Construction & Mobile. Innovative solutions for steel constructions, bridges, cranes and mining

Transcription

1 Construction & Mobile Innovative solutions for steel constructions, bridges, cranes and mining voestalpine Grobblech GmbH

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3 voestalpine Grobblech your partner for highly advanced markets and more. Our high-quality performance is based on our niche expertise. voestalpine Grobblech GmbH is a synonym for innovation and top quality all around heavy plates. We are a 100 % subsidiary of voestalpine Stahl GmbH situated in Linz, Austria. We are the world s top supplier of special heavy plates to the energy market and Europe s leading producer of roll-bonded clad plates and heads. We deliver shell plates, heads and cones for advanced pressure vessels. Based on our technological developments in the energy sector we offer innovative solutions for steel construction, bridge building and vehicle manufacture. Our partners are demanding customers in the following sectors: Offshore & Linepipe Oil- and gas industry Energy Processing Chemical industry and refineries Transportation and storage Environmental technology Construction & Mobile Steel construction and bridge building Vehicle manufacture Mechanical engineering and plant building Sales per branch Construction & Mobile 26% 2008 Business year: Euro 780 million Energy Processing 26% Offshore & Linepipe 48% Product overview Linepipe plates Offshore plates Pressure vessel plates and heads Clad plates and heads High-strength plates Wear-resistant plates Structural steel plates 3

4 High-strength and wear-resistant steels voestalpine Grobblech quantity trend Quantity wear-resistant high-strength Business year Weight reduction achieved by high-strength steels Weight [%] S355 S460 S550 S690 S960 Strength grade Energy and mobility change our world. We have the materials. Our expertise meets customer requirements in demanding branches. We follow the dynamics of the markets and offer solutions to our customers to increase their performance. This is the mission of voestalpine Grobblech. For innovative solutions we use our technological experience from the energy branch. Moreover we are on top in processing technology especially in thermomechanical rolling. The result: our high-strength and wear-resistant steels. 4

5 The market We deliver heavy plates for all applications in steel construction, shipbuilding and mechanical engineering as well as for vehicle manufacture and mining equipment. We produce structural steels for various applications and specialise in highstrength fine-grain steels and wear-resistant steels for abrasive service. All our materials provide optimum workability, resulting in countable customer benefits. Best surface quality and excellent weldability of our highstrength steels are integral parts of our top-quality philosophy. Our customers are the processing industry, stockists and steel service centers for heavy plates. We offer a wide product range for the following applications: Construction & Mobile Bridges Mobile cranes Ships Mining equipments High-pressure pipes 5

6 High-strength steels... double size means double stress... Things get bigger often double size. If you double the size of a construction (double length, width and height), then weight increases by factor 8 while the cross section is raised by factor 4. Therefore the stress in the component material is doubled. x 2 l w h length width height specific weight Weight: (2 l x 2 w x 2 h) x = x 8 Cross-section: (2 l x 2 w) = x 4 Stress: weight / cross-section = x 2 Why high-strength steels? High-strength steels can bear higher stresses than normalstrength steels. For a given load respectively a fixed stress in the component high-strength steels lead to smaller cross-sections and therefore to reduced weight which results in decreasing costs. Higher strength Smaller cross section Reduced weight Reduced costs 6

7 Cost benefits Reduced steel weight leads to Reduced purchasing volume Reduced costs for transport, assembly and foundations Reduced costs during further processing, especially in welding Less filler material Less welding time Less expense for checking the welds S mm Reduced thickness 24 % S mm Reduced weld volume 42 % Reduced thickness leads to superproportionally reduced weld volume. What about high strength? min. Yield strength Delivery voestalpine (MPa) condition brand Standard 355 NR, TMCP Medium strength TMCP High strength 700 TMCP 700 Q+T 960 TMCP+T NR normalising rolled TMCP thermomechanical control process Q+T quenched and tempered T tempered 7

8 Slabs from our top steel plant The basis for the production of high-quality linepipe and offshore plates are excellent slabs. We procure continously cast slabs from our top steel mill at voestalpine Stahl GmbH in Linz. Steel with a high purity is produced by LD-process (Linz- Donawitz-process, invented by engineers of voestalpine), with subsequent metallurgical and vacuum treatment. Process models guarantee the precise chemical composition. The roller gap in the casting machine is adjusted by using dynamic soft reduction to minimise centre segregation. High-level automation of the casting process, including computer aided quality control, ensures optimum surface quality of the slabs. 8

9 250 Number of heats Phosphorus [mass %] LD-process leads to low phosphorus 300 Number of heats Sulphur [mass %] Sophisticated calcium treatment in the ladle furnace for lowest sulphur 500 Number of heats Nitrogen [mass %] Pure steel by vacuum degassing: low level of nonmetallic inclusions, low hydrogen, low nitrogen Dynamic soft reduction to minimise centre segregation in the slabs. 9

10 Heavy plate production Slab reheating The slabs are heated in a pusher-type furnace. After a throughput time of around three hours the slabs reach a temperature of 1100 to 1200 Celsius. A process model is used to ensure uniform heating of the slabs. Hot rolling The core process of heavy plate production is hot rolling. Heavy plates with proper dimensions, surface quality and flatness as well as with desired technological properties are produced on the four-high rolling stand. Accelerated cooling The online accelerated cooling process results in excellent material properties. Even with low alloy and carbon contents, high strength and highest toughness values are achieved. The low carbon equivalent leads to better weldability. Rolling and cooling parameters are completely process controlled. Thus close size tolerances, excellent flatness and surface quality as well as reproducible material properties are achieved. Modern technologies are used for measuring, recording and evaluation of the main process parameters. This method provides transparency of the production process and is the basis for continuous improvements. 10

11 «Cooling bed Plate turner» «Levelling «Marking & Stamping «Finishing «Ultrasonic testing online «Heat treatment Test house» «Shipping 11

12 TMCP TMCP- (Thermomechanical Control Process) steels are fine grain steels with High strength combined with high toughness Excellent weldability Best formability High reliability in welded structures High toughness in the heat-affected zone (HAZ) High resistance against cold cracks TMCP-steels from voestalpine Grobblech are produced with Very pure steel (low S-, P-, tramp element level) Low carbon content and low carbon equivalent (CE) Microalloying High-quality processing during melting, casting, rolling and accelerated cooling Different rolling and cooling processes TM1 TM2 ACC DIC Rolling Cooling TM Thermomechanical rolling Temperature T Nr Ar 3 MAE ACC DIC T T Nr Ar 1 Accelerated cooling Direct intensive cooling Tempering Recrystallisation-stop-temperature End of phase transformation Ar 1 M s (+T) Ar 3 M S MAE Start of phase transformation Martensite-start-temperature Microalloying elements 12

13 Fabrication benefits of TMCP steel plates: Remarkable reduction or elimination of preheating Great savings in fabrication costs Improved working environment for operators Reliable welded joint Almost no additional repair welding even without preheating High heat input welding Major reduction of welding pass Far lower welding costs Much shorter fabrication time Easier surface cleaning due to thin, homogeneous scale N + air cooling TM + air cooling TM + ACC TM + DIC S355 alform 420 M alform 500 M alform 500 M alform 700 M alform 960 M CE IIW =0.41 CE IIW =0.33 CE IIW =0.41 CE IIW =0.41 CE IIW =0.43 CE IIW =0.55 The effect of finer grain: higher strength higher toughness better weldability and formability 50 μm 50 μm 50 μm 50 μm 50 μm 50 μm 1,100 The same yield strength Yield strength [MPa] 1, CE = C + Mn/6 + (Cr + Mo + V)/5 + (Ni + Cu)/15 according to IIW Cooling rate TM TM+ACC N TM+DIC QT + Alloying elements + Microalloying elements level is possible on different CE levels depending on the delivery condition. Low carbon equivalent (CE) is most important for good weldability. N Normalising rolled QT Quenched and tempered TM Thermomechanically rolled 300 plate thickness ACC DIC Accelerated cooled Direct intensive cooled Carbon equivalent CE 13

14 Heat treatment High-quality heavy plates in larger plate thicknesses are subjected to additional heat treatment by normalising or quenching and tempering. Two heating furnaces and a quenching unit are available for these processes. Delivery conditions We deliver our plates in the following delivery conditions: As rolled Normalising rolled Normalised (furnace) Quenched and tempered Thermomechanically rolled and accelerated cooled Microstructures As rolled Normalising rolled Normalised (furnace) Quenched + tempered TMCP 14

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16 Quality assurance Product integrity for steel constructions is of great importance. Products, processes and business systems of voestalpine Grobblech are approved by Lloyds Register of Quality Assurance to ISO This approval covers all aspects of sales, service, design, manufacture and testing. voestalpine Grobblech is certified for heavy plates by the Verband der Technischen Überwachungsvereine (VdTÜV) (Union of Technical Inspection Groups) resp. by the Technischer Überwachungsverein Industrie (TÜV-Süd) (former Technical Inspection Group Bavaria): AD-Merkblatt W0 / TRD 100 EG-Druckgeräterichtlinie Nr. PED97/23/EG (PED = Pressure Equipment Directive) In addition quality approvals are held from several external inspection groups (ABS, DNV, Lloyds, BV, RINA, RMRS, Deutsche Bahn AG, Deutsches Institut für Bautechnik, ) Product support Our Research & Development department is a dedicated centre of expertise. We permanently invest in the education of our staff and into the latest research tools to assure first class technical investigation. We have an independent and fully accredited test house at our site. Our R & D continually developes the basis for new materials for more complex applications and contributes to the optimisation of our production processes. Additional work includes simulations of material performance such as weldability, deformation and edging behaviour, fatigue tests and fracture mechanics. These tests provide a complete performance profile of our steels under practical conditions. Welding Simulator 16

17 Health, Safety and Environment (HSE) voestalpine Grobblech has created a work environment that values diversity in thought and experience teamwork ethical behavior performance excellence The HSE management is based on continuous improvement in accordance with international standards (ISO 14001). voestalpine Grobblech is proud to have an excellent safety performance. We use the management system EMAS to improve our environmental performance. LIFE With LIFE voestalpine runs a comprehensive program aimed at adapting its corporate culture to find the best possible mix of performance, working conditions, health, sense of work and cooperation. 17

18 Structural steel plates You will find our standard structural steels in various applications of steel construction, bridgebuilding, vehicles and building construction. Our weather resistant steels are mainly used in bridgebuilding and save costs in maintenance of the bridges. We offer: Special plate dimensions: thickness up to 150 mm, width up to 3,950 mm. High quality steel: tough analysis, low spread of mechanical-technological values, Z-tests, ultrasonic tests of all classes. Steels with best performance in workability, as welding, edging and cutting. 18

19 Steel grades and standards Steel group Standard Steel grade S235 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N Unalloyed structural steels EN S275 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N S355 JR+AR, JR+N, J0+AR, J0+N, J2+AR, J2+N K2+AR, K2+N S275N, NL Fine-grain steels, normalising rolled, normalised (furnace) EN S355N, NL S420N, NL S460N, NL S275M, ML S355M, ML; alform 355 M Fine-grain steels thermomechanically rolled EN S420M, ML; alform 420 M S460M, ML; alform 460 M alform 500 M alform 550 M S355 J2W+AR S355 J2W+N Weather resistant structural steels EN S355 K2W+AR S355 K2W+N (S)A 36 Structural steels ASTM/ASME (S)A 283 Grade C (S)A 572 Grade 50 Type 1 Weather resistant structural steels ASTM/ASME (S)A 588 Grade A Dimensions Min. Max. Comment Thickness 8 mm 150 mm depending on steel grade and width Width 1,600 mm 3,950 mm depending on steel grade and thickness Length Weight per order item Weight per plate 20 mt 18,700 mm 11.7 mt depending on steel grade and thickness lengths up to 24,000 mm on request 19

20 Thermomechanically rolled fine-grain steel plates We deliver standard and medium-strength thermomechanically rolled fine-grain steels with minimum yield strength of MPa. These steels combine excellent toughness with best weldability and formability. Utilisation of higher yield strength of S420, S460, alform 500 and 550 M compared to conventional S355 results in smaller cross sections of steel constructions. That leads to cost savings due to smaller component weight and therefore savings in transport, assembling and foundations as well as savings in processing, especially in welding. Steel grades and standards Designation according Designation according voestalpine brand to EN to EN alform 355 M S 355 MC S 355 ML alform 420 M S 420 MC S 420 ML alform 460 M S 460 MC S 460 ML alform 500 M S 500 MC alform 550 M S 550 MC Dimensions Steel grade Min. Max. Comment Thickness alform 355 M and alform 420 M 8 mm 50 mm voestalpine special grade alform 460 M 8 mm 40 mm voestalpine special grade alform 500 M and alform 550 M 8 mm 30 mm voestalpine special grade S355, S420, S460 M, ML 8 mm 50 mm depending on steel grade and width Width 3,950 mm depending on steel grade and thickness Lenght Weight per order item Weight per plate 20 mt 18,700 mm 11.7 mt depending on steel grade and thickness; lengths up to 24,000 mm on request You will find more information in our technical terms of delivery. Subject to change pursuant to further development. The current version is available at 20

21 Shipbuilding steel plates We can offer a wide range of dimensions and grades with best workability for shipbuilding, especially best welding characteristics and good flatness of the plates. Our shipbuilding plates are mainly used in the cabin structures of big ocean cruisers. We deliver standard and higher-strength shipbuilding steels according to all well-known classification companies. Germanischer Lloyd (GL) / Germany Det Norske Veritas (DNV) / Norway Registro Italiano Navale (RINA) / Italy Bureau Veritas (BV) / France Lloyd's Register of Shipping (LR) / Great Britain American Bureau of Shipping (ABS) / USA Russian Maritime Register of Shipping (RMRS) / Russia Steel grades A, B, D, E AH 32 TM, A 32 TM, DH 32 TM, D 32 TM, EH 32 TM, E 32 TM AH 36 TM, A 36 TM, DH 36 TM, D 36 TM, EH 36 TM, E 36 TM Dimensions Min. Max. Comment Thickness 5 mm 150 mm depending on steel grade and width Width 1,600 mm 3,950 mm depending on steel grade and thickness Length 18,700 mm depending on steel grade and thickness Weight per order item Weight per plate 2 mt 11.7 mt 21

22 Case-hardened and Q+T steel plates Case-hardened and quenched and tempered steels will normally be heat treated after the manufacture process by the customer. Typical applications are tool manufacturing and mould production (e.g. for concrete blocks). Steel grades and standards Steel group Standard Steel grade Quenched and tempered steels EN C45, C45+N, C45E, C45E+N, C45E+QT, 42CrMo4 Case-hardened steels EN MnCr5, 20MnCr5 Dimensions Min. Max. Comment Thickness 10 mm 150 mm depending on steel grade and width Width 1,600 mm 3,950 mm Length 18,700 mm Weight per order item 20 mt Weight per plate 11.7 mt depending on steel grade and thickness widths up to 3,800 mm for Q+T depending on steel grade and thickness lengths up to 12,750 mm for Q+T 22

23 Brands We offer special high-strength and wear-resistant steels as voestalpine brands according to our technical terms of delivery. High-strength steels Thermomechanically rolled fine-grain steels Quenched and tempered fine-grain steels Wear-resistant steels Wear-resistant plates High wear-resistant multi-layer plates 23

24 alform 700 M and alform 960 M Thermomechanically rolled high-strength fine-grain steels with a minimum yield strength of 700 MPa and 960 MPa. voestalpine special grades alform 700 M and alform 960 M are mainly used in branches with a high extension of manufacturing, when weight savings are the main goals to reach. This is typical in the field of mobile cranes, concrete pump trucks and vehicles. 24

25 Production process alform -steels are produced by thermomechanical rolling with accelerated cooling directly after the rolling process. Conventional quenching and tempering in heating furnace and quenching device is no longer necessary. This type of steel provides a fine-grained, homogeneous structure with high tensile strength and excellent toughness. Benefits alform -steels show benefits in comparison with conventional quenched and tempered steels as following: Best weldability because of low C-equivalent, low C-content, easy edge preparation, reduced or abolished preheating, high resistance against cold cracks because of high toughness in the heat-affected zone (HAZ). Best bending properties because of the very fine grained structure, smallest bending radius and insensibility against cracks during edging. Best surface because of a homogeneous, thin secondary scale which is easily to remove. No scale scarred from hardening process. Dimensions Steel grade Min. Max. Thickness alform 700 M 8 mm 60 mm alform 960 M 10 mm 15 mm Width Length 2,500 mm 12,750 mm Weight per order item 20 mt Weight per plate 11.7 mt You will find more information in our technical terms of delivery. Subject to change pursuant to further development. The current version is available at 25

26 aldur 700 Q, QL, QL1 Quenched and tempered high-strength fine-grain steels with a minimum yield strength of 700 MPa. Quenched and tempered high-strength aldur -steels are used in advanced welded constructions. Weight reduction and reliabilty in operation at low temperatures are very important goals. aldur -steels are mainly used for mobile cranes and vehicles, mining and high-pressure pipes as well as for offshore applications. 26

27 Production process aldur -steels are melted according to the LD process (oxygen top blowing process). The combination of high strength and good toughness is achieved by water quenching and tempering. Benefits Higher tensile strength in comparison with common structural steels result in weight reduction. In the field of mobile cranes and vehicles higher payloads are possible. Cost efficient constructions give additional benefit. Excellent weldability as a result of low carbon equivalents: high resistance against cold cracks in the heat affected-zone (HAZ), lower preheating temperatures in processing and high reliability of components due to high toughness in the welded seam. Toughness We offer 3 different grades of toughness Design temperature aldur 700 Q 20 C aldur 700 QL 40 C aldur 700 QL1 60 C Dimensions Min. Max. Thickness 12 mm 100 mm Width 3,000 mm Length 12,750 mm Weight per order item 20 mt Weight per plate 11.7 mt You will find more information in our technical terms of delivery. Subject to change pursuant to further development. The current version is available at 27

28 durostat 400, 500 und B2 durostat -steels are specially suitable for components exposed to high mechanical stress and heavy abrasion, e.g. loading devices, shovels of wheel loaders, bodies of trough tipping wagons, conveyors, excavator components, road machines, screens and crushers. Additionally we deliver durostat B-steels in as-rolled condition for components in agricultural machines (e.g. ploughs and harrows), cutting edges for front-end loaders or brick-molding boxes. 28

29 Production process durostat -steels are melted according to the LD process (oxygen top blowing process). The high hardness is achieved by accelerated cooling after hot rolling or by conventional hardening. Benefits Longer service life: As a result of their high hardness durostat - steels enable wear resistance many times higher in comparison to conventional steels. Less weight: Due to the high hardness compared to conventional steels the thickness of durostat -plates can be reduced significantly. This results in lower dead weights and thus higher payloads. Best weldability: durostat 400 can be welded without problems. Due to the relatively low carbon content preheating is not necessary for small thicknesses. Best surface: durostat 400 up to 15 mm are produced online by accelerated cooling directly after hot rolling. Thus a thin homogeneous secondary scale is built, which is easy to remove compared to furnace scale from conventional hardening. Steel grades and hardness Steel grade Delivery condition Hardness durostat 400 in hardened condition approx. 400 HB durostat 500 in hardened condition approx. 500 HB durostat B2 in as-rolled condition approx. 500 HB obtainable Dimensions Steel grade Min. Max. Thickness durostat mm 100 mm durostat mm 30 mm durostat B2 8 mm 50 mm Width Length Weight per order item Weight per plate 20 mt 2,500 mm 12,750 mm 11.7 mt You will find more information in our technical terms of delivery. Subject to change pursuant to further development. The current version is available at 29

30 High wear-resistant multi-layer plates altrix combines a tough base material and an extreme hard cladding material in two or three layers. Typical applications of altrix multi-layer plates are dredging pipes, mold plates for plows, wear plates in mill housings and mould manufacturing, paddles in log-washers, chutes, runners and transfer components in sand, gravel and cement industries as well as lateral claddings in crusher units. 30

31 Production process altrix -plates are compound materials and are produced as two- or three-layer plates in a special roll cladding process developed by voestalpine. The base material ensures high toughness and good weldability. The cladding material provides extreme hardness and best wear resistance in hardened condition. Benefits Longer service life: As a result of the higher hardness across the entire cladding thickness, altrix -plates provide an obviously longer service life as compared to other wear-resistant steels. High resistance against fracture: The high toughness of the base material guarantees a high resistance against fracture of the compound material. Smooth surface: Compared to other manufacturing methods the smooth surface of altrix -plates enables excellent flowability and largely prevents caking. Best weldabilty: The altrix base material is optimised for easy welding in the delivered condition as well as in the hardened condition. Easy fixing methods: Direct welding to the back of the altrix base material; drilling of fixing holes. Steel grades The standard base material for altrix multi-layer plates is similar to structural steel grade S235 according to EN For the hardenable cladding material different grades are available. In hardened condition hardness up to 66 HRC is achievable. altrix -plates are supplied in as-rolled condition. Dimensions Min. Max. Thickness 7 mm 80 mm Width Length 3,600 mm 12,750 mm Weight per order item 10 mt Weight per plate 6.3 mt Individual fracture and wear resistance requirements can be accommodated by providing various layer distributions. 50 % base material and 50 % cladding material of total thickness is a common combination for two layers and % (hard - tough - hard) for three layers. 31

32 A unique service package Project management voestalpine Grobblech provides professional project management to ensure successful delivery of large and complex contracts. We have a dedicated mill-based project management team whose role is to manage the contract from pre-production to post-production back-up support. We work in partnership with our clients and customers. Logistics voestalpine Grobblech recognises that steel construction projects require ongoing support. Highest priority is given to a reliable and flexible delivery performance. We care for prompt reaction in case of all arising issues within our partnership. We operate a system of capacity reservation which keeps rolling mill time available for the contract. 32

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34 Your partners for a successful business Karl Fischer Head of sales branch karl.fischer@voestalpine.com Annita Hahn (Structural steels) annita.hahn@voestalpine.com Franz Thurn (High-strength and wear-resistant steels) franz.thurn@voestalpine.com Markus Kasticky (Structural steels and multi-layer plates) markus.kasticky@voestalpine.com International sales organisation Being close to the customer is about more than just physical presence it s about really being there when the he or she needs you. voestalpine Eurostahl GmbH supports its customers in their efforts to meet ever harder challenges as and when they need it. As a reliable partner, voestalpine Eurostahl opens the door for customers to the full range of voestalpine products and services. As the company s international sales organisation, voestalpine Eurostahl is the direct link between customers and the producing companies. Sales and distribution subsidiaries and representatives in twenty countries speak the voestalpine language and guarantee hassle-free, one-stop customer access to competent support and solutions. All foreign offices and contact partners will be found at 34

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36 voestalpine Grobblech GmbH voestalpine-straße Linz, Austria T. +43/50304/ F. +43/50304/ grobblech@voestalpine.com May 2008 Edition