The Kolhapur Steel LimitedA Kirloskar Group Company

Pioneers in Steel Castings

for over 50 Years

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1. Who we are

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2. Our Location

3. Our Capabilities

4. Our Certifications

5. Our Manufacturing Facilities

6. Our esteemed customers

7. Product Showcase

About Kolhapur Steel Limited

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Kolhapur Steel Limited (TKSL) is a

wholly owned subsidiary company of

Kirloskar Brothers Limited (KBL).

KBL is a flagship company of $ 2.1

billion Kirloskar Group

Established in the year 1965 Kolhapur

steel is a premier steel casting

manufacturer & exporter providing

high quality castings across industries

like Pumps & Valves, Power, Earth

Moving Equipment, Shipping and

Heavy Engineering Applications and

many more…

With a Installed capacity of 3600 MT

per annum Kolhapur Steel produces

Steel castings in the weight range of

300 Kg to 10 T per piece with

governing dimensions up to 4m x 4m.

Carbon Steel Castings | Stainless Steel Castings | Alloy Steel Castings

1. Who we are

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2. Our Location

3. Our Capabilities

4. Our Certifications

5. Our Manufacturing Facilities

6. Our esteemed customers

7. Product Showcase

Kolhapur : The Foundry and Engineering Cluster

Kolhapur Steel is situated in Kolhapuron the Pune – Bangalore highwayproviding excellent accessibility.

It‟s location in Kolhapur, one of themost prominent foundry and

engineering clusters in India offersmany strategic advantages

• Skilled and Qualified Manpower

• Excellent Connectivity to major

industrial hubs like Bangalore, Pune

and Mumbai (Mumbai port is one of

the busiest ports for import/ export in

the country)

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1. Who we are

2. Our Location

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3. Our Capabilities

4. Our Certifications

5. Our Manufacturing Facilities

6. Our esteemed customers

7. Product Showcase

Product Grades

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Kolhapur Steel specializes in manufacturing Carbon steel, Stainless steel, Duplex Steel, Super

Duplex and Alloy steel castings in as cast, proof machined and finish machined conditions meeting

highest quality standards for customers across industries.

Type of Casting Material Specification Capability

Carbon Steel Castings for

General Engineering purpose

IS-1030, ASTM A 27, IS-2707, IS-2644,

DIN-1681

300 kg to 10 MT Single

Piece

Corrosion Resistant Stainless

Steel Castings

ASTM A 351, Gr. CF-8M, CF-8, CA

6NM, CF3M

300 kg to 6.5 MT Single

Piece

Duplex Stainless Steel Castings

for high pressure and corrosion

resistant application

ASTM A 890 & ASTM A 995 Gr. 1A,

3A, 4A, 1B

300 kg to 6.5 MT Single

Piece

Super Duplex Stainless Steel

Castings for high pressure and

corrosion resistant applicationASTM A 890 & ASTM A 995 Gr. 5A

300 kg to 3.5 MT Single

Piece

High Alloy Castings resistant

to abrasion and cavitation

corrosion

ASTM A 743, Gr. CA6NM, CA15 and

CF8M

300 kg to 10 MT Single

Piece

1. Who we are

2. Our Location

3. Our Capabilities

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4. Our Certifications

5. Our Manufacturing Facilities

6. Our esteemed customers

7. Product Showcase

Certification & Approvals

Kolhapur Steel is committed to providing

high quality castings and has been

approved by various certifying authorities

ISO 9001:2015 ISO 14001:2015 IRS

PED Well Known FoundryNORSOK

ISO 9001: 2008 by TUV-NORD

ISO 14001:2004 by TUV-NORD

NORSOK M630 Ed.6, MDS D56 Rev. 05

ASTM A995 GR.5A

Pressure Equipment Directive

2014/68/EU (PED)

Indian Register of Shipping (IRS)

National Thermal Power Corporation

(NTPC)

Well Known Foundry (IBR)

We are committed to obtain America

Bureau of Shipping (ABS)

certification.

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1. Who we are

2. Our Location

3. Our Capabilities

4. Our Certifications

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5. Our Manufacturing Facilities

6. Our esteemed customers

7. Product Showcase

Pattern Services

Kolhapur Steel‟s In-house Pattern Shop is

adequately equipped to maintain rectify and

repair existing customer patterns serviced by a

dedicated and skilled team.

While new patterns and core boxes are prepared

by reputed third party suppliers located nearby

equipped with CNC & VMC setup

Kolhapur Steel offers basic pattern services to

it‟s customers. These services include

• Design

• Layout

• Manufacturing of new patterns

• Maintenance of existing patterns.

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Methoding

Kolhapur Steel uses state of the art

Magma 5.3 and 10 Core processor

Simulation software to predict the

complete casting process including filling,

solidification and cooling which allows the

quantitative predication of various

properties.

Such simulation accurately describes a cast

component‟s quality up-front before

pattern manufactured and the Casting

methoding can be designed to meet

required quality invariably reducing casting

development time.

SPD Pump

24”-600 Plug Valve Body Casting42”-150 GTV Body Casting

SPD Pump

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Moulding

Omega Continuous Sand Mixer – 20 MT

3D Printed Moulds & Cores

The Moulding Shop of Kolhapur Steel

Limited is equipped with the latest

moulding facilities

20 MT Omega make continuous sand

mixer.

3 MT Omega make continuous sand mixer

10 MT/hr. Omega make sand reclamation

unit

Gas fired mould heating oven

Four E.O.T cranes (30 MT, 25 MT , 10

MT , 5 MT)

At Kolhapur Steel we also have access to

WORLD‟s LARGEST 3D printing

machine of Kirloskar Brothers Limited.

The Moulds created by 3D printing

provide superior casting quality specially

for castings having weights upto 10T13

Melting

Ladle Refining Furnace (LRF) - 14 MT capacity.

Argon oxygen decarburization (AOD) - 7 MT

capacity with pollution control equipment

Wire Injection machine for deoxidization.

of a well equippedKolhapur Steel boasts

Melting shop

5 Induction Furnaces

One - 2 MT

Two - 5 MTOne - 8 MTOne - 12 MT

LRF – 14 MT

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AOD – 7 MT with Pollution ControlInduction Furnace - 12 MT

Benefits of AOD

Argon Oxygen Decarburization “AOD”, is

an advanced technology at TKSL which

gives it unparalleled capability to make any

grade of stainless steel casting

In AOD process, through the

management of an additional high oxygen

partial pressure gas mix and argon, the

metal is refined and can reduce carbon

levels to 0.01% or lower which is critical

for production of modern duplex, super-

duplex, and super-austenitic grades

AOD process provides significant quality

improvements thru pinpoint accuracy in

chemistry (surface and internal cleanliness)

associated with low levels of sulphur,

dissolved gases (oxygen, nitrogen, and

hydrogen), carbon and volatile tramp

element (Zn, Pb, and Bi) contents

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Argon oxygen decarburization (AOD)

Heat Treatment

Kolhapur Steel‟s Heat treatment shop is

equipped with two HT furnaces well

calibrated as per API 6A standard.

CBG Fired Furnaces

• 5 m x 4.5 m x 2 m – 13 MT

• 3.5 m x 3.5 m x 2 m – 10 MT

Water Quenching Tank – 6.1 m x 5.2 m x

3.8 m – 1,20,000 Ltrs.

Adequately supported with a 60 HP

pumping system to achieve good

hardenability.CBG Fired Furnace – 10 T with Automated water Quenching

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Fettling

Apart from various pneumatic and electric

grinders, Kolhapur Steel‟s fettling shop is

equipped with

Grit blasting facility

Shot blasting machine – 3MT

TKSL has qualified welders as per ASME

section IX for various grades equipped

with suitable welding machines and ovens

Grit Blasting Shot Blasting – 3MT

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Machining

Additionally TKSL has a well established

vendor base for outsourcing finished machining

activities. These Vendors are equipped with

advanced CNC machines and CMM.

TKSL Offers castings in machined condition.

The company has in-house machining facilities

viz.

Vertical Turning Lathe – 4 m dia, 2.2 m height

Vertical Turning Lathe – 2 m dia

Heavy Duty Lathe – 2 m Swing dia

Vertical Turning Center Ø 2m

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Vertical Turning Center Ø 4m

Quality

Sand Testing

• Universal Strength Machine – 60 Kg/cm2• Sand Muller - 5 Kg capacity• Rapid Moisture Tester• Sieve Shaker• Permeability Meter

• Code Permeability Tube

Kolhapur Steel has a well equipped Laboratory

for testing all requirements of product quality

Chemical Testing

• Spectrometer – 31 Elements including

Nitrogen Facility

• Storlines Apparatus for Wet Analysis

Image Analyser for micro structure study Spectrometer – 31 Elements including Nitrogen Facility

• Standard Samples • Mould Permeability Tester19

Quality

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Non Destructive Testing

Ultrasonic Inspection - Einstein II DGS Ultrasonic Inspection - da. Vinci. DeltaIIW – Magnaflux Probe for magnetic particle inspection

Radiography Testing

TKSL has access to KBL Radioactive testing labs at Kirloskarwadi which can provide Cobalt,Iridium and also X-Ray

TKSL‟s testing Laboratory is also equipped with Mechanical & NDT testing equipment

Mechanical Testing

• Universal Testing Machine – 100 MT• Impact Testing withCryogenictesting upto460C

• Machine Profile Projector for „V‟ Notch Insp.• Broaching Machine for Charpy „V‟ Notch• 0.2% Proof Test Facility with Extensometer

Calibrated ASTM B2

Ultrasonic Tester Universal Testing MachineImpact Testing machine with

Cryogenic testing up to 460C

1. Who we are

2. Our Location

3. Our Capabilities

4. Our Certifications

5. Our Manufacturing Facilities

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6. Our esteemed customers

7. Product Showcase

Our Major Customers

Pumps

Valves

General

Engineering

International ClientsDomestic Clients

International ClientsDomestic Clients

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Our Major Customers

Steam

Turbines

Hydro

Turbines

Shipping &

Marine

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Customer Recognition

Kolhapur Steel‟s commitment to quality

and has been appreciated by our

customers over the years

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1. Who we are

2. Our Location

3. Our Capabilities

4. Our Certifications

5. Our Manufacturing Facilities

6. Our esteemed customers

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7. Product Showcase

Pumps

Valves

Pump BowlPump Casing Casing

Sample of our products made

Diaghpharam

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Valve BodyValve Body

Hydro

Turbines

Steam

Turbines

SWVELL HOUSINGUPPER & LOWER HALF CASING OUTER CASING BOTTOM HALF

Francis Runner Guide Vane Pelton Runner (Using 3D Mould)Runner Blade

Sample of our products made

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Crushers &

Earth Moving

Shipping &

Marine

Sample of our products made

End Frame Jaw CastingJaw Casting

Stern Tube Boss AFT Naval PipeTIller

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General

Engineering

Sample of our products made

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Gear Wheel Lower Bell Cylinder

Kolhapur Steel’s Castings have been pivotal in

executing Marquee projects across the globe

TKSL‟s Castings were used in the 2x1.5 MW Kalpan Hydro

Turbine generator Set in the Kayyakam SHEP project

commissioned by Kerala State Electricity Board (KSEB)

TKSL‟s supplied castings for the Auxiliary, Cooling and Raw water

pumps for the 400 MW Combine Cycle Power Plant Bibiyana III

in Bangladesh commissioned by Larsen & Toubro Limited

Hydro

Turbines

Pumps

TKSL‟s manufactured castings CV CW Pumps and the

VT Pumps for the Circulating water System in the

Darlipalli Super Thermal Power project by NTPCPumps

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The Kolhapur Steel Limited(Subsidiary company of Kirloskar Brothers Limited)

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Pune Bangalore Highway,

Shiroli (Pulanchi), Hatkanangale,

Kolhapur, Maharashtra, 416122, INDIA

Tel: +91 - 0230 - 2468061/62/63 Fax: +91 - 0230 – 2468761

Email: marketing@kolhapursteel.com Website: www.kolhapursteel.com