Heavy Plate Tech

Heavy Plate Symposium 2008
Agenda
● Mechanical Testing at Ilsenburger Grobblech
● Production of Heavy Plates
● Major Developments at Ilsenburger Grobblech
● Investment Program Ilsenburger Grobblech
Andreas Rost
Firma, Abteilung, Folie 1,

Manager Quality Control, Product Development and
Application Services
Mechanical Testing at Ilsenburger Grobblech

Mechanical Properties
Tensile and Yield Strengths
Calculation of minimum requirements
● Yield: Reh, Rp 0.2, Rt 0.2
● Tensile: Rm
σ existing </= σ allowed

F/A Re/ SF

Mechanical Properties
Toughness
● Empiric Min. Requirements
● Charpy-V Noch, Bead on Plate Test
● Pellini DWT Test
● Fracture Mechanics

Tensile Test

Tensile Testing - Ilsenburg
● Number of Tests 2007:

approx. 71,000
● Standards:
DIN EN 10002
ASTM E8
● Test Equipment: RM 1000

Load 1,000 kN
- Automatic measurement of
prismatic tensile specimen
- portal handling system
- direct data transfer for certification

Tensile Testing - Ilsenburg
● Test Equipment: Z1200
Automatic for Tensile Testing
Load 1,200 kN
- Magazin for 175 specimen
- Portal handling system
- Direct data transfer for
certification

Tensile testing - Ilsenburg
● Test Equipment: UTS-100
Tensile Testing of cylindric
specimen
Load 100 kN
- tensile test up to 1,000°C
- digital temperatur controlling
System

Trough Thickness Test DIN EN 10164
Result:
Elongation in Z - direction
Equipment:
Elongation (s0 – sU) / s0 x 100 [%]
(15 – 400mm and Rp0,2 ≤ 960MPa)

Mechanical Testing – Assessment of Brittle Fracture
Transition temperature
Charpy – V notch Shear area
Lateral Expansion
DWT, Pellini Test Borderline temperature test
Not valid for constructions, due to influence of samples-geometry and

or defect size
Results are empiric values. Not useful for any calculation

Charpy-V-Notch DIN EN 10045
Determination of toughness by providing critical ambient conditions

Equipment:
Impact testing unit
Results:
Joule- value at defended temperature
lateral expansion
shear fracture area

Charpy-V-Notch DIN EN 10045
200
Toughness in Joule
150
good
100
50
27
bad

-80 -60 -40 -20 20 40
Temperature in C°
Impact Testing Ilsenburg

approx. 60,000
● Standards:
DIN EN 10045
ASTM E23
● Test Equipment: PW 75 / 30
Impact Testing System
Energy: 750 Joule
- Automatic system of cooling an testing of impact test specimen

- cooling unit up to -70°C

- automatic specimen transfer
Impact Testing - Ilsenburg
● Test Equipment:
PW 75 / 30, PW 30 / 15
Impact Testing System
Energy: 750 / 450 Joule
- Cooling unit up to -70°C
- N2 cooling up to -196°C
- direct data transfer for
certification

Impact Testing - Ilsenburg
● Test Equipment:
TE – Temperature Unit
- temperature unit
+300 < T ≤ -190°C
- digital temperature
controlling system

Hardness Measurement - Ilsenburg

Brinell approx. 9,000
Vickers approx. 2,000
Rockwell approx. < 50
● Standards:
DIN EN ISO 6506, 6507, 6508
ASTM
● Test Equipment: TESTOR 971

Semi automatic measurement for
Brinell, Rockwell and Vickers

Load 3,000 kg
Hardness Measurement - Ilsenburg
● Test Equipment: EMCO-Test M4C
Automatic for Brinell, Vickers, Rockwell
Load 250 kg
- 5-times revolving system
- High sensitive camera for focussing

and determination

Bead on Plate Test SEP 1390
Determination of materials crack arresting possibilities
Test equipment: Bend test – Tensile tester
Result:
● o.k. / not o. k.
(Crack behavior at a bending radius of 60°)

Experimental Determination of the CTOD
Standards:
• ISO 12135
• ESIS P2
• ASTM E 1820
• BS 7448

•…
Production of Heavy plates

Development of Tensile Strength
Development of structural steels
1350
S1100QL
1200
S960QL
Minimum yield (MPa)
1050
S890QL1
900
S690QL1
750
X100
600
StE460 X80
450 St52 X70/S460ML
St37 X60/S420ML
300
X52/S355ML

150
1925 1950 1975 1990 2005
Design of Material Properties
Chemical Composition Microstructure
● 150 different compositions ● TM

● normalized
● annealed
● quenched

Chemical Composition
Increase of Yield / Tensile Strength
● N-Steels / N+A Steels

Alloying of C, Mn, Re up to 355 MPa
+ Cu, Cr, Ni, Mo, Nb, N, V approx. 500 MPa
Decrease of thougness, weldbility, formability
● TM - Steels
Mirco alloying of Nb, V, Ti Re up to 550 MPa
● Q&T Steels
Alloying of C, Mn, Re up to 1100 MPa

Cu, Cr, Ni, Mo, Nb, N
Rolling Methods
as rolled normalized rolled TMCP
Mikrolegierung
Mn Ar3
Ar1
Haspeln beschleunigte
Abkühlung
Time

Rolling Methods
Normalized rolled Thermo mechanic controlled processed
S355J2G3 S355M
C 0.18 % Re 429MPa C 0.08 % Re 420MPa
Si 0.35 % Rm 568MPa Si 0.35 % Rm568MPa

Mn 1.50 % Mn1.50 %
40 mm 40mm
TMCP Steels
Toughness Re/CEV
500
200 400
100 300
-100 - 50 0 ]a
[n
M
p
ize
rckg
tS
0,34 0,38 0,42 0,46 0,50

Z
ä
h
g
ik
e
tn
[J
]
TM Steels N Steels
Heat treatment: Normalizing
● Heating up to 900°C followed by cooling in still air
Necessary: plate thickness > 80 mm

low Charpy test temp < -50°C
RT 900 °C slow cooling:

Ferrit Austenit Ferrit

Quenching
Chemical composition: CEV 1. Slow cooling

Austenitisation temperature Austenit Ferrit
Cooling intensity
Ac3
Ac1
2. Fast cooling
Austenit Martensit

Abrasion Resistant Steels
IMPROVEMENT OF LIFETIME
HARDNESS CARBIDES
BRINAR® 400, 450 BRINAR® 400 Cr
BRINAR® 500

High Strength Steels Q&T
Chemical composition:
C = 0,18 Si = 0,40 Mn = 1,60

High Strength Steels Q&T
Water-quenching equipment:
- state-of-the-art facility, one of the most modern
facilities worldwide
- patented water distribution
Results after quenching:

- steady steel properties and low inner tension
- high flatness
- excellent working properties
Steel grades:
- high-tensile steels
MAXIL® 500 Q, QL, QL 1 to MAXIL® 1.100 Q
- wear-resistant steels
BRINAR® 400, BRINAR® 500
Plate dimensions:
Thickness: 5 - 80 mm

Width: up to 3.500 mm
Length: max. 13,5 m
Major Developments at Ilsenburger Grobblech

Andreas Rost
Manager Quality Control, Product Development and Application Services

Agenda
Conditions for a constant development

- Steel plant Salzgitter
- Heavy plate mill Ilsenburg
Quality performance
Product development
- Low temperature steels
- High ambient temperature steels
- Sour gas resistant steels
- Steels supposed for extended PWHT
- Stainless steels

Major Developments
Conditions:
- Extensive standards and regulations
- Additional limitations by specifications

Largely unchangeable chemical contents, production processes,
properties ….

Major Developments
Improved properties
Meeting challenging specifications
Process optimisation
Cost reduction

Quality improvement

Major Developments Steel Plant
Optimized use of raw materials
Efficient pig iron desulphurisation,

efficient primary and secondary metallurgy
Improved slag retaining when tapping
Modification of segregation properties during continuous cast

Major Developments Steel Plant
Slag retain improvement (1999)

Special alloy converter (2004)
Modernisation process system converter (2007)
Modernisation process system secondary metallurgy (2008)
Building of the fifth secondary metallurgy stand (2008)
SGA 4 (2010)

New Caster No. 4
Improvement of piece weight
</= 2500 mm 20,5 t
> 2500 mm 15,1 t
Actual 2010

20,5 t up to 3500 mm
New Caster No. 4
Improvement of thickness
180
150
120
90
ASTM / ASME EN- Standard

New Caster No. 4
Improvement of Dimensions
Thickness in mm maximal lenght vs. width

Width in mm 1,50 1,75 2,00 2,25 2,50 2,75 3,00 3,25 3,50
60 24,0 24,0 21,8 19,3 17,4 15,8 14,5 13,4 12,4
70 24,0 21,3 18,7 16,6 14,9 13,6 12,4 11,5 10,7
80 21,8 18,7 16,3 14,5 13,1 11,9 10,9 10,0 9,3
90 19,3 16,6 14,5 12,9 11,6 10,6 9,7 8,9 8,3
100 17,4 14,9 13,1 11,6 10,4 9,5 8,7 8,0 7,5
110 15,8 13,6 11,9 10,6 9,5 8,6 7,9 7,3 6,8
120 14,5 12,4 10,9 9,7 8,7 7,9 7,3 6,7 6,2
130 13,4 11,5 10,0 8,9 8,0 7,3 6,7 6,2 5,7
140 12,4 10,7 9,3 8,3 7,5 6,8 6,2 5,7 5,3
150 11,6 9,9 8,7 7,7 7,0 6,3 5,8 5,4 5,0
160 10,9 9,3 8,2 7,3 6,5 5,9 5,4 5,0 4,7
170 10,2 8,8 7,7 6,8 6,1 5,6 5,1 4,7 4,4

Major Developments Roller Stand
Roller stand enlargement

Improved logistics, heavier plates
Stationary water quenching equipment, car bottom furnace
Modernisation mill stand and hot leveller
Modernisation pusher type furnaces
Dispatch and shape cutting hall
ACC unit, cold leveller

Product Development
Possibility's for product design:
Chemical composition Alloying concept

Microstructure Rolling methods, Heat treatment


Extended Product Range
Blech-
dicke Röhrengüten
TM/IK-gew alzt
in mm < XX80
70 X80 X100
2007
=60
2007
=50
=40
2007
=30
=25
=12
2006 2007 2007 2008
Product range with new accelerated cooling (ACC)

Sortimentserweiterung neue ACC-Anlage

Product range with old intensive cooling
Sortiment Pilotanlage
Technology Comparison API X70

Cold Leveler 3

Product Related Development
Nickel-alloy
Nickel-alloysteels
steelsfor
for
liquid ethylene tanks
liquid ethylene tanks
Case
Casehardened
hardened
nickel-alloy
nickel-alloysteels
steels
Sour
Sourgas
gasresistant
resistant
vessel plates
vessel plates
Case
Casehardened
hardenedheat
heat
resistant steels
resistant steels
Steels
Steelswith
with modified
modified
elastic limits
elastic limits

Steel for Cold Tank Constructions
Flat floor tank for Tanker for

Liquid Natural Gas (LNG) Liquid Natural Gas (LNG)
Steel for Cold Tank Constructions
Standard Steel Type S Re Rm A T Charpy V Lateral Heat

Grade [mm] [MPa] [MPa] [%] [°C] [J] Exp. Treat-
Trans / [mm] ment
Long
EN 12Ni1 ≤ 30 ≥ 355 490 to ≥ 22 -100 ≥ 27 / ≥ 40 N
10028-4 4 >30≤ ≥ 345 640 N+T
[3,5%] 50 ≥ 335 Q+T
>50≤
80
EN X12Ni ≤ 30 ≥ 390 530 to ≥ 20 -120 ≥ 27 / ≥ 40 N
10028-4 5 >30≤ ≥ 380 710 N+T
[5%] 50 Q+T
EN X8Ni9 QT ≤ 30 ≥ 490 640 to ≥ 18 -196 ≥ 40 / ≥ 50 Q+T

10028-4 [9%] 640 >30≤ ≥ 480 840 ≥ 20 ≥ 0,381 N+N+T
A/SA Type 50 ≥ 515 690 to Q+T
ASTM 353 I 825
Type ≥ 585 690 to
ASME A/SA I 825
553

Spec. 9% Ni Acc. Acc. Acc. -196 27J…100J 0,381…
Requirem Stand. Stand. Stand. 80% 0,51
Reduction of Alloyed Elements

Technology Optimisation 9 % Ni
Improved surface quality

Shorter throughput times
Increased capacity
Larger dimensions
Reduction of flaws
Increased tensile strength for special applications

Product Development –
High Ambient Temperature Steels
Chrome-Molybdenum steel
13 CrMo 44
10 CrMo 910
A387 Gr 11 /12 /22

Background
Conventional production method for A387 Gr. 12/11 steels:

Normalizing at 910 °C (1670°F)
Tempering at 650°C -700°C (1200-1292°F)
Problem: Requirements (due to design reasons or of HAZ max hardness)

for higher tempering temperature can not be guaranteed.
Diffusions processes lead to microstructures which change
the material properties.
Solution: Accelerated cooling and tempering

SA 516 Gr 60-70 PWHT
Restriction max 6 h at 610°C
Requirements PWHT up to 16h holding times or and 640°C
Improvement Chemical Compositions

SA516Gr. 70 Influence PWHT
PWHT 6,6 h 610 °C 38 mm A516.70
570
550
530
510
490
470
450
Rt0,5 S
S: PWHT 6,6 h
430
Rm S
at 610°C
Mpa
410
Rt0,5 U
390
370
Rm U U: without PWHT
350
330
310
290
270
250
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Number of Tests
Distribution Charpy V -45°C transverse
Without PWHT PWHT

A516.70 -45°C U A516.70 -45°C S 6,6 h 610°C
35 40
35
30
30
25
25
20
approx. 40Joule
Häufigkeit
Häufigkeit
20
15
15
10
10
5
5
0 0
1
0
42
59
77
94
53
68
83
99
er
er
11
12
14
16
18
19
21
23
11
12
14
15
17
19
20
22
öß
öß
gr
gr
d
d
un
un
Klasse Klasse

Influence Holding Time up to 16 h – Tensile Test
Rp0,2 640°C
Rp0,2
Tensile Test after PWHT 640 °C and 620 °C Rm 640 °C Tensile Test after PWHT 610°C
Rm
Rp0,2 min
Rp0,2 min
650 Rm min 650
Rm min
Rm max
Rm max
Rp0,2 620 °C
600 Rm 620 °C 600
550 550
500 500
Rp0,2 / Rm (MPa)
Rp0,2 / Rm (MPa)
450 450
400 400
350 350
300 300
250 250

200 200
0 5 10 15 20 0 5 10 15 20
t (h) t (h)
Influence Holding Time up to 16 h – Charpy V Notch
Charpy V transv. 910 °C + 640 °C Charpy V transv. 910 °C + 620 °C and

-50 °C
Charpy V long. 910 °C + 610 °C
-40 °C
250 250 -50 °C Anlasstemp. 620 °C
-20 °C -40 °C Anlasstemp. 620 °C
-20 °C Anlasstemp. 620 °C
225 225 -29 °C Anlasstemp. 610 °C
200 200
175 175
150 150
KV (J)
KV (J)
125 125
100 100
75 75
50 50
25 25

0 0
0 5 10 15 20 0 5 10 15 20
t (h) t (h)

Mechanics of Damaging
Influenced by:
Chemical composition
Strength level
Microstructure
Hydrogen sulphide pressure

Acidity pH –value
Temperature
Stress level (residual and actual)
Exposure time

Mechanics of Damaging
H2S S
S
Corrosive Gas
H2S S H2S Reduction of hydrosulphide
H H2S → S + 2H
H H H
Dislocation H Collection of hydrogen atoms in structural
Flaw
Steel H Non-metallic flaws
enclosure Grain boundary
H H
H2
Compounding of molecular hydrogen
(= recombination) at enclosures and flaws
Pressure caused by larger volume

H2
start and growth of cracks

Sulphide Stress Cracking (SSC)


Product Development - Sour Gas Resistant Steel
Steel plant:
- Adjustment of defined components and ratios in the heat (e.g. S, P, H, C)
- Vacuum degassing
- CaSi – treatment
- Avoiding brittle structures, (carbide strings, enclosures)
- Avoiding central segregation (C, Mn, P, casting conditions)
Rolling:
- Homogenous, fine-grain structure (low tolerances of the rolling
parameters)
- High durability
- Low hardening when subject to cold

US-Testing and CAR-Measurement

Metallographic Assessment per NACE TM 02-84
Evaluation of Test Specimens:
b
25mm 50mm 75mm
a
b

ILG – KGE K. Tigges
Product Development – Sour Gas Resistant Steel

www.ilsenburger-grobblech.de

Salzgitter AG
and
Salzgitter Steel

Group Structure and Key Data FY 2007
Salzgitter AG Group
External Sales cons.: € 10.2 billion Employees: 23,107
Internal Sales: € 3.6 billion
Steel Tubes Trading Services Technology
• Total Sales: • Total Sales: • Total Sales: • Total Sales: • Total Sales:
€ 4.0 billion € 2.6 billion € 5.0 billion € 1.2 billion € 0.6 billion
(H2 2007)
• Employees: • Employees: • Employees: • Employees: • Employees:

6,829 5,978 1,867 4,043 4,252

All data about employees as of 31.12.2007
Salzgitter AG - Group Structure
Salzgitter AG (Holding)
Salzgitter Mannesmann GmbH – Intermediate holding company
Steel Röhren
Tubes Trading Services Technology
Salzgitter Stahl GmbH Mannesmannröhren-
Werke GmbH
Salzgitter Mannesmann Klöckner-Werke AG

Salzgitter Flachstahl Europipe (50%) DEUMU
Handel Group (86%)
Salzgitter Mannesmann Salzgitter Service

Ilsenburger Grobblech Universal KHS-Gruppe
Grobblech und Technik
Salzgitter Mannesmann Verkehrsbetriebe Klöckner DESMA

Peiner Träger Hövelmann&Lueg Elastomertechnik
Grossrohr Peine-Salzgitter
HSP Hoesch Salzgitter Mannesmann telcat Klöckner DESMA

Spundwand und Profil Line Pipe Schuhmaschinen
SIT
Salzgitter Mannesmann GESIS Klöckner Hänsel
Salzgitter Bauelemente Processing
Precision
Hansaport (51%)
Salzgitter Mannesmann SIG Beverages
Salzgitter Europlatinen
Stainless Tubes

Salzgitter Mannesmann
Forschung
Hüttenwerke Krupp
Mannesmann (30%) Salzgitter Automotive
Engineering
simplified structure
Steel Division - Overview
Steel Division
Crude steel production 2007: 5.7 m tons
Rolled steel production 2007: 5.5 m tons
Strip steel Heavy plate Sections Processing
2007 2007 2007 2007

Shipment: 3,037 Tt Shipment: 805 Tt Shipment: 1,595 Tt Shipment: 108 Tt
Turnover: 1,953 m € Turnover: 800 m € Turnover: 1,097 m € Turnover: 117 m €

As of: December 31, 2007
Main Slab Supplier: Salzgitter Flachstahl GmbH
Coking Plant:
2 batteries: total of 108 coke ovens, each with 46.0 m3
3 Blast Furnaces:
Hearth diameter: 11.2 m, 11.2 m and 8.2 m
Steel Works:
Primary Metallurgy: 3 * 210 t LD Converter
Secondary Metallurgy: vacuum degassing, ladle
furnace and alloying
3 Continuous Casters:
1 Strand
210 - 250 mm thick, 1,100 – 2,000 mm wide
1 Strand
210 - 250 mm thick, 1,900 – 2,600 mm wide
1 Strand

(vertical / bending; soft reduction)
250 mm thick, 850 – 2,100 mm wide
Processing Lines Steel Group
Salzgitter Hot-Dip Galvanising

Cold Strip Mill
Hot Strip Mill
Electro-Galvanising
Hot Strip Cutting Plant
Surface Coating
Large Diameter Pipes
Profile Sheets
Peine
Ilsenburg
Heavy Section Mill
Heavy Plate Mill Universal Medium Section Mill

Key Facts
Ilsenburger Grobblech GmbH

“Top producer of Quarto plates with a

broad product range for the upper
segment of the market”

Heavy Plates Made in Ilsenburg
Facts:
Capacity: app. 800.000 t/year

Work force: 810
Location: Ilsenburg & Salzgitter

Abstract Ilsenburg
Headquarters Ilsenburg:
• Heavy Plate Mill with adjustment line and dispatch area
• Supply with slabs mainly from Salzgitter, computer controlled production
scheduling, Quality Management
• Main supplier of heavy plates in the Salzgitter group
• Investments of more than 115 Mill. Euros during the last 15 years
Benefits: improving the plant, plate quality and logistics
Further Processing at Salzgitter
• Water quenching equipment, for the production of BRINAR® (abrasion-resistant

steels) and MAXIL® (high-strength steels)
• Wide range of possibilities for individual plate-steel processing (shot blast and
coating facilities, edge preparation, plate bending)

• Investments of more than 15 Mill. Euros during the last 15 years
History
1595 Foundation of the Ilsenburger Copper hammer

1843 Start of operation of a Copper Mill
1946 First heavy plates
1954 Start of operation of a new two-high mill stand and a double pusher type
furnace; the production of copper is continued on the basis of recycling
1979- Extensive modernisation of the production line:
1982 modern 4-high mill stand, 2 pusher type furnaces, 1 pit furnace,
modernisation of the shear line and dispatch area, automation,
New capacity: 650.000 t
1992 Takeover by Preussag Stahl AG as a subsidiary
1995 Only heavy plate mill of the Preussag Stahl AG
1998 Separation of the Preussag Stahl AG: Foundation of the Salzgitter AG –
Steel and Technology
2001 Foundation of the ILSENBURGER GROBBLECH GmbH
2002 Modernisation of the 4-high mill stand and the hot leveller, revamping of
the pusher type furnaces
2005 New dispatch bay and burning facilities
2006 Installation of a new accelerated cooling system (ACC)

2007 Commissioning of a cold leveller
Steel Grades
Fine
Finegrain
grainstructural
structural
steel
steel
HIC-resistant
HIC-resistant
General
Generalstructural
structural steel
steel
steel
steel
Shipbuilding
Shipbuilding
Corrosion-,
Corrosion-,acid-
acid- steel
and heat steel
and heat
resistant
resistantsteel
steel
Nickel
Nickelalloyed
alloyed TMCP-/SZ-
TMCP-/SZ-
low temperature
low temperature steel
steel
steel
steel
Stainless
Stainless Pressure
Pressure
Abrasion
Abrasionresistant
resistant

steel
steel vessel
vesselsteel
steel
and
and
high
high strengthsteel
strength steel
Key Facts
Ilsenburger Grobblech GmbH
• Broad diversified heavy

2003plate program
2004 2005 2003 2004 2005 2006
Production (T tons) 729 754 772 xxx
- more than 350 steel grades Shipments (T tons) 735 753 767 xxx
Turnover (m€) 327 402 610 xxx
- about 8,000 orders per year Employees (31/12/2005) 756 742 742 xxx
Production (T tons) 729 754 772

• Brands by ILG - BRINAR 400, 450 and 500
®
- MAXIL® 500 up to 1100

- RESTIL® 60, 65 and 70
Shipments (T tons) 735 753 767
•
Production (T 2003 2004 2005 2006 2007

tons)
Shipments (T 729 754 772 796 834
Turnover (m€) 327 402
tons) 735 753 767610 775 805

Turnover (m €) 327 402 610 649 800
Employees
(31/12/2005) 756 742 742
As of: March 31, 2008
Current Production Program
Thickness: 5 – 125 mm
(5 – 80 mm for ASTM)
Width: max. 3.500 mm
Length: 4.000 – 24.000 mm
Max. plate weight : 15,1 t > 2.500 mm
20,5 t < 2.500 mm
Delivery conditions: as rolled, N, N&T, Q, Q&T & TMCP

Normalizing: 290.000 t per year* up to 3.500 mm
Tempering: 60.000 t per year* up to 3.500 mm
Quenching: more than 70.000 t per year*

* Including second finishing line in
Salzgitter
Prefabrication & Added Value
1. Profiling line Ilsenburg (mainly wind mill industry)

• 70,000 t per year
• Max. plate weight 20,5 t
2. Water quenching Ilsenburg/Salzgitter:
• High strength grades: MAXIL® 500 up to 960
• Abrasion resistant grades: BRINAR® 400
• Thickness: 5 – 125 mm
• Width: 2,000 – 3,500 mm
3. Prefabrication line Salzgitter:
• Shot-blasting and coating (min. 15 µm – max. 25 µm; up to 3,200 mm width)
• Edge preparation (V, X, Y, double-Y seams; up to 3.000 mm)
• 4 roll bending (min. diameter 1,200 mm, up to 35 mm and 3,000 mm)

Water Quenching Line – Salzgitter
Water-quenching equipment
- state-of-the-art facility, one of the most modern
facilities worldwide
- patented water distribution
Results after quenching

- steady steel properties and low inner tension
- high flatness
- excellent working properties
Brands
- BRINAR® 400, 450 and 500
- MAXIL® 500 up to 1100
Plate dimensions
Thickness: 5 - 80 mm
Width: up to 3,500 mm
Length: max. 13,5 m

Special Grades
Offshore Grades
e.g. 355 EM/ EMZ, API-2 H, S 355 M1/ 2/ 3 /4. S 420 G1/2, S 460 G1/2 …
Thickness: 5 – 65 mm (depending on Certification Company LRS, …)

5 – 80 mm for API-2 H
Boiler Plates
e.g. P 265/ 295GH, 16 Mo 3, 13 CrMo 4-5, SA 516 Gr. 60/ 65/ 70 (HIC), SA 387 Gr. 11 cl.2
(5 - 80 mm for ASTM)
Pipe Steels
e.g. A, B, X 52 – X 70, Sour gas X 65/70, L 360MB – L485MB

(5 - 80 mm for X 60 – X 70, L 415 – L 450; L 485 max. 60
mm)
Products
Heat and low temperature resistant steels, pressure vessels steels

• temperature range: -196°C up to + 500 °C
heat resistant steels: steels for low temperatures:

i.e. 16Mo3, 13CrMo4.5, 10CrMo9.10, i.e. P355/460NL2, 13MnNi63, 10Ni14
A/SA 387Gr 11/12/22 CL1/Cl2 (ASTM A 203 Gr. D), 12Ni14, X8Ni9 (ASTM
A 553 NNA or A 559 Q+T), STZ36A/SA
553/335/203 A516/537

Products
High-strength steels MAXIL®
• weight reduction combined with high lifting capacity

• reduction of expenses for the welding process
• high resistance against brittle fracture
MAXIL® 500, MAXIL® 620, MAXIL® 690, MAXIL® 890, MAXIL® 960, MAXIL® 1100

(corresponding to the steel grades S 500 - S 1100)
Products
Abrasion-Resistant Steels - BRINAR®
• increasing of the service life combined with good workability

• steady properties, low inner tension
• high dimensional accuracy, high flatness
Water-quenched
abrasion-resistant steels
BRINAR® 400
BRINAR® 450
BRINAR® 500
Chromium-alloyed
abrasion-resistant steels
BRINAR® 325 Cr
BRINAR® 400 Cr

Heavy Plates in Practice
Regenerative Energy Sources
• up till now delivered more than 660T t

plates (2008)
• steel grades S 235 - S 355 NL/ML
• thickness range 8 - 120 mm
• construction of more than 5,500 wind
mill towers, total capacity > 8,250 MW
• At wind force of 15 m/sec.
supply of 8 mill households

Quality Assurance & Approvals
1. Certified Integrated Management System according to ISO 9000:2000 /

ISO 14001:2004 / OHSAS 18001:2007 by Lloyds Register
2. Authorisation to perform testing and inspection without the attendance of

the Surveyor (ABS, BV, DNV, GL and LR)
3. Numerous product approvals (TÜV, Decreto Ministeriale)
4. Accreditation of the mechanical engineering laboratory

Integrated Management Certificate

Development,
Sales Policy
and
Customer Relationship

Sales Policy
- long term orientated

- reliable
- capacity and productivity related sales
- monitoring of >20 partial capacities
- continuous improvement of product mix
- risk limitation (10% Q+T, 10% wind industry, 10% pipe, 10% shipyard, …)
- management of payment terms
- analysis of margins per market, customer, sales person, …
- binding price and quantity management
- continuous, but careful improvement of customer structure

Regional Split of Sales
Strong German export

29 % 58 % tradition:
EU 27 - Indirect trade ex stocks
Germany - Machinery
Export - Heavy and special trucks

- Pipe
- Mining equipment
13 % - Vessels
- Yellow Goods
Germany biggest single market, but

indirect export and influence of global market

Total Sales app. 771.115 t
(2007)
Tonnage ASTM/ASME Development India
T
21.000 20.190
14.000
11.320
7.190
6.680
6.180
7.000
4.520 4.790
4.370
3.780
3.120 3.050

0
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008
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Heavy Plate Tech

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Heavy Plate Symposium 2008

● Mechanical Testing at Ilsenburger Grobblech

● Production of Heavy Plates

● Major Developments at Ilsenburger Grobblech

● Investment Program Ilsenburger Grobblech

Firma, Abteilung, Folie 1,

Mechanical Testing at Ilsenburger Grobblech

Firma, Abteilung, Folie 2,

Tensile and Yield Strengths

Calculation of minimum requirements

● Yield: Reh, Rp 0.2, Rt 0.2

σ existing </= σ allowed

Firma, Abteilung, Folie 3,

Firma, Abteilung, Folie 4,

Firma, Abteilung, Folie 5,

● Number of Tests 2007:

● Test Equipment: RM 1000

Firma, Abteilung, Folie 6,

● Test Equipment: Z1200

Automatic for Tensile Testing

- Magazin for 175 specimen

- Portal handling system

- Direct data transfer for

Firma, Abteilung, Folie 7,

● Test Equipment: UTS-100

Tensile Testing of cylindric

- tensile test up to 1,000°C

- digital temperatur controlling

Firma, Abteilung, Folie 8,

Elongation (s0 – sU) / s0 x 100 [%]

(15 – 400mm and Rp0,2 ≤ 960MPa)

Firma, Abteilung, Folie 9,

Mechanical Testing – Assessment of Brittle Fracture

DWT, Pellini Test Borderline temperature test

Not valid for constructions, due to influence of samples-geometry and

Firma, Abteilung, Folie 10,

Determination of toughness by providing critical ambient conditions

Firma, Abteilung, Folie 11,

Firma, Abteilung, Folie 12,

● Number of Tests 2007:

- Automatic system of cooling an testing of impact test specimen

Firma, Abteilung, Folie 13,

Impact Testing System

Energy: 750 / 450 Joule

- Cooling unit up to -70°C

- direct data transfer for

Firma, Abteilung, Folie 14,

Firma, Abteilung, Folie 15,

● Number of Tests 2007:

● Test Equipment: TESTOR 971

Firma, Abteilung, Folie 16,

● Test Equipment: EMCO-Test M4C

Automatic for Brinell, Vickers, Rockwell

- 5-times revolving system

- High sensitive camera for focussing

- direct data transfer for certification

Firma, Abteilung, Folie 17,

Determination of materials crack arresting possibilities

Test equipment: Bend test – Tensile tester

Firma, Abteilung, Folie 18,

Firma, Abteilung, Folie 19,

Production of Heavy plates

Firma, Abteilung, Folie 20,