Solutions for long product rolling mills

Technology, mechanics, automation and electrical engineering

for bar mills, rod mills and section mills

Metals Technologies
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The most reliable and innovative technology from a single source

For a large range of applications, steel must first be processed in a rolling mill before it can be used.

Our job is to perfectly coordinate and match a number of factors to ensure not just the quality of the

steel, but an exceptional level of mill productivity. As the pioneers of key technologies in long rolling,

such as the Morgan Vee No-Twist Mill, Red Ring Stands, multi-slitting rolling, Morgan Reducing/Sizing

Mills, Morgan Stelmor controlled cooling systems and thermo-mechanical rolling, we have the know­

ledge and experience to provide the best solution for your mill.

You expect …
K Consistent reliability of all units
within the mill
K Increased productivity through
intelligent process design
K Maximum plant flexibility, minimum
set up times
K Optimum cost efficiency through
integration of automatic equipment
K E xcellent product quality with precise
tolerances
K Responsible handling of emissions
and recycling.

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Your challenges:
Greater production.
Higher quality. Lower costs.
Factors to consider
You should expect a great deal from your
solutions partner. Reliable equipment,
process consistency, production flexibili-
ty and waste minimization. All in one
package, managed from start to finish.
All of these factors have to be taken into
account in designing the optimal solu-
tions for your mill.
Maximizing productivity
through process optimization
How much time is needed for each
process step? What temperature profiles
are required? How can transfer areas be
made more efficient? For the best an-
swers to these questions, your rolling
mill partner should have expertise with
equipment technology and know-how
to optimize complex plant layouts.
Flexibility comes first
Short delivery times and fast production
changeover are key criteria for you to
meet your customers’ demands. That’s
why you need to be ready to convert
your rolling stands to the next order
while still processing the current one,
and change your line from one product
to another with virtually no downtime.
Quality throughout
You can achieve very high precision
with rolling stands designed to with­s tand
high loads and changing temperature
­requirements. That same capability,
­coupled with sophisticated control
­technology, allow a wide range of process
conditions for desired product qualities.
Cost reduction
Cost optimization has many facets,
including process-controlled yield
maximization, downtime reduction and
maintenance cost controls. When the
entire system is managed through one
source, you benefit from a high degree
of standardization.
Environmental influences
There are sound legal and cost reasons
for conservation of resources within your
plant, such as water application for tem-
perature control. You should also evalu-
ate your solutions provider by how well
they support you in this area.
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The right starting point:
Siemens VAI long product rolling mills

Top quality of all individual
rolling components …
All components from Siemens VAI are
designed for high durability and maxi-
mum uptime.
The high quality of the components, and
a reliable supply of spare parts thanks
to extensive standardization, ensure we
meet or exceed our customers’ expecta-
tions. Siemens VAI rolling stands are suit-
able for use in a wide range of situations.
Our convertible stands, for example, can
be switched over from horizontal to ver-
tical operation at the press of a button.
In the past, set up times were measured
in minutes, whereas now production can
be changed in a matter of seconds.
… and in the complete system design
A state-of-the-art rolling mill needs more
than just first-class components. It takes
analysis and mapping of all processes,
and possibly their redesign, as part of
an integral system layout, to create a
solution that’s not simply a rolling mill.
In concrete terms, that translates into
considerably higher productivity through
minimized downtime and seamless inter-
linking of production stages.
standardized mill automation utilizing
technological know-how
continually developed and partially
self-learning process models for the
reproducible manufacture of steel
products of defined quality
an MES (Manufacturing Execution
System) solution for optimized produc-
tion planning and for minimizing
rejects
a Level 2 and mill management system
for maximizing everyday performance
and reliable product tracking through
the mill.
Resource management included
We take care to ensure that your most
important resources are available with
absolute certainty, such as efficient
power quality solutions for a dependable
and stable power supply, or with a tailor-
made concept for closed-circuit water
treatment to match the process
requirements.
Naturally, we also take all current emis-
sion levels into account in the design of a
rolling mill – and if necessary, anticipate
tomorrow’s standards as well.
Guaranteed performance throughout
the entire life cycle
Knowledge transfer by our training
experts, combined with a dependable
supply of spare parts, ensures reliable
operation. A full range of services from
Siemens VAI helps maintain high mill
availability over the entire life cycle.
This is backed by carefully planned mod-
ernizations for cost-effective technical
upgrades.
Where’s the proof?
The numbers demonstrate the success
of our concept. More than 1,000 rod,
bar and billet mills all around the world
are Morgan, Pomini, Ashlow and VAI
mills, now all joined within Siemens VAI.
These mills have set world­wide bench-
marks for technological leadership, reli-
ability and performance, and have cap-
tured the greatest market share in long
rolling equipment.

Success from a single source

Automation from
the global market leader
All processes of our rolling mills are moni-
tored and controlled by an integrated
automation solution from Siemens VAI.
Beyond the actual process control, we also
offer:
Our turnkey solutions ensure that all as-
pects of the mill’s design, manufacture,
installation and start-up are managed with
close coordination and expertise. This
comprehensive approach is unique. As
prime contractor, we handle the complex
details, and monitor all required rules and
regulations, so you can concentrate on
your core business of manufacturing long
products and marketing them profitably.

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Our experience in the field of rolling mills dates back to 1886, with the founding of Pomini in

Castellanza, Italy, and 1888, when Morgan Construction began U. S. operations in Worcester,

Massachusetts. Siemens VAI continues to innovate for competitive advantage, with the

­expertise required for all elements of plant construction: process, engineering, manufacturing,

installation and commissioning, plus life-cycle management. No other rolling mill manufac-

turer today can offer a comparable range of products, ­solutions or ­experience.

Good reasons to choose

our rolling mill solutions
Maximum reliability, thanks to 250
years of combined experience
Thousands of roll stands commissioned
Over 1,000 rolling mills installed or
upgraded on six continents
Verifiable expertise for all elements
of plant design and construction
Global presence and economicm
strength as a part of Siemens
Solution providers to cover all
aspects of long rolling
– Mechanical
– Electrical
– Automation
– Fluids
– Process and plant services
– Metallurgical services
– Services
In-house manufacturing and testing
of proprietary technology equipment
One contact for all questions.

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Every rolling mill is different, varying

in design according to the desired products,

qualities and volume. Siemens VAI offers you

the right solution for every requirement –

for high-speed production, for precise micro-

structure qualities, for the shortest possible

changeover time from one long product to

another – and much more.

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 Our rolling mill products –
a well-coordinated ensemble

Coil handling Morgan Stelmor Laying head Morgan Rod Reducing/Sizing Mill
Cooling conveyor

Coil compactor

Cooling bed High speed entry to cooling bed Bar bundling

Morgan No-Twist mill Pouring reel Billet welding

Red Ring stands

Bar sizing Crop and cobble shear Water cooling system

Across all processes:
Expertise, automation, services

Automation SIROLL LR
From mill management, supervisory and control
systems, all the way to motors, drives and individual
component and sensor controls, Siemens offers a
complete solution to your rolling mill automation
needs from Level 1 to Level 3. With a full array of
mechatronic packages for equipment units through­
out the process, a totally integrated automation
solution is available from the factory floor to upper
management.

Total engineering
Accurate planning that addresses everything from
energy supply and raw materials logistics to through­
put targets is a prerequisite for a successful start of
your plant. We provide all the up-front necessities
to make sure your project gets off to a safe start,
including technical consulting as well as simulation
of all processes.

Commissioning
In supervising installation and start-up of electrical
and automation, the task is to reach full production
and consistent operation in the shortest possible
time. That requires experienced automation and
electrical engineers knowledgeable in long products
to support the customer. For easier and quicker
trouble-shooting, the automation system is pre-
pared for remote access.

Services and life-cycle management

Ongoing availability calls for a well-designed service
concept, up to and including around-the-clock moni­
toring of the plant by Siemens. Clearly defined pro-
cesses, uniform manuals, assured parts availability
and a globally available team of specialists ensure
minimized shutdown times and high performance
throughout the life cycle of the plant.

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Mastering the processes – SIROLL LR

XpertManager/
SIROLL LR Level 2

SIROLL LR
Mechatronical
Basic Auto­-
Packages
mation System

Main & Aux Drives

A precise understanding of all aspects of production is our basis for developing practical,

integrated, standardized solutions for your rolling needs, developed by systems engi-

neers who understand the mechanical equipment and process. To insure that individual

im­provements do not negatively affect other part of the process, all steps must be

understood within their own context as well as in their role in the process chain. That’s

why we give top priority at Siemens VAI to developing process-oriented solutions for

everything from the mechanical equipment to the process control. The solution SIROLL LR

is part of our commitment to deliver comprehensive, totally integrated solutions from

a single source. Our process knowledge, combined with Siemens’ state-of-the-art auto-

mation components and software that run on user-friendly Human Machine Interfaces,

provide operators with simple and efficient tools to master the processes.

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Mill automation and process control
SIROLL LR
Typical two strand WRM overview screen
Providing a total solution
The combination of process technology,
electrotechnology, and automation is a
crucial aspect of Siemens VAI solutions.
From initial mill design to maintaining
your systems for years to come,
Siemens VAI offers:
Electrical … defining project scope and
requirements from Level 0 to Level 2, in-
cluding AC and/or DC drives, full voltage
devices and various controls; providing
full technical documentation and inte-
grated system testing.
Automation … Leading basic automation
SIMATIC S7 process control engineering
and process optimization created within
our company play a key role in stable
processes and greater system reliability,
as we design the system to meet your
specific requirements right from the
design phase. Therefore we offer engi-
neering of well-proven equipment, fully
integrated mill control systems SIROLL LR
and stand-alone systems, including
super­visory control, maintenance sched-
uling, process monitoring, product han-
dling and alarming systems.
SIROLL LR
Typical diagnostic screen
Commissioning … supervising installation Some of the systems available:
and start-up of electrical and automation
Basic automation functions
systems to ensure the shortest possible
time to reach full production and consis- Mill setup and control
tent operation, by experienced automation
Tension and loop control
and electrical engineers knowledgeable in
long products; remote access via cRSP. Sequencing and tracking.
Revamps … Our solution SIROLL LR
Technological functions for
can also be used for revamps including
optimization
upgrades of DC-Drives.
Cut length optimization
Self adaption.
Drives
For new plants, using only two types of Mechatronical packages
drives – SINAMICS as auxiliary drives and
Non-contact speed measurement
low-power main drives, and SINAMICS
and control
SM 150 as larger block drives – results in
significant savings on spare parts, train- Mechatronics systems for all key
ing, maintenance, and upgrades. equipment components
Features Bar counting.
Latest semiconductor technology:
Higher level automation
IGBT and IGCT
XpertManager, Level 2 setup and
Fast processors and optimized drive
recipes
algorithms
Mill management
Design according to required power,
speed and field weakening, also consid- Interfaces with production planning
ering the total power supply network and ERP.
Defined interface systems
to automation system.
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XpertManager mill management system interface
XpertManager – a Manufacturing
Execution System and much more
From the initial Manufacturing Resource
Planning stages to the actual production
process, our customized design provides
seamless integration of process data in
real time. By applying proprietary algo-
rithms to the collected data, XpertMan-
ager generates comprehensive reports of
current production performance, trends
and history. With Level 2 capabilities,
the production plan, the process and the
finished product are all integrated in a
seamless system of mill automation.
Features
KAutomates and unifies mill setup
and control
KProvides operators with comprehen-
sive information
KFacilitates use of best operating
practices
KEnables optimization of mill
performance
KEliminates obsolete, stand-alone
systems
KInterfaces well with SAP
KGenerates QA certificates.
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SINAMICS SM150 IGBT
RollMaster
For Compact Cassette Rolling (CCR)
stands and Flat Rolling Blocks, this
system determines – according to the
finished product – the rolling rolls, the
grooves and the guides to be utilized
and all the essential rolling parameters
such as speed, torques, and other
requirements.
This well-proven software has already
been applied in more than 15 mills.
Features
KEasy computer-aided creation of pass
schedules
KCalculation of material spread, mill
load and bar temperature on the basis
of a database containing the properties
of more than 200 steel grades and
special alloys
KAccurate setting of the mill guides for
product-dimension changes, including
print out of the set-up protocol
KCreation of the mill setup considering
the actual condition of all components
KEasy management of all important
data related to mill grooves, guides
and rolls.
Mechatronic solutions
Mechatronics merges mechanical, elec-
trical, control systems and software as an
intelligent approach to the design of
electromechanical systems. At Siemens
VAI, we use this technology to integrate
our process know-how along with our
advanced equipment to give you en-
hanced products that provide functional-
ity, flexibility and ease of use.
From a single-source supplier, you can
get these robust and proven systems
to help your operation run smoothly.
When supplying a full rolling mill solu-
tion, these systems are integrated into
the mill control SIROLL LR. For modern-
ization solutions, they can be supplied as
stand-alone systems and interfaced with
the existing mill control.
Standard mechatronic packages:
Can be easily integrated in new or exist-
ing systems. When supplied as part of a
full mill control system, the mechatroni-
cal packages are embedded into the
SIROLL LR.
Mechatronic solutions in long rolling mill

Water box control system (mill floor) Water box control system (HMI)

Shear control Morgan Bar Reducing/Sizing Mill Lubrication systems

Temperature control Fully automated control of stand Monitors temperature control and
change and roll parting oil cleanliness
High speed finishing blocks
Fully automated control of drive Operates under a wide range of
Morgan Reducing/Sizing Mills
system clutches ambient conditions
Pinch rolls
Automated setup, with mechanical Incorporates vacuum dehydration.
Laying heads expertise incorporated in gear change
strategy Water systems/
Morgan Stelmor conveyor
product temperature control
 Direct interface to the SIROLL LR
Reform area
mill control system Designed specifically for in-line water
Coil handling boxes for product controlled cooling
Integrated tension control
Compactors Incorporates specially designed water
Easy-to-navigate HMI interface
valves for high speed operation
Cooling bed entry systems for the pulpit operators
Balanced design avoids water hammer
Bar counting Full local and remote control options.
Valve stands designed to be compact
Stackers
High speed shear and maintenance-friendly
Tyers and bundlers
Eliminates oversized front and tail Closed loop control
Fluid systems ends, reducing wear and impact
stress on downstream equipment Direct interface to the SIROLL LR
Inline measuring systems
mill control system.
 Automatic trimming of uncooled product
Non-contact measurement systems.
Synchronized with laying head
Further stand-alone packages: front end orientation
Flat Rolling Block Minimum deflection of rod from
cutting position
Compact multi-rougher
Increases product yield by eliminating
Rail pre-cambering.
manual cutting errors
Direct interface to the SIROLL LR
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mill control system.
Rolling stands
Red Ring stand
Red Ring stands
The Red Ring stand design has been a
popular solution for many roughing and
intermediate mill applications.
Red Ring stands are renowned worldwide
for their rigidity, ease of maintenance
and load capacity.
Different versions of these stands are
available, including vertical, horizontal
and convertible, which allow for rapid
adaptation to a variety of rolled products
needed to fulfill stringent market
demands.
With the quick disconnect capability of
the spindles and fluid utilities, the stands
can be interchanged very quickly.
Features
High rigidity
Reduced stress path
Fully automatic operation
Axial roll adjustment
Automatic screw-down system
Adjustment under load available
Roll balance system to eliminate
backlash
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Red Ring stands
Self-balancing spindle support for
minimum and positive engagement
Long-life bearings
Automatic utility connections.
Compact roughers
Compact roughers can be used where
space is limited or if higher reductions
are required. These roughers are
equipped with special shoe plates and
clamps to allow for minimized centers.
Greater reductions are possible by using
the billet’s own beam strength to help
it enter successive passes. When the cen-
ters are close, the stands can be shifted
in and out of the pass line to adjust
or change the guides.
Features
Small space requirement
High reductions possible
Easy guide change.
Reversing 2-high stands
Cast or forged billets can be rolled by a
group of two Red Ring stands in horizon-
tal and vertical (H-V) arrangement. Every
two passes, the roll gap is adjusted and
rolling direction changes. At the end of
the rolling process, a large-dimension
cylindrical bar is obtained for use as a
final product to be re-rolled.
Sliding stands
Modern 2-high sliding stands are revers-
ible and fully automated. They represent
an innovative solution for roughing and
intermediate trains.
Features
A fixed rolling line with sliding stands
to match the exact groove in the pass
design
Reduced roller table width
Advanced billet manipulation system
Automatic roll gap adjustment
Simple foundations
Compact multi-rougher arrangement.
Convertible stand
Convertible stands
Today’s mills can be used in a wide range
of configurations in order to provide an
unlimited selection of products from a
single mill layout. It is possible to change
from one product to an unrelated one
by simply pushing buttons, without the
lengthy procedures needed for an old-
style mill changeover. Convertible stands
allow either horizontal or vertical posi-
tioning and are mainly used in the inter-
mediate and finishing trains, in accor-
dance with production requirements.
Features
Less than two minutes to change
position
Reduced foundation depth
Excellent stand rigidity
Quick stand change system without
crane requirements.
Sliding rougher
Red Ring universal stands
This new generation of universal stands
uses the Red Ring design for the rolling
of structural shapes. In addition to the
horizontal rolls, the stands are fitted
with a set of idle rolls to work the flanges.
Red Ring universal stands can easily be
converted to conventional horizontal
rolling, accord­ing to production require-
ments, thus avoiding the need for addi-
tional horizontal stands.
Features
Fast stand and roll change
Hydraulic vertical and horizontal
roll adjustment
Modular design to reduce crane
requirements
Highest stiffness with a housingless
design.
Compact Cassette Rolling stands
Compact Cassette Rolling (CCR) stands
The compact and rigid cassette design
is suited to many special bar mill rolling
requirements. The extremely rapid cas-
sette change facility, in conjunction with
a high degree of automation, allows for
flexible and efficient production, even
for orders with a small number of billets.
Features
Three possible arrangements for twist-
free rolling: horizontal, vertical and
45° (X)
Most compact stand design available
on the market
Automated groove changing
Reduced bay height requirements
Open access to top of cassette
Possibility for automatic cassette
change robot system
Fast roll change, with no need for
special equipment
Interchangeable H-V-X cassettes within
the same stand size
Available with monogrooved or multi-
grooved stands and also as a reversing
block.
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Bar sizing technology
4-stand Morgan Bar Reducing/Sizing Mill
High precision rolling coupled with pro-
cess flexibility and equipment durability
describes the Siemens VAI bar sizing
technology. Based on the two-roll ar-
rangement, various solutions are avail-
able, which meet every need for size,
load capacity and productivity.
The two-roll design
The two-roll design offers user-friendly
operation as well as simplified mainte-
nance. It produces superior surface quality,
high dimensional precision and ultimate
processing flexibility. The two-roll design
can use multi-groove rolls, which signifi-
cantly lowers the investment and conver-
sion costs as well as reduces operation
downtimes.
Pass schedules provide reduction rolling
in the first stands followed by high pre­
cision sizing in the final stands.
The rigidity and load capacity of the
equipment permit the processing of a
wide range of steel grades, with both
conventional and low temperature, such
as thermomechanical, rolling practices.
Under-load remote adjustment of roll
gap is also possible.
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3-stand Morgan Bar Reducing/Sizing Mill
Features Sizing for bar-in-coil products
Single family rolling capability The Morgan Bar Reducing/ Sizing Mill
(BRSM) is the preferred solution for roll-
Free size rolling capability
ing small- to medium-diameter product
3-stand or 4-stand configuration typical of bar-in-coil production.
Pre-loaded stands with under-load Features
remote adjustment of roll gap
Compact arrangement to minimize
Automatic couplings of service utilities space
Inline quick change of stands Single or double groove to reduce
roll cost and downtimes
Off-line quick change of rolls
Guideless rolling
Easy preparation of rolls and
guides with off-line presetting for High speed capability
“plug & play” rolling campaign
Symmetrical mechanical preload
Single or multi-groove rolls
Split roll housing design for fast
Possibility to use both cast iron rolls, roll changes.
tool steel and tungsten carbide rings
Unique and patented pass designs
Possibility of automatic gap control
Over-driven stand arrangement
provides minimal impact on founda-
tion works.
 3-stand Pre-stressed Sizing Group
Sizing for straight bar products
The Pre-stressed Sizing Group (PSG) is
the preferred solution for rolling medium-
to large-diameter product typical for
straight bar mills. The available stand
sizes cover a range of finished bar diam­
eters up to 150 mm.
Features
Higher mill utilization with multi-
groove rolls
Hydraulic preload systems for both
radial and axial directions guarantee
very high rigidity
Automatic gap control
Motorized adjustment of guides and
axial roll movement.
4-stand Pre-stressed Sizing Group
Other solutions
The Cantilever Sizing Stand is the simple
solution for a quick and economical proj-
ect, to improve the size tolerance at 90°
to the last finishing stand.
Features
Easy and economical installation
in existing mills
Small dimension and weight
Easy positioning close to finishing
stand
Stand, gearbox, motor and hydraulic
unit are contained in a single trans­
ferable block
Can use cast iron rolls, tool steel and
tungsten carbide rings.
Mechatronic solution
Fully featured mechatronic packages
provide complete and effective control
of Siemens VAI’s bar sizing technologies
to ensure guaranteed performance.
Features
Full local and remote control options
Fully automated control of stand
change and roll gap
Fully automated impact compensation
and stand speed referencing
Automatic setup
Automatic under-load gap control
Direct interface to mill control system
Integrated tension control
Straightforward, easy-to-navigate
HMI interface for the pulpit operator
Electro-mechanical systems fully
tested prior to shipment for shorter
site commissioning times
Fully integrated into standard SIROLL
solution.
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Technologies for rails and sections
Red Ring universal stand
Red Ring universal stands
As with the 2-high Red Ring stand, the
Red Ring universal stand has no require-
ment for a standby stock of chocks. In-
stead, roll changes are performed using
a robot system, which mechanizes the
assembly/disassembly of roll chocks.
The process of disengaging a Red Ring
universal stand from the rolling line,
such as for stand clamping or spindle
holding, is exactly the same as for a
normal 2-high Red Ring stand.
Features
Easy conversion to conventional
horizontal stands
Four-row cylindrical bearings with
separate thrust bearings allow maxi-
mum load carrying capability
Fast roll and stand change
Vertical frame separates from tie rods
for quick assembly
Hydraulically adjusted horizontal and
vertical rolls.
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Continuous finishing mill for rails and sections
Increased life span and cleaner
operation
Main bearings and labyrinth seals have
extended life with oil/air lubrication in-
stead of automatic grease
Flume water contamination reduced.
Counterbalanced spindle support
Wrapped bearing design eliminates
hub wobble, reduces wear
Generous tapers on hub entry and roll
ends allow stand changing without
moving spindles.
Automated roll change operation
Significantly reduces roll assemblies’
changeover time
Roll change robot with hydraulic unit
furnished for change operation.
Pre-cambering systems
Rails may require an additional pre-
straight­ening operation that’s applied
at the cooling bed’s entrance. In fact,
non-uniform mass distribution in the
cross section of the rail tends to bend it
inwards on its head side. If not corrected,
this would make post-cooling straighten-
ing very difficult.
Features
Rails pre-cambered before cooling bed
Rails hydraulically clamped and lifted
Individually programmable travel
strokes allow application of different
pre-camber patterns.
Stacking systems
The layers of sections arriving from the
straightening and cold-cutting area are
properly braked and buffered onto the
first transfer table of the stacking area.
Aligning rolls and stoppers give bars
an orderly disposition.
Medium section straightening system Rail pre-cambering system

Features Straightening systems Features

Special system directs out-of-tolerance When sections are cool enough, below Rigid frame contains two sets of
bars to separate cradles approximately 100 –120 °C, they must double-supported horizontal rollers
be individually straightened before being
Disappearing stoppers and variable- Top rollers’ position is vertically
cut to their final length. This is necessary
speed devices form and separate adjusted according to bar size
to remove the deformations caused by
individual layers
the asymmetrical cooling effects. The Hydraulic counterbalance eliminates
Synchronized operation of suitable sections have to be subjected to a me- vertical movement backlashes
devices ensures correct sequence of chanical deformation to reach the yield
Axial adjustments for rollers
straight and 180-degree rotated layers tensile strength (YTS) value.
Rollers mounted in removable cassette
Electromagnets equip devices for firm Other types of straightening systems are
for quick changing operation
grip on bar designed for rail and special sections
processing. Special combing devices or pinch rolls
Adjustable width roller table transfers
ensure bar separation for effective
stacks to binding area
straightening process
Horizontal and vertical rollers maintain
Magnetic rollers at straightener’s exit
good stack alignment in transit
prevent bars slipping
Operations all fully automatic and
Suction system removes scale during
computer-controlled
straightening.
Divisible design provides flexibility
needed to process different stacks
of different lengths for greater
productivity
Combined mechanical-magnetic type
processes small to medium sections
Working sequences of stacking and
binding fully automated and interfaced
with the other areas of the rolling mill.

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Slitting and high speed cooling
bed entry systems
Rotary Entry System 4-slit rolling
Slitting systems
Siemens VAI’s powered slitters provide
highly accurate and consistent dividing.
They allow rebars to be rolled in multiple
strands, significantly improving the pro-
ductivity of small size rebars, without in-
creasing their finishing speeds. Slitting rolls
have ten times the life of slitting guides,
while offering higher speeds and better-
accuracy. Divided strands may be finished
in the same rolling stands or individually,
for better product quality and tolerance.
Benefits
Reheating furnace and rolling mill can
be operated to full design capacity also
for small size rebars, which become
less costly to produce
Easily applicable to most bar mill
configurations.
High speed cooling bed entry systems
High speed finishing maximizes rolling
operation over the entire product mix.
Beside consistent rolling at high speeds
in the mill, this calls for high speed deliv-
ery to the cooling bed. To meet these
requirements Siemens VAI provides the
Rotary Entry System (RES) as well as the
Multichannel Braking System (MBS).
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Multichannel Braking System
Rotary Entry System (RES) Applicable with all sizes of both cold
(low carbon quenched) and hot material
Each strand has a pair of rotating drums,
(microalloyed steel rebar)
where bars are indexed after being
braked by the high speed pinch rolls. A hydraulic system allows an easy
off-line removal for maintenance
Benefits
and when larger sizes are processed
Bar maximum delivery speed: 40 m/s via conventional brake slides.
Accommodates 2-way slitting
Allows the discharge of one bar per Mechatronic solutions
notch, which gives a better alignment
An integral part of the bar mill’s high
and separation of bars
speed capability is the specialized
Can be installed along with conven- mechatronics package developed by
tional run-in roller table and brake Siemens VAI for this application. This
slides for large size rebars includes:
Modular design. Coordinated speed control for
powered slitter and rolling stands
or Morgan No-Twist mill
Multichannel Braking System (MBS)
Divide shear control
The system can be used to discharge
Bar cut length optimization
single strand, multistrand, and up to
4-slit rebars. The bars are braked by Braking pinch rolls control
pinch rolls into channels which open
Bar positioning system on cooling bed
over the cooling bed.
Fully integrated into standard SIROLL
Benefits
solution.
Bar maximum delivery speed: 40m/s
Smooth discharge of one bar per
notch, for easier and flexible bar
counting and handling
Cooling beds

Cooling bed for large rounds Cooling bed for rebars

Cooling beds Features

Siemens VAI cooling beds are designed Perfect repeatibility of braking cycle,
using standard elements that can be at any speed
combined in accordance with plant prod-
Bar separation during braking,
uct mix requirements and production ca-
if required by layout and speed
pacity. Full mechanical component stan-
dardization assures constant equipment Pack annealing device available
quality, as well as high performance for spring steel flats
­levels.
Bar alignment by rollers
The design features cover a variety of
Bar layer prepared by chains and
applications: rounds from Ø 8 to 300 mm,
transferred by cars.
light, medium and heavy sections up to
1,000 mm and rails.
For special applications, the cooling beds
offer slow cooling with insulated covers
and forced cooling through water spray
systems or water tanks.
At the end of the cooling bed, bars are
aligned by rollers, separated into orderly
layers and transferred onto exit roller
tables.

Aligning rollers, chains and transfer cars 21

High speed finishing blocks:
Morgan Vee No-Twist mills
10-stand Morgan No-Twist mill
High speed, high production capacity
and reliability are critically important on
the finishing end of your mill. The rolling
equipment must have flexibility to pro-
duce a wide range of sizes and steel qual­
ities, while providing the best possible
product dimensional accuracy.
Siemens VAI finishing blocks have
been installed in scores of rolling mills
through­out the world, having set the
standard for successful mill operations.
These blocks are available in a variety of
stand combinations and can satisfy virtu-
ally any need on the finishing end. Roll-
ing load capacity and pass design are tai-
lored to the product requirements.
Morgan Vee No-Twist mills are capable of
sustained, reliable operation at speeds of
up to 120 m/s. This results in production
in excess of 150 tons/hr – achieved
under everyday operating conditions at
mill installations worldwide.
When it comes to versatility, the Morgan
Vee No-Twist mill can roll grades ranging
from carbon steels to tough to roll, heat-
resistant alloys. Mills can be supplied with
pass reduction of anywhere from 10 %
to 25 % per stand. Morgan Vee No-Twist
22
Morgan No-Twist mill rolling stands
mills can be built with four, six, eight, or Designed for thermomechanical
ten roll stands. The mills can be config- rolling, with capacity for low rolling
ured with any combination of 250 mm, temperatures
230 mm or 160 mm ultra heavy-duty
Capable of rolling to tight tolerances
(UHD) housings, depending on your mill’s
requirements. All housings have provi- Tungsten carbide rolls give better
sions for remote adjustments under load. rod quality and longer roll life.
Moreover, they can be equipped with
monitoring facilities for bearing condition.
Modular No-Twist mill
Features
This patented new design enables the
All major drive components are below
changing of pairs of roll stands in a few
floor level, thus reducing noise, im-
minutes, so that size changes can occur
proving visibility and providing conve-
very quickly.
nience for mill crews
The drive system is designed so that
New entry end drive arrangement
stands not used on larger sizes are dis-
allows easier access to the motor
connected, thereby extending the overall
and no restriction on motor size
life of the equipment and reducing main-
Entry end drive enables disconnection tenance costs. This design also minimizes
of finishing line shafts when not in use power consumption and thereby reduces
to minimize wear on high-speed operating costs.
components
Used in conjunction with a Morgan
High-quality sealed roll housings Reducing/Sizing Mill and single family
provides reduced maintenance rolling, the Modular No-Twist mill maxi-
and long life mizes utilization in the rolling mill.
Roll housings are easily lifted out
for quick change times
Mini-blocks

Mini finishing block Morgan Vee mini-blocks as pre-finishing mills

The Morgan Vee mini-block is an innova- Features Mechatronic solutions

tive 2- or 4-stand mill expandable up to

an 8-stand unit, with a host of benefits
for rod and bar producers. In numerous
existing installations around the world, 
mini-block mills have increased produc-
tivity by as much as 50 %, permitted the
rolling of various diameter rod and bars,

and achieved thermomechanical rolling
properties.






Small footprint makes it ideal
for retrofit situations
Can be used as a pre-finishing mill,
usually in 2-stand or 4-stand
configurations
Can be used as a mini-finishing mill
after an existing finishing block to
increase speed and productivity
Capable of improving tolerance of feed
sections to an existing block
Increases finishing speed when used
after an existing finishing block
Can be used to roll finished sizes from
4.0 mm up to as large as 35 mm
Able to roll at low temperatures
Perfect for retrofit applications in both
bar mills and rod mills
Can be used upstream or downstream
of existing finishing blocks.
The performance and reliability
of the Morgan No-Twist Mill and
Morgan Mini-Blocks can be enhanced
with the application of specialized
mechatronics packages, including:
Bearing temperature monitoring
Provides temperature status for bear-
ings in the block
Issues warnings of high temperatures
that can be caused by bearing wear or
lubrication problems
Constant monitoring improves perfor-
mance and prevents system downtime
Fully integrated into standard SIROLL
solution.
Lube oil water content
Continuously monitors for any water
ingress
Specifically monitors water content
in the lubrication system
Real time trending of water content
and lube oil temperature
Historical logging
Fully integrated into standard SIROLL
solution.
23
Rod sizing technology
Morgan Rod Reducing/Sizing Mill with off-line units
Morgan Rod Reducing/Sizing Mills
With over a decade of operational know-
how on more than 60 installed strands,
our engineers have advanced the Morgan
Rod Reducing/Sizing Mill into the most
versatile, sought-after rolling technology
available. There is no other rod sizing
system on the market today that can
compare with this technology.
The advantages of the Rod Reducing/
Sizing Mill are nearly unlimited. It can be
integrated after a conventional finishing
block, boosting the mill productivity on
small sizes by up to 60 %. Its extreme
precision has been proven in many prac-
tical applications.
24
Product dimension features
Produces all sizes to ultra-precision
tolerances
Tolerances as low as +/–0.1 mm
Ovality at 0.12 mm about the nominal
size and within 2 sigma statistical
limits
Flexibility to produce a size range
from 4.2 mm to 26 mm
Free size rolling capability.
Improves the operation
The patented pass design enables true
single family rolling from the first stand
after the reheat furnace to the last stand
of the block ahead of the Morgan Reduc-
ing/Sizing Mill. Added after a convention-
al rod finishing block, the patented unit
can significantly increase finishing
speeds on smaller sizes.
Productivity features
Single family rolling dramatically
­increases utilization
Productivity on small sizes increases
by as much as 60%
Quick change transfer car ensures
rapid and error-free setup
Roll parting adjustment under load
­directly from the operator station with
roll gap feedback
Patented built-in bypass troughs pro-
vide immediate setup for dummying
roll units
Guideless rolling in sizing stands allows
for fast parting adjustments and free
size rolling.
Morgan Rod Reducing/Sizing Mill in single strand high speed rod outlet
Increases product quality
The combination of advanced technolo-
gies allows very low-temperature rolling.
This results in a more refined microstruc-
ture that can eliminate additional
processes.
Features
Degree of grain refinement possible
with thermomechanical rolling results
in improved properties
Unique oval-round-round-round pass
sequence delivers high-reduction rolling
for internal quality while enhancing
surface quality and extending roll life.
Rolling stands
Mechatronic solution
The Morgan Rod Reducing/Sizing Mill
mechatronics package is a proven system
on dozens of mills around the world.
Features
Full local and remote control options
Direct interface to mill control system
Straightforward, easy-to-navigate HMI
interface for the pulpit operator
Automated product change increases
productivity
Incorporates Siemens VAI’s mechanical
­expertise in gear change strategy
Electro-mechanical system fully tested
prior to shipment and commissioned
on site
Fully integrated into standard SIROLL
solution.
25
High speed laying heads
and intelligent pinch rolls
High speed intelligent pinch roll and laying head
The laying head and intelligent pinch roll
system plays a crucial role in the success
of a high speed rod mill. It must be capable
of high speeds with smooth operation,
while providing well-shaped rings cor-
rectly positioned on the conveyor. This
calls for a precise mechanical system,
accurate control and continuous
monitoring.
Our patented intelligent pinch rolls and
laying heads are proven for sustained
operation at high speeds and for flexibility
across a large range of product sizes.
Features
Durable drive for reliable high speed
operation
Universal design fits all installations
Closer calibration of pinch force
Faster set up after roll change
More compact installation
Pipe path designed to optimize wear
Easy-change pipe support
High quality bearings for reliability
Front end orientation to eliminate
snags on the conveyor
Tail end control for good coil package.
26
High speed laying head with patented tail end control
Improving the ring pattern
The laying head design with patented tail
end control helps improve the ring pattern
on the conveyor for both small products
at speeds up to 150 m/s and large prod-
ucts at lower speeds. It allows increased
production, improved yields and consis-
tent product quality.
Mechatronic solution
A key element to the success of our lay-
ing heads and intelligent pinch rolls is the
mechatronics system, which provides for:
Repeatable front end positioning
of each coil
Speeds coordinated with pinch rolls
for error-free operation on tail ends
Fine adjustment to allow control of
coil diameter
Wobble adjustment for varying ring
diameter on large sizes
 Servo control of pinch force and position
Closed loop control of pinch force and
pinch roll drive motor
Self-regulated system to avoid roll slip
and remove user input from the pulpit
Fully integrated into standard SIROLL
solution
Rapid roll closing times,
0.1 to 0.15 seconds
Repeatable roll close times, within
+/-5 milliseconds.
A good coil package delivered from the
laying head to the Morgan Stelmor con-
veyor is important for achieving uniform
metallurgical properties during the con-
trolled cooling process as well as for get-
ting a well-formed coil for shipping.
Laying head capabilities
 High speed capability proven over 120 m/s
Ability to lay plain rounds, rebar plus
quenched and temperature rebar
 Handles rod sizes from 4.0 mm to 26.2 mm
Pipe change times of 15 minutes or less.
Other capabilities
Interchangeable vertebrae and roller-
ized pipe features available for surface-
sensitive grades
Twin pipe design available for produc-
ing different coil dimensions for differ-
ent product sizes
Pipe bending services available to pro-
vide your mill with ready-to-use pipes.
Morgan Stelmor controlled cooling conveyor
and reform ring distributor
Morgan Stelmor controlled cooling conveyor
The Morgan Stelmor controlled cooling
conveyor system enables processing in a
wide range of conditions, including both
fast and slow cooling modes within a sin-
gle system. This capability enables mills
to produce a broad spectrum of plain car-
bon and alloy steels, as well as stainless
steels and other specialty grades. The
results are improved as-rolled rod prop-
erties. This enables the production of
more grades in a directly usable condi-
tion, thus reducing or eliminating down-
stream processes, such as spheroidize
annealing.
Controlled cooling capabilities
Forced air cooling with high capacity
fans gives fast cooling rates
Excellent cooling uniformity in fast
cooling mode, accomplished with
either the traditional Optiflex system
or the new patented Optimesh system
Slow cooling with insulated covers
Hybrid cooling with combined fast,
natural and slow cooling for custom-
ized cooling of special grades.
High capacity fans on Morgan Stelmor conveyor Morgan Stelmor conveyor exit end
The more than 350 Morgan Stelmor lines The Ring Distributor
installed at mills throughout the world
The patented Ring Distributor collects
have established this system’s reputa­tion
rings high in the reform tub using a ro-
as the best for product quality, processing
tating blade for optimal placement. This
versatility and equipment performance.
system shortens the coil package, easing
The robust design includes durable shipping and storage space concerns,
drives for reliable high speed operation which in turn reduces costs. Improved
and high quality components for reduced collection also results in better-shaped
maintenance downtime and cost. coils for fewer tangles and snags at
payoff.
Features
Other system possibilities
Simple, low maintenance coil forming
Optional capabilities that can be incorpo-
design
rated into the Morgan Stelmor system
include: Allows for increased coil weight capacity
Slow cool pots Works with new or existing horizontal
hook and vertical pallet coil handling
In-line heat treatment
systems
Water quench baths.
Permits removal or change of blade in
5 minutes or less.
Mechatronic solution
To ensure the greatest benefits from pro-
cessing and production, a mechatronic
system provides for:
Automated product cooling setup
Conveyor speed control
Automated fan cooling control
Fully integration into standard SIROLL
solution. 27
 Coil handling and compactors
Vertical stem pallet coil handling system
Vertical or horizontal
From complete handling systems to sys-
tem upgrades, Siemens VAI has many
solutions to every coil handling need.
Both the vertical stem pallet and horizon-
tal hook carrier systems are of modular
design, providing for unique configura-
tions with standard components.
Features
Standard modules can be arranged
in highly customized installations
Individually driven and controlled
modularized conveyor system offers
high productivity and ease of
maintenance
System movements provide scratch-
free handling of the coils
Blowing stations available for acceler-
ated cooling of selected grades
Patented heat retention tunnels
available for slow cooling of sensitive
grades.
28
Horizontal hook system for coil handling Horizontal coil compactor
Mechatronic solution
For maximum benefits in the coil hand­
ling system, a mechatronic system
provides for:
Fully-automated coil transport system
Minimized installation and start up
times
Individual AC drive motors
Customized coil distribution
and storage
Automatic “pushing” and “pulling”
strategies to maximize cooling time
and product throughput
Recipe driven system
Coil tracking.
Compactors
Both the horizontal compactor and the
vertical compactor systems provide a
wide range of capabilities for all coiled
products, with either wire binding or
strapping.
Features
Standard compactor design allows for
easy retrofit from wire to strap, or vice
versa
Unique wire binding unit design with
quick-replace wear cassettes
Low operating and maintenance costs.
Mechatronic solution
The automation of the compactor system
includes:
Automated compression of coils into
compact bundles for efficient transport
and storage
Automatic wire feeding and monitor-
ing of coil compression
Different press force settings.
Bar in coil
Pouring reel
Pouring reels
The Siemens VAI pouring reels, or Garrett
coilers, enable the production of bar
products in coiled form, typically for
bar sizes of approximately 10 mm to
60 mm.
Features
Interchangeable entry spouts accom-
modate a wide product size range
Multiple pinch rolls assist the bar into
the tub and control tail ends
Traversable pinch rolls allow for quick
groove change between sizes
Elevating coil plate for easy coil
removal
Collapsing inner fingers minimize
damage to rings on coil inner diameter
Wear strips prevent damage to rings
on outside diameter of coil
No direct water cooling required,
reducing maintenance
Designed for minimum foundation
depth.
Garrett coil
Coil removal and transfer Process capabilities
A pivoting mast supports a boom assem- In addition to forming a well-shaped
bly for transporting the coil from the coil with excellent surface quality, the
elevated coil plate to a pallet or coil con- bar-in-coil system is designed for optimal
veyor. Depending on the configuration metallurgical and scale characteristics.
when using a pallet system, elevators
Features
may transfer the pallets between levels
in the mill. Coiling temperature can be controlled
with upstream water boxes
Blowing stations available for
Interface with coil handling
accelerated cooling
The coiling line can be provided with a
Insulated tunnels available for slow
new coil handling system or interfaced
cooling of critical grades
with an existing vertical pallet or hori-
zontal hook system. System length and operational practice
designed to give optimal final coil
­temperature.
Interface components
Downenders
Transfer cars
Trimming stations
Inspection stations.
The coil handling system can be shared
with a rod mill or rod outlet on a combi-
nation mill.
29
Bar spooling system
Spooling system layout 3D rendering
The spooling system is the latest innova-
tion in bar-in-coil production.
It creates a twist-free winding of round,
flat and square bars.
Unlike with the Garrett coiler, the wire
is distributed in sequential, regular,
homogeneous and compact layers,
producing high weight coils with small
overall dimensions, which can be easily
transported and stored.
30
Spooling system mandrel 3D rendering
As the spooled coil is twist-free, the de-
coiling operation is smoother and faster.
The innovative spooling system is a
considerable technological step forward
in bar-in-coil production, offering bar
producers the opportunity to be more
competitive by offering final users a re-
duction of post-rolling costs, as well as
a better product appearance with easier
transportation and storage.
Features
KHigher efficiency, speeds and
productivity
KFixed height and inner diameter
KVariable outer diameter (depending
on coil weight)
KGreater compactness with very high
filling factor
KEasy uncoiling capability
KSubstantial cost reduction in coil
transportation and storage
KHigher material yield
KFinal product properties are uniform
and consistent
KNo residual internal stresses (torsion).
Flat Rolling Block

Flat Rolling Block

Flat Rolling Block

The Flat Rolling Block is the perfect
instru­ment for the economic production
of flat bars in any lot size. Flat bars can
be rolled in a wide range of sizes with
tight tolerances and sharp corners. Prod-
uct size can be changed automatically
within seconds.
Features
Grooveless rolling of an infinitely
variable product size range
Product size changes within seconds
Sharp product edges
Fulfillment of highest product
tolerances, reducing downstream
machining requirements.

Mechatronic Solution
To ensure the greatest benefits from pro-
cessing and production, a mechatronic
system provides for:
Roll gap control with servo motors
Mill load control using load cells
Flat Rolling Block detail
Fully automated system integrating
the roll pass set up (RollMaster) with
the Level 1 control system.

31
Mill shears and saws
Sawing unit
Hot shears
Siemens VAI offers a full line of hot shears
necessary in a bar or rod mill for a wide
variety of requirements, such as head/tail
cropping, dividing, sampling or scrapping.
Available shear types
Pendulum, toggle or snap shears pre-
vent the flow of material through the
rolling line
Up & down shears for billets, blooms
and larger sections, for cropping and
dividing
Rotary, crank and convertible shears
along the rolling mill, for flexible oper-
ation according to bar size and speed
Bar cut length optimization available at
dividing shear, so that only multiples of
saleable length are sent to cooling bed.
High speed trimming shear and shear
control systems
Enables inline rod trimming of out-of tol-
erance head and tail ends in the finishing
train. Used either ahead of a post-finish-
ing block such as a Morgan Reducing/
Sizing Mill or immediately before the
pinch roll and laying head, this results
in substantial operational cost savings.
Crop and cobble shear
Features Flat or profiled blades according to use
Synchronized with laying head control Fully automated cutting procedures
for front end positioning
Quick-change device for blade
Trimmable sizes from 5.0 mm replacement.
to 26.0 mm
Maximum operating speeds of 120 m/s
Sawing units
Minimal disturbance of the rod path
For rails, medium-large sections, large
High speed motion controller to mini- bars, and special steel grades, where
mize delays between tracking system sawing is preferred over shearing. Better
and servomotor control cut quality and precision are provided,
and bar end deformation is eliminated.
Dynamic positioning of shear blades
to ensure cut length accuracy. Features
Metallic or abrasive disc technologies
available
Cold shears
Pendulum or linear disc movement
Siemens VAI designs flying and static
type cold shears, with clutch and brake Automatic removal of nose
or direct drive, to produce the ultimate and tail crops
end product.
Collection of sawing swarf
Features
Dust removal and filtering system
Cutting table width up to 1,800 mm
Fully automated sawing procedures.
Cutting speed up to 2.5 m/s
Direct start-stop drive for reduced
maintenance and shorter cycle time
Very precise cutting
Compatible with high strength steels,
as quenched rebar and high-alloy grades
Bar finishing components

Bar counting area Bar counting system Bar bundling system

In addition to the wide array of rolling Bar counting Bundling system

stands, finishing blocks and cutting-to-
Fully-automated counting of bars moving Bundlers for round and flat bars are avail-
length systems for every bar product,
from the cooling bed to the bundling able together with bar counting for rounds
Siemens VAI has an extensive portfolio
station assures that customer orders are and small bundle processing systems.
of equipment to cover the complete
filled accurately and completely. The sys- The packaging form can be round, square,
range of final processing needs. From
tem is capable of high production rates rectangular and hexagonal shapes.
counting to bundling and stacking, and
and is accurate for all types and sizes
then unloading bundles – everything
of bars. Current count and end-of-batch
can be arranged for a smooth final pro-
signals can be output to downstream Binding systems
duction process.
equipment and to the mill tracking sys-
Automatic binding of the packages and
tem for full control and information on
bundles are available with strap or wire.
the process.

Weighing, labeling & unloading

All bundles can be automatically weighed
and further labeled for quality-assured
delivery of the finished products at the
bundle unloading station. With accurate
product tracking such as that provided
by the Siemens VAI XpertManager sys-
tem, tagging accuracy and reliability of
the final shipment are assured.

33
Water boxes and in-line thermal processing
Water cooling system
The Siemens VAI proven water cooling
systems can make a significant differ-
ence in the operation of a bar or rod
rolling mill, from improved utilization
to better product quality. Available cool-
ing elements include conventional solid
injector and cooling pipe to the more
advanced split nozzle design.
The high cooling efficiency in these
water box systems results in reduced
water usage, increased lifespan of
pumps, valves and other critical compo-
nents and lower water consumption costs.
Features
Sturdy water box construction
Replaceable wear parts within the
cooling nozzles and extensions
Less water in contact with the product
reduces the tendency for cobbles,
enabling higher rolling speeds
Improved split-style nozzles are retro-
fittable replacements for previous-gen-
eration split nozzle design water boxes
Optional lift-out headers and travers-
able water box designs for minimizing
change times.
34
Rebar quenching system
Rebar quenching systems
Water quenching systems with station-
ary, lift-out or traversable water boxes
provide efficient cooling of ribbed prod-
ucts in straight lengths to a cooling bed
or in coil form to meet virtually any
worldwide specification for quenched
and tempered rebar.
Features
Martensitic self-tempered outer
surface, with ferrite-pearlite core
High yield strengths
Controlled values of tensile strength/
yield strength ratio and elongation
Elimination of micro-alloying elements
in melt shop (V, Nb)
Elimination of expensive post-rolling
treatment (e.g. cold drawing or
­s tretching)
Excellent weldability due to low carbon
content
Up to 4-slit rolling.
Mechatronic solution:
Temperature Control System
The Temperature Control System pro-
vides monitoring and control of stock
temperature to insure that the correct
mechanical and metallurgical properties
are obtained accurately and consistently
throughout the process. By monitoring
product speed and temperature, along
with cooling water pressures and tem-
peratures, the system can provide real-
time feedback for closed-loop control
of cooling zones, from the furnace exit
to the laying head or cooling bed.
Benefits
Consistency of properties
+/–10 °C accuracy
Standard operating practices
Recipe systems for fast and consistent
setups
Minimizes uncooled rings
Reduces disturbances to water system
Historical and real time logging
Improves detection of problems
Event sequence analysis.
Thermomechanical rolling
High speed rod rolling mill for thermomechanical rolling
Thermomechanical Rolling (TMR) re-
quires a combination of proper arrange-
ment of rolling and cooling equipment,
adequate load capacity in the rolling
stands and intelligent rolling and cooling
practices. The result is a refined micro-
structure in the product that has superior
as-rolled mechanical and metallurgical
properties.
By improving as-rolled properties and mi-
crostructures of rod and bar products,
subsequent downstream processes, most
of which are done in-house by the major
steel producers, can be eliminated or sig-
nificantly reduced, therefore lowering
the conversion cost.
Effect of finishing temperature on rod microstructure
TMR in a rod mill
Although high productivity and effi­
ciency remain the main attraction of
the Morgan Rod Reducing/Sizing Mill
to most plain-carbon unalloyed steel
producers, metallurgical processing flexi-
bility is becoming an equally important
benefit to the specialty steel and cold
heading quality producers.
Through an engineered combination of
high load design of the patented mill and
proper mill layout, thermomechanical
rolling at low temperatures becomes a
practical production process. A success-
ful combination of equipment design and
process design has been developed, evi-
dence of which is provided by more than
60 installed and operating post-finishing
mill blocks in a variety of mill configura-
tions, from existing two-strand rod mills
to new high speed, high production rate
single-strand rod mills.
Advantages of fine grain size
Low rolling temperatures reduce
hardenability, promote ferrite
formation and retard the evolution
of bainite and martensite
More uniform grain size from surface
to core
Reduction in as-rolled tensile strength
Increased ductility
Improved heat treat response including
a reduction in spheroidize annealing
times
Increased work hardenability.
With respect to rod structure, the refined
structure associated with reduced rolling
temperatures improves diffusion during
heat-treating and can result in reduced
heat treatment times and temperatures.
For those rods which are not heat-treat-
ed, the refined and complex structures
resulting from low temperature rolling
increases tensile pickup during cold
deformation.
35
Endless rolling technology
Welding machine
In recent years, market demand is for
bigger billets to increase material yield
and produce higher weight coils.
Siemens VAI’s technology is based on
JP Steel Plantech Co.’s EBROS.
The welding system is installed between
the reheating furnace and the first roll-
ing stand to weld together consecutive
hot billets and therefore provide a con-
tinuous rolling process.
The system operation consists of two
main phases:
Phase 1 – Billet welding
Billets are clamped in the welding
machine, which is moving at a speed to
follow the entry speed of the rolling mill.
Incoming billets are joined by flash weld-
ing, through rapid heating of billet ends,
followed by application of a counter
force to complete the joining.
Welded joint
Welding machine 3D rendering
Phase 2 – Burr removal High quality of the flash process weld,
so that the joint area does not affect
The welding machine has an efficient
final rolling quality
burr cutting system at the exit to com-
pletely remove the burr from the welded Able to weld rough and oxidized
zone and to avoid potential defects dur- surfaces
ing rolling operations.
Welded joint area free from inclusions,
filler metal or other impurities, for ho-
mogeneous and consistent product
Features
quality
No inter-billet time
Highly efficient operation, for reduced
Improved yield by reducing losses energy consumption.
at both head and tail ends
Lower risk of cobbling
Possibility of producing higher and
customized coil weights, without in-
creasing billet size, for better product
marketability
Reduced maintenance costs
Before deburring After deburring
Turnkey solutions
Success from a single source
There are many requirements involved
in building or modernizing a rolling mill,
including on-time and cost guarantees,
reliable start up and rapid achievement
of expected production volumes and
product qualities.
To ensure that these require­ments are
met, Siemens VAI offers a turnkey solu-
tion. We take on complete responsibility
for project implementation and start up
production, so you can concentrate on
your core business of manufacturing long
products and market­ing them profitably.
Our responsibility, not yours
Most projects require the coordination
of a large number of suppliers on timing,
technology, and logistics. Given the
number of players involved, we offer
a solution as prime contractor.
We work through all technical inter­ Your security: our financial
faces so that all components work strength and project expertise
efficiently together in the overall plan
In a turnkey project you profit from the
We work in partnership with all sub- global strengths of Siemens: our sound
contractors, and guarantee overall financial base as well as our ability to
quality plan projects with foresight and imple-
ment them reliably. We bring to each
We ensure on-time completion and a
project many years of experience in com-
smooth start-up, so you can pay down
plying with all rules and requirements,
debt on schedule
from customs regulations to approval
We construct your plant for a fixed conditions.
price.
Another benefit is the enthusiasm of our
engineers, fitters and start-up engineers,
all eager to work together with you to
Secondary processes
create a world-class system.
are no minor matter
If you’re planning to invest in a long
We provide our own Siemens solutions
product rolling mill, we can provide the
for nearly all processes associated with
comprehensive product, system, inte­
production, from the power supply to
gration and service expertise you need
water treatment, and from fire protec­­-
for success.
tion to railway siding. And everything
is backed by services from our local
partners. This comprehensive approach
is unique. Cross-functional concepts such
as Totally Integrated Automation and
Totally Integrated Power provide syner-
gies and a high degree of standardization.
37
Our services
For the best performance of your plant throughout its lifetime

Long rolling services from Siemens VAI “Peace of Mind” maintenance 24/7 Spare parts delivery
enables you to take advantage of the
This new program maximizes mill utiliza- By using our spare parts in your equip-
combined experience of our people and
tion by maintaining optimal running con- ment, you receive guaranteed perfor-
deliver comprehensive life-cycle support
ditions on your critical equipment. This mance quality for your needs. To help
for your mill. The rolling mill is a long-term
is particularly useful for high-speed maintain and service your operation, we
investment, and therefore you want a
equipment in rod mills. have parts warehouses in strategic loca-
long service life, along with productivity
tions around the world, providing deliv-
and high utilization, profitability, and
ery 24 hours per day, 7 days per week,
product quality.
Mechanical and lube system audits every day of the year.
The range of services we offer is compre-
With detailed studies by our mill experts,
hensive and covers every aspect of your
we can determine if the components are
operation. Guides
meeting current demands and look for
ways to improve their performance. Backed by our comprehensive process
knowledge in long rolling mills, Siemens
Services available
VAI expertise in guides provides solu-
Maintenance Predictive maintenance tions for all conceivable rolling applica-
tions. This expertise, together with a
Reconditioning Through vibration monitoring, we can
wide array of designs for mounting and
predict when individual pieces of equip-
Rebuilds ancillary guiding equipment, means that
ment in your mill will probably need
no problem is too difficult to solve.
Guides maintenance. Therefore, you can better
plan for downtimes.
Upgrades
Training
Spare parts
Reconditioning and rebuilds A wide range of training programs are
Equipment and process audits
available for maintenance, operations
We can help you get more out of your
Training and processing. To handle special re-
existing equipment through this service,
quirements, we can develop customized
Metallurgical. and possibly introduce some new innova-
training for your people.
tions while minimizing the downtime in
your operation.

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Life-cycle management
Partnership never ends
• I nvestigation/inspections & feasibility study
• Design
• Layout
• Construction
• Installation
• C ommissioning
t
stmen
inve
New
Consulting | Planning | Financing
Recycling
Siemens VAI life-cycle services
As a plant operator, you have conflicting
needs. On the one hand, your perfor-
mance is measured each quarter against
short-term profitability expectations. On
the other hand, you have to think on a
totally different timescale compared with
the capital market. Depending on the
lifetime of your plant, you have to con-
sider the next 15 years or more – at the
very least, that is 60 full quarters.
• Service contracts
• Spare parts and components
• Consulting and training
• Online and offline
maintenance
• Maintenance contracting
Operation
tion
rniza
Mode
• Migration packages
• Upgrading and
modernization
Thanks to our comprehensive expertise
and integrated approach to solutions,
you can benefit both short-term and
long-term from our life-cycle services.
In the short term: Backed by our exten-
sive experience with many reference
plants, we provide you with the certainty
of fast, dependable production, start-up
and shorter amortization periods.
In the long tem: Our master plan guaran-
tees competitive performance for your
plant in every phase of its life cycle.
Whether we’re providing 24/7 technical
or spare parts service, optimizing main­
tenance, or making permanent plant
improvements, we’re always working
to ensure the cost-effective operation
of your plant.
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Excellence through experience
Selected success stories with rolling mills

Profitable expansion for rapidly growing market

Customer: V izag Steel, Visakhapatnam (Andra Pradesh), India, part of Rashtriya Ispat Nigam Ltd.
The task: One of the largest Indian steel producers, Vizag wanted to expand to 6.3 million tpy, improve productivity
and optimize costs of its Special Bar Quality production line.
Our solution: A new mill with 18 Red Ring rolling stands followed by a 3-stand Pre-stressed Sizing Group, with a double
finishing area with cooling bed and three Garrett reeling stations. Initial mill capacity of 750,000 tpy.
The result:  lexible and reliable operation in expanded modern facility that profitably positions Vizag in one of the
F
world’s most rapidly developing areas.

Achieving huge capacity, productivity gains

Customer: V illares Metals, Sumaré (São Paulo), Brazil, part of Voestalpine Group
The task:  ne of the most important South American producers of high-alloy steels and specialty alloys, Villares wanted
O
to expand its portfolio, increasing rolling capacity and productivity, and optimizing operation costs.
Our solution:  new multiline mill, including a straight bar line with 16 Compact Cassette Rolling stands, a rod line with
A
two finishing monoblocks and a line with a Flat Rolling Block.
The result: Rolling capacity increase of approximately 40 %, with optimized costs and an installation schedule that
eliminated potential impact on existing production.

Meeting speed and quality goals

Customer: Votorantim Metais, Resende (Rio de Janeiro), Brazil
The task: Add capacity for coiled rebar and other rod products to support growing South American market on green-
field site with the best technology for high production rates and quality.
Our solution: New single-strand rod mill with roughing and intermediate train, pre-finishing Morgan Mini-Blocks, finish-
ing Morgan No-Twist mill, in-line quenching, Morgan high speed pinch roll and laying head, Morgan Stelmor
conveyor, reform and coil handling system. Provisions for future second strand.
The result:  igh quality rod and coiled rebar produced at finishing speeds up to 110 m/s for at least 500,000 tpy on
H
single strand. Mill has rolled HYQST quenched and tempered rebar products at highest speeds in the world.
40
 World-class slit rolling bar mill
Customer: Tata Iron & Steel Co. Ltd., Jamshedpur, India
The task:  s one of the largest steel producers in the world, Tata wanted to expand capacity in India to support
A
growing infrastructure with latest techniques for rolling rebar, and remain best-quality construction supplier.
Our solution:  ew single-strand bar mill with 16 stands for roughing and intermediate trains, two-way slitting unit, two
N
6-stand Morgan No-Twist mills, water boxes for HYQST processing, dividing shears, patented high speed
Rotary Entry System to the cooling bed, cold shear, plus bundling and strapping equipment.
The result:  esigned to produce 600,000 tpy, mill exceeded production targets several times at commissioning. One
D
of the fastest and most efficient mills in the world for slit rolling in straight lengths, with rolling line yields
above 95 %.

Modernization yields production growth

Customer: Global Steel Wire, S.A., Santander, Spain, part of the Celsa Group
The task: As a renowned supplier of high quality rod products, Global Steel Wire needed to expand product size
range, increase production and improve quality for changing markets, including new bar-in-coil market.
Our solution: Series of mill modernizations: equipment improvements and additions to 2-strand rod mill to increase pro-
duction rate and productivity, including Morgan Mini-Blocks, Morgan No-Twist mills, Morgan Rod Reducing/
Sizing Mills, rod outlet; bar-in-coil outlet with water cooling and Morgan Bar Reducing/Sizing Mill for high
quality bar products.
The result:  ver 10 years of mill modifications, Global Steel Wire has increased production from 570,000 tpy
O
to over 900,000 tpy, with increases in coil weight, product size range and quality.

Longer long products

Customer: Corus, Scunthorpe, UK, part of Tata Group
The task: As part of company’s overall investment program, mill revamp needed to improve Corus’ production
capability and cost-effectiveness.
Our solution: A new finishing mill with 7 in-line Red Ring universal stands, cooling area with rail precambering,
and handling equipment.
The result: The mill enables Corus to roll rail lengths up to 120 meters in an in-line continuous finishing mill.
It offers unsurpassed flexibility to process both rails and sections, with minimized change operations
and improved tolerances.

Highest productivity in the Middle East

Customer: Habas Sinai Ve Tibbi Gazlar Istihsal Endustrisi A.S., Aliaga, Turkey
The task: One of the leading players in the Middle East, Habas needed a greenfield rebar rolling mill,
with high productivity and equipment reliability.
Our solution: A state-of-the art fully automated multi-slitting rolling mill with 25 Red Ring stands, including a double
finishing train, with in-line bar quenching, Multichannel Braking System for high speed delivery to a 120 m
cooling bed and handling areas. Bars ranging from 8 to 42 mm diameter rolled in up to 4-slit process.
The result:  esigned for 1,185,000 tpy, one of the most productive rebar plants in the world. Production exceeds
D
4,500 tons per day, equivalent to an average rebar production of 180 t/h.
41
Siemens Industry Inc.
15 Belmont Street
Worcester, MA 01605-2665, USA
Phone: +1 508 755-6111
Fax: +1 508 832-0139
E-mail: longrolling.metals@siemens.com

Siemens VAI
Metals Technologies S.r.l.
Via L. Pomini, n. 92
21050 Marnate (VA), Italy
Phone: +39 0331 741211
Fax: +39 0331 741386

Siemens VAI
Metals Technologies GmbH & Co.
P.O. Box 4, Turmstr. 44
A 4031 Linz, Austria
E-mail: contact.metals@siemens.com

The information provided in this bro-

chure contains merely general descrip-
tions or characteristics of performance
which in actual case of use do not always
apply as described or which may change
as a result of further development of the
Order No.: E10001-M3-A14-V1-7600
products. An obligation to provide the Printed in Germany
respective characteristics shall only exist Dispo No.: 21661 K No.: 28104
if expressly agreed in the terms of GB 100026 WS 10101.5
contract. Subject to change without prior notice

© Siemens AG 2010.
All rights reserved.
No Twist is a registered trademark
of Siemens Industry Inc.
Stelmor is a registered trademark
of Siemens Industry Inc.
EBROS is a registered trademark
of JP Steel Plantech Company

www.siemens-vai.com
52