Casalmaggiore plant

december 2012
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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 frst transformation,
within its controlled value chain
Marcegaglia develops the worlds widest
range of customer tailored steel
semi-products and fnished goods.
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Marcegaglia stands among the steel markets
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 frst
transformation processes is carried
out within 50 facilities worldwide.
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Antwerpen Bremen Dsseldorf
Munhall
Garuva
Dublin
Dudley
Lyon
Barcelona
Doha
Cluj
Moscow
Praszka
Kluczbork
Yangzhou
Timioara
Calcutta
Istanbul
Lima
Vladimir
6,000,000 sqm
manufacturing
areas
Casalmaggiore
Headquarters
MARCEGAGLIA WORLDWIDE PRESENCE
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Casalmaggiore plant
The Marcegaglia manufacturing unit
of Casalmaggiore (Cremona, Italy) spreads
over 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, rectangular
and of special shapes, with thickness ranging
from 1,35 to 16 mm diameters from 17 to 406,
in accordance to current norm requirements
as well as to custom specifcations.
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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 capacity
up to over 700,000 tonnes/year.
New additions include:
a new slitting line allowing it to process
up to 16 mm thickness coils
three new tube production lines
adding new dimensional range capacities
up 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 integrated
photovoltaic roofng employing Marcegaglia
own produced panels, generating 2.1 MWh
peak power, equal to 2,000,000 kWh/year
electrical power.
Other electrical installations increase effciency
with energy recovery systems, such as
a 4-quadrant inverter connected
to overhead cranes.
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Casalmaggiore plant development
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5
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Casalmaggiore plant
Manufacturing areas
Slitting
Tube mills
Heat treatments
Straightening
Tube cutting
Warehouse
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2
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3
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4
2
5
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Main manufacturing standards
EN 10305-3
Round and shaped
precision tubes
EN 10305-5
Square and rectangular
precision tubes
EN 10219
Cold formed welded
structural tubes
(CE homologation)
EN 10210
EN 10217-1
Structural hollow sections,
hot fnished 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 pipelines
for combustible fuids
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 covers
a wide range of structural
and mechanical applications,
guaranteeing specifc suitability
for subsequent processing.
Tubes for steel
structural work
Tubes for piling
Typical applications
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Some applications:
building frames
(offces, residential, industrial buildings,
sports venues, halls)
bridges for pipelines and conveyors
road and pedestrian bridges
stairs, footbridges, railings
machinery frames
poles and frameworks
for traffc 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 specifcations
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 or shaped
manufacturing capacity (t/y) 700,000
wall thickness (mm) from 1.3 up to 16
diameter (mm) from 16.75 up to 406.4
length 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 (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
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 adherence
to 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 fux leakage
(Rotomat) after bevelling
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Production line
TC002 (8)
ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 3
Max. thickness (mm) 16
Min. 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 possibly
use pickled and coated strips)
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Production line
TC002 (8)
NON DESTRUCTIVE TESTS
Induced eddy currents online
Eddy current + magnetic fux leakage
(Rotomat) after bevelling
TECHNICAL FEATURES
Marking of strips prior to forming
Trimming of strip edges before welding
Weld fash trimming/removal
Heat treatment (normalisation) of the welding area
Online laser gauge to control adherence
to tolerances on 100% of the outside diameter
Reel 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)

ROUNDS
SQUARES AND RECTANGULARS
Min. thickness (mm) 4
Max. thickness (mm) 16
Smallest square (mm) 244
Largest square (mm) 406
Min. thickness (mm) 4 (3)
Max. thickness (mm) 16
Min. diameter (mm) 200x200
Max. diameter (mm) 325x325
and all rectangular derived
Welded tubes from hot rolled black strips
(upon mutual agreement we can possibly
use pickled and coated strips)
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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 fash trimming/removal
Heat treatment (normalisation) of the welding area
Online laser gauge to control adherence
to tolerances on 100% of the outside diameter
Reel 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 operators 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 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
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) ITALIA
SITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASING
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALES
VOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
PRODUCTION OF STEEL TUBES AND HOLLOWSTEEL SECTIONS WELDED
LONGITUDINALLY
PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE
30.12.1996
13.07.2012
Per informazioni sulla validit
del certificato, visitare il sito
www.rina.org
For information concerning
validity of the certificate, you
can visit the site
www.rina.org
CISQ la Federazione Italiana di
Organismi di Certificazione dei
sistemi di gestione aziendale
CISQ is the Italian
Federation of management
system Certification Bodies
CERTIFICATE No.
CERTIFICATO N.
SI CERTIFICA CHE IL SISTEMA DI GESTIONE PER LA QUALIT DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
PER I SEGUENTI CAMPI DI ATTIVIT / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES
NELLE SEGUENTI UNIT OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
L'uso e la validit del presente certificato sono soggetti al rispetto del documento RINA: Regolamento per la Certificazione di Sistemi di Gestione per la Qualit
La validit del presente certificato subordinata a sorveglianza periodica annuale / semestrale ed al riesame completo del sistema di gestione con periodicit triennale
The 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 emissione
First Issue
Emissione corrente
Current Issue
RINA Services S.p.A.
Via Corsica 12 - 16128 Genova Italy
CONFORME ALLA NORMA / IS IN COMPLIANCE WITH THE STANDARD
Riferirsi al Manuale della Qualit
per i dettagli delle esclusioni ai
requisiti della norma
Data scadenza
Expiry Date 12.07.2015
SGQ N 002 A SSI N 001 G
SGA N 002 D DAP N 001 H
PRD N 002 B PRS N 066 C
SCR 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 the
Quality Manual for details
regarding the exemptions from the
requirements of the standard
ISO 9001:2008
Membro degli Accordi di Mutuo
Riconoscimento EA, IAF e ILAC
Signatory of EA, IAF and ILAC Mutual
Recognition Agreements
Certication
ISO 9001:2008
The plant is certifed 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) ITALIA
SITI DI SUPPORTO / REMOTE LOCATIONS
COMMERCIALE ED APPROVVIGIONAMENTI / SALES AND PURCHASING
VIA BRESCIANI, 16 46040 GAZOLDO DEGLI IPPOLITI (MN) ITALIA
COMMERCIALE / SALES
VOGELSANGER WEG 38 AMTSGERICHT DUSSELDORF HRB 24326
40470 DUSSELDORF GERMANIA
ISO/TS16949:2009
PRODUCTION OF STEEL TUBES AND HOLLOWSTEEL SECTIONS WELDED
LONGITUDINALLY FOR THE AUTOMOTIVE INDUSTRY
PRODUZIONE DI TUBI E PROFILATI CAVI IN ACCIAIO SALDATI LONGITUDINALMENTE
PER L'INDUSTRIA AUTOMOBILISTICA
14.10.2002
13.07.2012
Per informazioni sulla validit
del certificato, visitare il sito
www.rina.org
For information concerning
validity of the certificate, you
can visit the site
www.rina.org
CISQ la Federazione Italiana di
Organismi di Certificazione dei
sistemi di gestione aziendale.
CISQ membro di IQNET.
CISQ is the Italian Federation of
management system
Certification Bodies. CISQ is a
member 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 CERTIFICATO
EMESSO IN CONFORMIT
ALLE REGOLE IATF
CISQ AUTOMOTIVE -
The 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 emissione
First Issue
Emissione corrente
Current Issue
RINA Services S.p.A.
Via Corsica 12 - 16128 Genova Italy
Riferirsi al Manuale della Qualit 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 validit del presente certificato subordinata a sorveglianza
periodica annuale / semestrale ed al riesame completo del
sistema di gestione con periodicit triennale
Having been assessed in accordance with "ISO/TS 16949:2002 certification scheme rules Third Edition October 2008"
Data di scadenza
Expiry date
Certificato IATF n.
IATF Certificate n. 0143175
THIS CERTIFICATE IS
ISSUED IN CONFORMITY
WITH 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 QUALIT DI
IT IS HEREBY CERTIFIED THAT THE QUALITY MANAGEMENT SYSTEM OF
NELLE SEGUENTI UNIT OPERATIVE / IN THE FOLLOWING OPERATIONAL UNITS
CONFORME ALLA NORMA E AI REQUISITI DELLO SCHEMA
IS IN COMPLIANCE WITH THE STANDARD AND THE SCHEME REQUIREMENTS
PER I SEGUENTI CAMPI DI ATTIVIT / FOR THE FOLLOWING FIELD(S) OF ACTIVITIES
EA:17
Certication
ISO TS 16949:2009
The plant is certifed according to
ISO TS 16949:2009 with RINA
(Registro Italiano Navale)
Requisiti particolari per lapplicazione
della ISO 9001:2008 per la produzione
o serie e delle parti di ricambio
nellindustria automobilistica
(Components for the automobile industry)
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TV - PED
Certications
Marcegaglia is qualifed according to
AD 2000 - Merkblatt W0
(directive 97/23/EC) with TV Rheinland
The qualifcation currently applies to norm
EN 10217-1/2, grades P235TR1, P235TR2
and P235GH
The qualifcation allows Marcegaglia
to supply certifcates conform to W4
according to PED directive
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Homologation CE
Marcegaglia is qualifed 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 certifed with CE marking:
S235JRH, S275J0H, S275J2H, S355J0H, S355J2H
Micro-alloyed grades certifed with CE marking:
S355MH, S420MH, S460MH
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RINA approval
Certicate of Approval
of Manufacturers of Materials
Tubes for naval constructions
EN 10219
EN 10217
S235JR, S355J0, S303J2
P235 TR1 - TR2 - GH
thank you
via Bresciani, 16 46040 Gazoldo Ippoliti, Mantova - Italy
www.marcegaglia.com