Casalmaggiore plant
may 2013
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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 chainMarcegaglia develops the world’s widest range of customer tailored steelsemi-products and finished goods.
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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.
Steel coil processing is at the core of Marcegaglia activities. The complete range of first transformation processes is carried out within 50 facilities worldwide.
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Antwerpen Bremen Düsseldorf
Munhall
Garuva
Dublin
Dudley
Lyon
Barcelona
Doha
Cluj
MoscowPraszka
Kluczbork
Yangzhou
Timişoara
Calcutta
Lima
Vladimir
6,000,000 sqm manufacturingareas
Casalmaggiore
Headquarters
MARCEGAGLIA WORLDWIDE PRESENCE
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Casalmaggiore plant
The Marcegaglia manufacturing unit of Casalmaggiore (Cremona, Italy) spreadsover 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, rectangularand of special shapes, with thickness ranging from 1,35 to 16 mm diameters from 17 to 406, in accordance to current norm requirementsas well as to custom specifications.
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Casalmaggiore plant
The production surface and equipment additions were completed in 2011 and have allowed the plant to increase its manufacturing capacityup 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
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Casalmaggiore plant
The new area is covered with an integratedphotovoltaic roofing employing Marcegagliaown 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.
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Casalmaggiore plant development
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Casalmaggiore plantManufacturing areas
Slitting
Tube mills
Heat treatments
Straightening
Tube cutting
Warehouse
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Main manufacturing standards
EN 10305-3 Round and shaped precision tubes
EN 10305-5 Square and rectangularprecision tubes
EN 10219 Cold formed welded structural tubes (CE homologation)
EN 10210
EN 10217-1
Structural hollow sections, hot finished or cold formed and heat treated
Tubes for pressure purposes, for use at room temperature
Upon request: supply of grades not included in the above mentioned standards
EN 10217-2 Tubes for pressure purposes, for use at high temperatures
EN 10208-1 Steel pipes for pipelinesfor combustible fluids
EN 10224 Tubes for the conveyance of water and other aqueous liquids
EN 10255 Tubes suitable for welding and threading
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The production program of Marcegaglia tubes from hot rolled strip coversa wide range of structural and mechanical applications, guaranteeing specific suitability for subsequent processing.
Tubes for steel structural work
Tubes for piling
Typical applications
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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
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.
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Major applications include: axles for vehicles and industrial vehicles, tubes for dump trucks, stabilizers and steering components.
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Tubes for pressure purposes include applications for the heat exchanger industry, heating and ventilation, gas and water line pipes, district heating tubes.
Tubes for heat exchangers
Tubes for gas and water line pipes
Tubes for district heating
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Tubes suitable for drawing
Roller conveyor tubes Tubes for lifting equipment
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.
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Marcegaglia Casalmaggiore
Slitting lines
lines 5
manufacturing capacity (t/y) 700,000
coil thickness (mm) from 1.3 up to 16
coil width (mm) up to 2,000
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lines 11
product type round, square,
rectangular, special shaped tube
manufacturing capacity (t/y) 700,000
wall thickness (mm) from 1.3 up to 16
diameter (mm) from 16.75 up to 406.4
length feasibility (mm) from 5,000 to 16,000
Marcegaglia Casalmaggiore
Tube mills
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Production line TC011 (3’’)
Welded tubes ex hot rolled strip (black or pickled), cold rolled strip, coated strip
ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 1,35
Max. thickness (mm) 6,6
Min. diameter (mm) 21,25
Max. diameter (mm) 89
Min. thickness (mm) 1,35
Max. thickness (mm) 6
Smallest square (mm) 20x20
Largest square (mm) 75x75
and all rectangular derived
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Production line TC011 (3’’)
Mill lengths 5.000-14.000 mm
Length tolerance -0+50 mm on demand -0+25 mm
Thickness range 1,35 - 6,6 mm
TECHNICAL FEATURES
Marking of strips prior to forming
Weld seam removingOnline laser gauge to control adherence to tolerances on 100% of the outside diameterReel mounted stampingOn demand,“cold saw” cutoff (no trimming but burr-free ends)Internal washing
Bevel endsDot matrix cast marking(on tubes for pressure applications)This may involve some speed reductionAir blowing of trimmings and swarf
NON DESTRUCTIVE TESTSInduced eddy currents onlineEddy current + magnetic flux leakage (Rotomat) after bevelling
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Production lineTC002 (8’’)
ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 3
Max. thickness (mm) 16
Min. diameter (mm) 114,3
Max. diameter (mm) 219,1
Min. thickness (mm) 3,7
Max. thickness (mm) 16
Smallest square (mm) 90x90
Largest square (mm) 180x180
and all rectangular derived
Welded tubes from hot rolled black strips (upon mutual agreement we can possibly use pickled and coated strips)
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Production lineTC002 (8’’)
NON DESTRUCTIVE TESTSInduced eddy currents onlineEddy current + magnetic flux leakage (Rotomat) after bevelling
TECHNICAL FEATURES
Marking of strips prior to forming
Trimming of strip edges before welding
Weld flash trimming/removal
Heat treatment (normalisation) of the welding areaOnline laser gauge to control adherence to tolerances on 100% of the outside diameterReel 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 -0+50 mm on request -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
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Production lineTC001 (16’’)
ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 4
Max. thickness (mm) 16
Smallest square (mm) 244
Largest square (mm) 406
Min. thickness (mm) 4 (3)
Max. thickness (mm) 16
Min. diameter (mm) 200x200
Max. diameter (mm) 325x325
and all rectangular derived
Welded tubes from hot rolled black strips (upon mutual agreement we can possibly use pickled and coated strips)
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Production lineTC001 (16’’)
Length feasibility 6.000-16.000 mm
Length tolerance -0+50 mm on request -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 TESTSInduced eddy currents onlineRotomat after deburring
TECHNICAL FEATURES
Marking of strips prior to forming
Trimming of strip edges before welding
Weld flash trimming/removal
Heat treatment (normalisation) of the welding areaOnline laser gauge to control adherence to tolerances on 100% of the outside diameterReel mounted stamping
Online cutting with coated saw blades
Internal washing
Deburred ends/bevel ends
Dot matrix cast marking
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furnaces 3
heat treatments:
• normalization
• annealing
• stress relieving
manufacturing capacity (t/y) 200,000
wall thickness (mm) from 0.9 up to 16
diameter (mm) from 16 up to 355
Marcegaglia Casalmaggiore
Heat treatments
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lines 4
manufacturing capacity (t/y) 80,000
wall thickness (mm) from 0.9 up to 14
diameter (mm) from 13 up to 219
Marcegaglia Casalmaggiore
Straightening
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lines 6
length (mm) from 100 to 12,000
also in bundles
manufacturing capacity (t/y) 50,000
wall thickness (mm) from 0.9 up to 16
diameter (mm) from 21.25 up to 406.4
Marcegaglia Casalmaggiore
Tube cutting
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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.
Marcegaglia Casalmaggiore
Automated warehouse
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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
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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
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EA:17
505/96/S
MARCEGAGLIA S.p.a.
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIASITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASINGVIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALESVOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDEDLONGITUDINALLY
PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE
30.12.1996
13.07.2012
Per informazioni sulla validitàdel certificato, visitare il sito
www.rina.org
For information concerningvalidity of the certificate, you
can visit the sitewww.rina.org
CISQ è la Federazione Italiana diOrganismi di Certificazione dei
sistemi di gestione aziendale
CISQ is the ItalianFederation of managementsystem Certification Bodies
CERTIFICATE No.
CERTIFICATO N.
SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES
NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
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
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
Prima emissioneFirst Issue
Emissione correnteCurrent Issue
RINA Services S.p.A.Via Corsica 12 - 16128 Genova Italy
È CONFORME ALLA NORMA / IS IN COMPLIANCE WITH THE STANDARD
Riferirsi al Manuale della Qualitàper i dettagli delle esclusioni ai
requisiti della norma
Data scadenzaExpiry Date 12.07.2015
SGQ N° 002 A SSI N° 001 GSGA N° 002 D DAP N° 001 HPRD N° 002 B PRS N° 066 CSCR N° 003 F LAB N° 0832
The use and validity of this certificate are subject to compliance with the RINA document : Rules for the certification of Quality Management Systems
Dott. Roberto Cavanna(Managing Director)
Reference is to be made to theQuality Manual for details
regarding the exemptions from therequirements of the standard
ISO 9001:2008
Membro degli Accordi di MutuoRiconoscimento EA, IAF e ILAC
Signatory of EA, IAF and ILAC MutualRecognition Agreements
CertificationISO 9001:2008
The plant is certified according to ISO 9001:2008 with RINA(Registro Italiano Navale)
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TS/505/96
MARCEGAGLIA S.p.a.
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIASITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASINGVIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALESVOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
ISO/TS16949:2009
PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDEDLONGITUDINALLY FOR THE AUTOMOTIVE INDUSTRY
PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTEPER L'INDUSTRIA AUTOMOBILISTICA
14.10.2002
13.07.2012
Per informazioni sulla validitàdel certificato, visitare il sito
www.rina.org
For information concerningvalidity of the certificate, you
can visit the sitewww.rina.org
CISQ è la Federazione Italiana diOrganismi di Certificazione deisistemi di gestione aziendale.
CISQ è membro di IQNET.
CISQ is the Italian Federation ofmanagement system
Certification Bodies. CISQ is amember of IQNET.
CERTIFICATE No.
CERTIFICATO N.
Essendo stati valutati in accordo alle “Regole per lo schema di certificazione ISO/TS 16949:2002 – Terza Edizione Ottobre 2008”
IL PRESENTE CERTIFICATOÈ EMESSO IN CONFORMITÀ
ALLE REGOLE IATF
CISQ AUTOMOTIVE -
The validity of this certificate is dependent on an annual/sixmonthly audit and on a complete review, every three years, of
the management system
Prima emissione
First Issue
Emissione correnteCurrent Issue
RINA Services S.p.A.Via Corsica 12 - 16128 Genova Italy
Riferirsi al Manuale della Qualità per i dettagli delle esclusioni ai requisiti della norma
Reference is to be made to the Quality Manual for details regarding the exemptions from the requirements of the standard
La validità del presente certificato è subordinata a sorveglianzaperiodica annuale / semestrale ed al riesame completo del
sistema di gestione con periodicità triennale
Having been assessed in accordance with "ISO/TS 16949:2002 certification scheme rules – Third Edition October 2008"
Data di scadenzaExpiry date
Certificato IATF n.IATF Certificate n. 0143175
THIS CERTIFICATE ISISSUED IN CONFORMITY
WITH THE IATF RULES
Via Quintiliano 41 – 20138 MILANO
Dott. Roberto Cavanna(Managing Director)
12.07.2015
SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
È CONFORME ALLA NORMA E AI REQUISITI DELLO SCHEMA
IS IN COMPLIANCE WITH THE STANDARD AND THE SCHEME REQUIREMENTS
PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIESEA:17
CertificationISO/TS 16949:2009
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)
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CertificationISO/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”
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TÜV - PEDCertifications
• 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
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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
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RINA approvalCertificate of Approval of Manufacturers of Materials
Tubes for naval constructions
EN 10219
EN 10217
S235JR, S355J0, S303J2P235 TR1 - TR2 - GH
thank you
via Bresciani, 16 • 46040 Gazoldo Ippoliti, Mantova - Italywww.marcegaglia.com