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8/12/2019 Marcegaglia CasalmaggioreEN_dic2012
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Casalmaggiore plant
december 2012
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we give shape to steel
Marcegaglia is the leading industrial groupworldwide in the steel processing sector,with a yearly output of 5 million tons.
After first transformation,within its controlled value chainMarcegaglia develops the world’s widestrange of customer tailored steelsemi-products and finished goods.
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Marcegaglia stands among the steel market’stop independent players in the world.A worldwide network of partnershipagreements provides reliable supplyof raw materials of all grades to our facilities.
Steel coil processing is at the coreof Marcegaglia activities.The complete range of first
transformation processes is carriedout within 50 facilities worldwide.
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Antwerpen Bremen Düsseldorf
Munhall
Garuva
Dublin
Dudley
Lyon
Barcelona
Doha
Cluj
MoscowPraszka
Kluczbork
Yangzhou
Timişoara
CalcuttaIstanbul
Lima
Vladimir
6,000,000 sqmmanufacturingareas
Casalmaggiore
Headquarters
MARCEGAGLIA WORLDWIDE PRESENCE
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Casalmaggiore plant
The Marcegaglia manufacturing unitof 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 processingof carbon steel hot rolled coils for theproduction of welded tubes and hollowsections, round, square, rectangularand of special shapes, with thickness rangingfrom 1,35 to 16 mm diameters from 17 to 406,in accordance to current norm requirements
as well as to custom specifications.
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Casalmaggiore plant
The production surface and equipment additionswere completed in 2011 and have allowedthe plant to increase its manufacturing capacityup to over 700,000 tonnes/year.
New additions include:
• a new slitting line allowing it to processup to 16 mm thickness coils• three new tube production linesadding new dimensional range capacitiesup to 406 mm diameter and 16 mm thickness• a new normalisation furnace• a new automated warehouse
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Casalmaggiore plant
The new area is covered with an integratedphotovoltaic roofing employing Marcegagliaown produced panels, generating 2.1 MWhpeak power, equal to 2,000,000 kWh/yearelectrical power.
Other electrical installations increase efficiencywith energy recovery systems, such asa 4-quadrant inverter connectedto overhead cranes.
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Casalmaggiore plant development
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Casalmaggiore plantManufacturing areas
Slitting
Tube mills
Heat treatments
Straightening
Tube cutting
Warehouse
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Main manufacturing standards
EN 10305-3 Round and shapedprecision tubes
EN 10305-5 Square and rectangularprecision tubes
EN 10219 Cold formed weldedstructural tubes(CE homologation)
EN 10210
EN 10217-1
Structural hollow sections,hot finished or cold formedand heat treated
Tubes for pressure purposes,for use at room temperature
Upon request: supply of grades not included in the above
mentioned standards
EN 10217-2 Tubes for pressure purposes,for use at high temperatures
EN 10208-1 Steel pipes for pipelinesfor combustible fluids
EN 10224 Tubes for the conveyance of waterand other aqueous liquids
EN 10255 Tubes suitablefor welding and threading
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The production program of Marcegaglia
tubes from hot rolled strip coversa wide range of structuraland mechanical applications,guaranteeing specific suitabilityfor subsequent processing.
Tubes for steelstructural work
Tubes for piling
Typical applications
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Some applications:
• building frames (offices, residential, industrial buildings,
sports venues, halls)
• bridges for pipelines and conveyors
• road and pedestrian bridges• stairs, footbridges, railings
• machinery frames
• poles and frameworks for traffic signs and lightings
• masts for data, tv and radio communication
• agricultural machinery, tractors, earthmovers• vehicle cabs, frames, bodies, trailers, hitches
• railway cars
• warehousing
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Tubes for automotive applications
With a dedicated productionfor the automotive sector, Marcegagliais the supplier of choice for carmakersand 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, stabilizersand steering components.
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Tubes for pressure purposes includeapplications for the heat exchanger industry,heating and ventilation, gas and water linepipes, district heating tubes.
Tubes for heatexchangers
Tubes for gasand water line pipes
Tubes for districtheating
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Tubes suitable for drawing
Roller conveyor tubes Tubes for liftingequipment
Marcegaglia has developed a unique
know-how in the manufacturingof precision tubes to meet the strictdimensional and surface specificationsrequired by manufacturers in severalmechanical 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 or shaped
manufacturing capacity (t/y) 700,000
wall thickness (mm) from 1.3 up to 16
diameter (mm) from 16.75 up to 406.4length feasibility (mm) from 5,000 to 16,000
Marcegaglia Casalmaggiore
Tube mills
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Production line
TC011 (3’’)
Welded tubes ex hot rolled strip (blackor pickled), cold rolled strip, coated strip
ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 1,35
Max. thickness (mm) 6,6Min. diameter (mm) 21,25
Max. diameter (mm) 89
Min. thickness (mm) 1,35
Max. thickness (mm) 6
Smallest square (mm) 20x20
Largest square (mm) 75x75
and all rectangular derived
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Production line
TC011 (3’’)
Mill lengths 5.000-14.000 mm
Length tolerance -0+50 mm on demand -0+25 mm
Thickness range 1,35 - 6,6 mm
TECHNICAL FEATURES
Marking of strips prior to forming
Weld seam removing
Online laser gauge to control adherenceto tolerances on 100% of the outside diameter
Reel mounted stamping
On demand,“cold saw” cutoff(no trimming but burr-free ends)
Internal washing
Bevel ends
Dot matrix cast marking(on tubes for pressure applications)This may involve some speed reduction
Air blowing of trimmings and swarf
NON DESTRUCTIVE TESTS
Induced eddy currents online
Eddy current + magnetic flux leakage(Rotomat) after bevelling
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Production line
TC002 (8’’)
ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 3
Max. thickness (mm) 16Min. diameter (mm) 114,3
Max. diameter (mm) 219,1
Min. thickness (mm) 3,7
Max. thickness (mm) 16
Smallest square (mm) 90x90
Largest square (mm) 180x180
and all rectangular derived
Welded tubes from hot rolled black strips(upon mutual agreement we can possiblyuse pickled and coated strips)
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Production line
TC002 (8’’)
NON DESTRUCTIVE TESTS
Induced eddy currents online
Eddy current + magnetic flux leakage(Rotomat) after bevelling
TECHNICAL FEATURES
Marking of strips prior to forming
Trimming of strip edges before welding
Weld flash trimming/removal
Heat treatment (normalisation) of the welding area
Online laser gauge to control adherence
to tolerances on 100% of the outside diameterReel mounted stamping
Online cutting with coated saw blades
Internal washing
Deburred ends/bevel ends
Dot matrix cast marking
Length feasibility 5.000-16.000 mm
Length tolerance -0+50 mm on request -0+25 mm
Thickness feasibility 13 - 16 mm
* on demand we can offer a : -0+15 mm tolerancefor lengths 6.000, 12.000 and 16.000 mm
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Production line
TC001 (16’’)
Length feasibility 6.000-16.000 mm
Length tolerance -0+50 mm on request -0+25 mm
Thickness feasibility 4 - 16 mm
* on demand we can offer a : -0+15 mm tolerancefor lengths 6.000, 12.000 and 16.000 mm
NON DESTRUCTIVE TESTS
Induced eddy currents online
Rotomat after deburring
TECHNICAL FEATURES
Marking of strips prior to forming
Trimming of strip edges before welding
Weld flash trimming/removal
Heat treatment (normalisation) of the welding area
Online laser gauge to control adherence
to tolerances on 100% of the outside diameterReel mounted stamping
Online cutting with coated saw blades
Internal washing
Deburred ends/bevel ends
Dot matrix cast marking
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furnaces 3
heat treatments:
• normalization
• annealing• stress relieving
manufacturing capacity (t/y) 200,000
wall thickness (mm) from 0.9 up to 16
diameter (mm) from 16 up to 355
Marcegaglia Casalmaggiore
Heat treatments
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lines 4
manufacturing capacity (t/y) 80,000
wall thickness (mm) from 0.9 up to 14
diameter (mm)from 13 up to 219
Marcegaglia Casalmaggiore
Straightening
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lines 6
length (mm) from 100 to 12,000
also in bundles
manufacturing capacity (t/y)50,000
wall thickness (mm) from 0.9 up to 16
diameter (mm) from 21.25 up to 406.4
Marcegaglia Casalmaggiore
Tube cutting
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It allows the automated storage
and preparation of bundles to ship,
avoiding the operator’s access
to the loading bays.
The storage area spreads over 14 hall aisles.
Marcegaglia Casalmaggiore
Automated warehouse
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Marcegaglia Casalmaggiore
Optional processing
• Suitability for subsequent galvanizing
• Complete normalization or weld areanormalization
• Additional heat treatments
• Weld seam removing
• Special end finishing
• Cut to length
• Customer defined marking
• Restricted tolerances
• Welding position
• Specific corrosion protection
• Specific packaging method
• Hot galvanization
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Marcegaglia Casalmaggiore
Testing
• Chemical composition
• Tensile test
• Flattening test
• Expansion test
• Impact test
• Eddy current test
• Flux leakage test
• Ultrasonic test
• Visual test
• Hydraulic test
• Dimensional test
• Micrographic analysis
• Release of special certificates
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EA:17
505/96/S
MARCEGAGLIA S.p.a.
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
SS 420 SABBIONETANA 26041 CASALMAGGIORE (CR) ITALIASITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASINGVIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALESVOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
PRODUCTION OF STEEL TUBES AND HOLLOW STEEL SECTIONS WELDEDLONGITUDINALLY
PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE
30.12.1996
13.07.2012
Perinformazionisulla validitàdelcertificato,visitareil sito
www.rina.org
Forinformation concerning validityofthecertificate,you
canvisitthesitewww.rina.org
CISQè laFederazioneItalianadiOrganismidiCertificazionedei
sistemidi gestioneaziendale
CISQistheItalianFederationofmanagement systemCertification Bodies
CERTIFICATE No.
CERTIFICATO N.
SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
PER I SEGUENTI CAMPI DI ATTIVITÀ / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES
NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
L'usoelavaliditàdelpresentecertificatosonosoggettialrispettodeldocumentoRINA:RegolamentoperlaCertificazionediSistemidiGestioneperlaQualità
Lavaliditàdelpresentecertificatoèsubordinataasorveglianzaperiodicaannuale/semestraleedal riesamecompletodelsistemadigestioneconperiodicitàtriennale
Thevalidity ofthis certificateis dependentonanannual/six monthly auditandona completereview,every threeyears,ofthemanagementsystem
Prima emissioneFirst Issue
Emissione correnteCurrent Issue
RINA Services S.p.A.ViaCorsica12- 16128GenovaItaly
È CONFORME ALLA NORMA / IS IN COMPLIANCE WITH THE STANDARD
RiferirsialManuale dellaQualitàperi dettaglidelleesclusioniai
requisitidellanorma
Data scadenzaExpiry Date 12.07.2015
SGQN°002ASSIN°001GSGAN°002DDAPN° 001HPRDN°002BPRSN° 066CSCRN°003F LABN°0832
Theuseandvalidityofthis certificatearesubjecttocompliancewiththeRINAdocument:Rules forthecertificationofQuality ManagementSystems
Dott. Roberto Cavanna(Managing Director)
Referenceis tobemadeto the
Quality Manualfordetailsregardingtheexemptions fromthe
requirementsofthestandard
ISO 9001:2008
MembrodegliAccordidi MutuoRiconoscimentoEA,IAFe ILAC
Signatory ofEA,I AFandILAC Mutual
RecognitionAgreements
CertificationISO 9001:2008
The plant is certified according toISO 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
Perinformazionisulla validitàdelcertificato,visitareil sito
www.rina.org
Forinformation concerning validity ofthe certificate,you
canvisitthesitewww.rina.org
CISQè laFederazioneItalianadiOrganismidiCertificazionedeisistemidi gestioneaziendale.
CISQèmembrodiIQNET.
CISQis the ItalianFederationof management system
CertificationBodies.CISQisa
memberofIQNET.
CERTIFICATE No.
CERTIFICATO N.
Essendostativalutatiin accordoalle“Regoleper loschema dicertificazioneISO/TS 16949:2002–Terza EdizioneOttobre2008”
ILPRESENTECERTIFICATOÈEMESSO INCONFORMITÀ
ALLEREGOLEIATF
CISQAUTOMOTIVE -
Thevalidityofthis certificateis dependentonan annual/six
monthly auditandon acompletereview,every threeyears,of themanagementsystem
Prima emissioneFirst Issue
Emissione correnteCurrent Issue
RINA Services S.p.A.ViaCorsica12- 16128GenovaItaly
RiferirsialManuale dellaQualitàper idettagli delleesclusioniai requisitidellanorma
Referenceisto bemadeto theQualityManualfordetails regardingthe exemptionsfromtherequirements ofthe standard
Lavaliditàdel presentecertificatoèsubordinataa sorveglianzaperiodicaannuale/semestraleed alriesamecompleto del
sistemadigestione conperiodicitàtriennale
Havingbeenassessedin accordancewith"ISO/TS16949:2002certificationschemerules– ThirdEditionOctober2008"
Data di scadenzaExpiry date
CertificatoIATFn.IATFCertificaten. 0143175
THISCERTIFICATEISISSUEDINCONFORMITY WITHTHEIATFRULES
ViaQuintiliano41–20138MILANO
Dott. Roberto Cavanna(Managing Director)
12.07.2015
SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALITÀ DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
NELLE SEGUENTI UNITÀ OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
È CONFORME ALLA NORMA E AI REQUISITI DELLO SCHEMAIS IN COMPLIANCE WITH THE STANDARD AND THE SCHEME REQUIREMENTS
PER I SEGUENTI CAMPI DI ATTIVIT / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES EA:17
CertificationISO TS 16949:2009
The plant is certified according toISO TS 16949:2009 with RINA(Registro Italiano Navale)“Requisiti particolari per l’applicazionedella ISO 9001:2008 per la produzioneo serie e delle parti di ricambionell’industria automobilistica”
(Components for the automobile industry)
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TÜV - PEDCertifications
• Marcegaglia is qualied according to AD 2000 - Merkblatt W0 (directive 97/23/EC) with TÜV Rheinland
• The qualication currently applies to norm EN 10217-1/2, grades P235TR1, P235TR2 and P235GH
• The qualication allows Marcegaglia to supply certificates conform to W4 according to PED directive
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Homologation CE
• Marcegaglia is qualied 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 certied with CE marking:S235JRH, S275J0H, S275J2H, S355J0H, S355J2H
• Micro-alloyed grades certied with CE marking:S355MH, S420MH, S460MH
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RINA approvalCertificate of Approval
of Manufacturers of Materials
Tubes for naval constructions
EN 10219
EN 10217
S235JR, S355J0, S303J2P235 TR1 - TR2 - GH
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via Bresciani, 16 • 46040 Gazoldo Ippoliti, Mantova - Italywww.marcegaglia.com
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