processing and
Road No. 1, Banjara Hills, Essar Steel India Ltd
Distribution Iberia, S.L.
Hyderabad - 500 034 27th KM, Surat Hazira Road
Z test Sampling requirements if required and level Poligono Industrial Ingruinsa,
Tel: +91 40 2337 0125 / 6677 0980 District - Surat
C/Jeronimo Roure, 43
Hazira - 394 270
Puerto de Sagunto - 46520
Gujarat, India
Flatness & waviness As per ASTM A6. Any closer tolerance would Pune Valencia, Spain
408, City Tower, Telephone: (+91 261) 2872400
Tel: 34 672053570
be possible subject to confirmation 17, Boat Club Road, Fax: (+91 261) 2872796
Pune - 411 001
Dual certification Certification specifications Tel: +91 20 6620 9901 / 2 International Offices
Indore Indonesia
Copper extra Percentage of Copper in LSA 409, City Centre, PT Essar Indonesia
570 M.G. Road, BFI Estate, Inds 3 Kav B1,
Indore - 452 001 Cibitung, Bekasi 17520,
Low sulphur Sulphur restriction 0.005% Max Tel: +91 731 2538 825 / 2537 974 West Java , Indonesia
Tel: +62 21 8980 152
Inclusion rating Rating
37 38
Essar Steel India Ltd
27th KM
Surat Hazira Road Mail us at
District - Surat
steel@essar.com
Hazira - 394 270
Gujarat, India www.essarsteel.com
Essar House ,
11 K. K. Marg,
Mahalaxmi,
Mumbai - 400 034.
India
Tel: +91 22 6660 1100