Marcegaglia Casalmaggiore plant

Casalmaggiore plant

december 2013

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we give shape to steel

Marcegaglia is the leading industrial group worldwide in the steel processing sector,with a yearly output of 5 million tons.

After fi rst transformation,within its controlled value chainMarcegaglia develops the world’s widest range of customer tailored steelsemi-products and fi nished goods.

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Marcegaglia stands among the steel market’s top independent players in the world.A worldwide network of partnership agreements provides reliable supply of raw materials of all grades to our facilities.

Steel coil processing is at the core of Marcegaglia activities. The complete range of fi rst transformation processes is carried out within our production facilities worldwide.

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Antwerpen Bremen Düsseldorf

Munhall

Garuva

Dublin

Dudley

Lyon

Barcelona

Doha

Cluj

MoscowPraszka

Kluczbork

Yangzhou

Timişoara

Calcutta

Lima

Vladimir

6,000,000 sqmmanufacturingareas

Casalmaggiore

Headquarters

MARCEGAGLIA WORLDWIDE PRESENCE

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Casalmaggiore plant

The Marcegaglia manufacturing unit of Casalmaggiore (Cremona, Italy) spreadsover a total surface of 320,000 square meters, of which 162,000 covered,currently employing about 460 employees.

The plant is mainly dedicated to the processing of carbon steel hot rolled coils for the production of welded tubes and hollow sections, round, square, rectangularand of special shapes, with thickness ranging from 1,35 to 16 mm diameters from 17 to 406, in accordance to current norm requirementsas well as to custom specifi cations.

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Casalmaggiore plant

The production surface and equipment additions were completed in 2011 and have allowed the plant to increase its manufacturing capacityup to over 700,000 tonnes/year.

Plant equipment include:

• 5 slitting lines allowing to process up to 16 mm thickness coils• 11 tube mills up to 16 mm thickness• 3 normalization furnaces• 6 tube cutting units• new automated warehouse spreading over 14 hall aisles

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Casalmaggiore plant development

201072.000 m2 1982

35.000 m2

19877.000 m2

199240.000 m2

200010.000 m2

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Casalmaggiore plantManufacturing areas

Slitting

Tube mills

Heat treatments

Straightening

Tube cutting

Warehouse

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Main manufacturing standards

EN 10305-3 Round and shaped precision tubes

EN 10305-5 Square and rectangularprecision tubes

EN 10219 Cold formed welded structural tubes (CE homologation)

EN 10210

EN 10217-1

Structural hollow sections, hot fi nished or cold formed and heat treated

Tubes for pressure purposes, for use at room temperature

Upon request: supply of grades not included in the above mentioned standards

EN 10217-2 Tubes for pressure purposes, for use at high temperatures

EN 10208-1 Steel pipes for pipelinesfor combustible fl uids

EN 10224 Tubes for the conveyance of water and other aqueous liquids

EN 10255 Tubes suitable for welding and threading

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The production program of Marcegaglia tubes from hot rolled strip coversa wide range of structural and mechanical applications, guaranteeing specifi c suitability for subsequent processing.

Tubes for steel structural work

Tubes for piling

Typical applications

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Some applications:

• building frames (offi ces, residential, industrial buildings, sports venues, halls)• bridges for pipelines and conveyors• road and pedestrian bridges• stairs, footbridges, railings• machinery frames• poles and frameworks for traffi c signs and lightings• masts for data, tv and radio communication• agricultural machinery, tractors, earthmovers• vehicle cabs, frames, bodies, trailers, hitches• railway cars• warehousing

Tubes for automotive applications

With a dedicated production for the automotive sector, Marcegaglia is the supplier of choice for carmakers and OEM manufacturers of structural parts, components and interior details.

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Major applications include: axles for vehicles and industrial vehicles, tubes for dump trucks, stabilizers and steering components.

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Tubes for pressure purposes include applications for the heat exchanger industry, heating and ventilation, gas and water line pipes, district heating tubes.

Tubes for heat exchangers

Tubes for gas and water line pipes

Tubes for district heating

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Tubes suitable for drawing

Roller conveyor tubes Tubes for lifting equipment

Marcegaglia has developed a unique know-how in the manufacturing of precision tubes to meet the strict dimensional and surface specifi cations required by manufacturers in several mechanical engineering sectors.

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Marcegaglia Casalmaggiore

Slitting lines

lines 5

manufacturing capacity (t/y) 700,000

coil thickness (mm) from 1.3 up to 16

coil width (mm) up to 2,000

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lines 11

product type round, square,

rectangular, special shaped tube


wall thickness (mm) from 1.3 up to 16

diameter (mm) from 16.75 up to 406.4

length feasibility (mm) from 5,000 to 16,000


Tube mills

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Production line TC011 (3’’)

Welded tubes ex hot rolled strip (black or pickled), cold rolled strip, coated strip

ROUNDS

SQUARES AND RECTANGULARS

Min. thickness (mm) 1,35

Max. thickness (mm) 6,6

Min. diameter (mm) 21,25

Max. diameter (mm) 89


Max. thickness (mm) 6

Smallest square (mm) 20x20

Largest square (mm) 75x75

and all rectangular derived

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Production line TC011 (3’’)

Mill lengths 5.000-14.000 mm

Length tolerance -0+50 mm on demand -0+25 mm

Thickness range 1,35 - 6,6 mm

TECHNICAL FEATURES

Marking of strips prior to forming

Weld seam removingOnline laser gauge to control adherence to tolerances on 100% of the outside diameterReel mounted stampingOn demand,“cold saw” cutoff (no trimming but burr-free ends)Internal washing

Bevel endsDot matrix cast marking(on tubes for pressure applications)This may involve some speed reductionAir blowing of trimmings and swarf

NON DESTRUCTIVE TESTSInduced eddy currents onlineEddy current + magnetic fl ux leakage (Rotomat) after bevelling

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Production lineTC002 (8’’)

ROUNDS


Min. thickness (mm) 3


Min. diameter (mm) 114,3

Max. diameter (mm) 219,1



Smallest square (mm) 90x90

Largest square (mm) 180x180


Welded tubes from hot rolled black strips (upon mutual agreement we can possibly use pickled and coated strips)

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NON DESTRUCTIVE TESTSInduced eddy currents onlineEddy current + magnetic fl ux leakage (Rotomat) after bevelling

TECHNICAL FEATURES


Trimming of strip edges before welding

Weld fl ash trimming/removal

Heat treatment (normalisation) of the welding areaOnline laser gauge to control adherence to tolerances on 100% of the outside diameterReel mounted stamping

Online cutting with coated saw blades

Internal washing

Deburred ends/bevel ends

Dot matrix cast marking

Length feasibility 5.000-16.000 mm

Length tolerance -0+50 mm on request -0+25 mm

Thickness feasibility 13 - 16 mm

* on demand we can offer a : -0+15 mm tolerancefor lengths 6.000, 12.000 and 16.000 mm

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ROUNDS


Min. thickness (mm) 4


Smallest square (mm) 244

Largest square (mm) 406

Min. thickness (mm) 4 (3)


Min. diameter (mm) 200x200

Max. diameter (mm) 325x325


Welded tubes from hot rolled black strips (upon mutual agreement we can possibly use pickled and coated strips)

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Length feasibility 6.000-16.000 mm

Length tolerance -0+50 mm on request -0+25 mm

Thickness feasibility 4 - 16 mm

* on demand we can offer a : -0+15 mm tolerancefor lengths 6.000, 12.000 and 16.000 mm

NON DESTRUCTIVE TESTSInduced eddy currents onlineRotomat after deburring

TECHNICAL FEATURES


Trimming of strip edges before welding

Weld fl ash trimming/removal

Heat treatment (normalisation) of the welding areaOnline laser gauge to control adherence to tolerances on 100% of the outside diameterReel mounted stamping

Online cutting with coated saw blades

Internal washing

Deburred ends/bevel ends

Dot matrix cast marking

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furnaces 3

heat treatments:

• normalization

• annealing

• stress relieving



diameter (mm) from 16 up to 355


Heat treatments

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lines 4



diameter (mm) from 13 up to 219


Straightening

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lines 6

length (mm) from 100 to 12,000

also in bundles



diameter (mm) from 21.25 up to 406.4


Tube cutting

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It allows the automated storage

and preparation of bundles to ship,

avoiding the operator’s access

to the loading bays.

The storage area spreads over 14 hall aisles.


Automated warehouse

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Optional processing

• Suitability for subsequent galvanizing

• Complete normalization or weld area normalization

• Additional heat treatments

• Weld seam removing

• Special end finishing

• Cut to length

• Customer defined marking

• Restricted tolerances

• Welding position

• Specific corrosion protection

• Specific packaging method

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Testing

• Chemical composition

• Tensile test

• Flattening test

• Expansion test

• Impact test

• Eddy current test

• Flux leakage test

• Ultrasonic test

• Visual test

• Hydraulic test

• Dimensional test

• Micrographic analysis

• Release of special certificates

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EA:17

505/96/S

MARCEGAGLIA S.p.a.VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA

SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIASITI DI SUPPORTO / REMOTE LOCATIONS

COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASINGVIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA

COMMERCIALE / SALESVOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326

40470 DUSSELDORF GERMANIA

PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDEDLONGITUDINALLY

PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE

30.12.1996

13.07.2012

Per informazioni sulla validitàdel certificato, visitare il sito

www.rina.org

For information concerningvalidity of the certificate, you

can visit the sitewww.rina.org

CISQ è la Federazione Italiana diOrganismi di Certificazione dei

sistemi di gestione aziendale

CISQ is the ItalianFederation of managementsystem Certification Bodies

CERTIFICATE No.CERTIFICATO N.

SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DIIT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF

PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES

NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS

L'uso e la validità del presente certificato sono soggetti al rispetto del documento RINA: Regolamento per la Certificazione di Sistemi di Gestione per la Qualità

La validità del presente certificato è subordinata a sorveglianza periodica annuale / semestrale ed al riesame completo del sistema di gestione con periodicità triennaleThe validity of this certificate is dependent on an annual / six monthly audit and on a complete review, every three years, of the management system

Prima emissioneFirst IssueEmissione correnteCurrent Issue

RINA Services S.p.A.Via Corsica 12 - 16128 Genova Italy

È CONFORME ALLA NORMA / IS IN COMPLIANCE WITH THE STANDARD

Riferirsi al Manuale della Qualitàper i dettagli delle esclusioni ai

requisiti della norma

Data scadenzaExpiry Date 12.07.2015

SGQ N° 002 A SSI N° 001 GSGA N° 002 D DAP N° 001 HPRD N° 002 B PRS N° 066 CSCR N° 003 F LAB N° 0832

The use and validity of this certificate are subject to compliance with the RINA document : Rules for the certification of Quality Management Systems

Dott. Roberto Cavanna(Managing Director)

Reference is to be made to theQuality Manual for details

regarding the exemptions from therequirements of the standard

ISO 9001:2008

Membro degli Accordi di MutuoRiconoscimento EA, IAF e ILAC

Signatory of EA, IAF and ILAC MutualRecognition Agreements

Certifi cationISO 9001:2008

The plant is certifi ed according to ISO 9001:2008 with RINA(Registro Italiano Navale)

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TS/505/96

MARCEGAGLIA S.p.a.

VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA

SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIASITI DI SUPPORTO / REMOTE LOCATIONS

COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASINGVIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA

COMMERCIALE / SALESVOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326

40470 DUSSELDORF GERMANIA

ISO/TS16949:2009

PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDEDLONGITUDINALLY FOR THE AUTOMOTIVE INDUSTRY

PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTEPER L'INDUSTRIA AUTOMOBILISTICA

14.10.2002

13.07.2012

Per informazioni sulla validitàdel certificato, visitare il sito

www.rina.org

For information concerningvalidity of the certificate, you

can visit the sitewww.rina.org

CISQ è la Federazione Italiana diOrganismi di Certificazione deisistemi di gestione aziendale.

CISQ è membro di IQNET.

CISQ is the Italian Federation ofmanagement system

Certification Bodies. CISQ is amember of IQNET.

CERTIFICATE No.

CERTIFICATO N.

Essendo stati valutati in accordo alle “Regole per lo schema di certificazione ISO/TS 16949:2002 – Terza Edizione Ottobre 2008”

IL PRESENTE CERTIFICATOÈ EMESSO IN CONFORMITÀ

ALLE REGOLE IATF

CISQ AUTOMOTIVE -

The validity of this certificate is dependent on an annual/sixmonthly audit and on a complete review, every three years, of

the management system

Prima emissioneFirst IssueEmissione correnteCurrent Issue

RINA Services S.p.A.Via Corsica 12 - 16128 Genova Italy

Riferirsi al Manuale della Qualità per i dettagli delle esclusioni ai requisiti della norma

Reference is to be made to the Quality Manual for details regarding the exemptions from the requirements of the standard

La validità del presente certificato è subordinata a sorveglianzaperiodica annuale / semestrale ed al riesame completo del

sistema di gestione con periodicità triennale

Having been assessed in accordance with "ISO/TS 16949:2002 certification scheme rules – Third Edition October 2008"

Data di scadenzaExpiry date

Certificato IATF n.IATF Certificate n. 0143175

THIS CERTIFICATE ISISSUED IN CONFORMITYWITH THE IATF RULES

Via Quintiliano 41 – 20138 MILANO

Dott. Roberto Cavanna(Managing Director)

12.07.2015

SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DIIT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF

NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS

È CONFORME ALLA NORMA E AI REQUISITI DELLO SCHEMAIS IN COMPLIANCE WITH THE STANDARD AND THE SCHEME REQUIREMENTS

PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES EA:17

Certifi cationISO/TS 16949:2009

The plant is certifi ed according to ISO/TS 16949:2009 with RINA(Registro Italiano Navale)“Requisiti particolari per l’applicazione della ISO 9001:2008 per la produzione o serie e delle parti di ricambio nell’industria automobilistica”(Components for the automobile industry)

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Certifi cationISO/TS 29001:2011

The plant is certifi ed according to ISO/TS 29001:2011 with RINA (Registro Italiano Navale)“Petroleum, petrochemical and natural gas industries, requirements for product and service supply organizations”

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TÜV - PEDCertifi cations

• Marcegaglia is qualifi ed according to AD 2000 - Merkblatt W0 (directive 97/23/EC) with TÜV Rheinland

• The qualifi cation currently applies to norm EN 10217-1/2, grades P235TR1, P235TR2 and P235GH

• The qualifi cation allows Marcegaglia to supply certifi cates conform to W4 according to PED directive

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Homologation CE

• Marcegaglia is qualifi ed with RINA according to the European directive 89/106/EEC (CE marking)

• CE marking refers to Appendix ZA of norm EN 10219-1

• Standard grades certifi ed with CE marking: S235JRH, S275J0H, S275J2H, S355J0H, S355J2H

• Micro-alloyed grades certifi ed with CE marking: S355MH, S420MH, S460MH

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RINA approvalCertifi cate of Approval of Manufacturers of Materials

Tubes for naval constructions

EN 10219S235JR, S355JO, S355J2

EN 10217P235 TR1 - TR2 - GH

via Bresciani, 16 • 46040 Gazoldo Ippoliti, Mantova - Italywww.marcegaglia.com

Documents

Marcegaglia Casalmaggiore plant