INDEX

Topic Page no.

1. Acknowledgement 2

2. Profile 3

3. Excellent surface finish 5

4. Excellent mechanical properties 5

5. Vision 6

6. Policies 7

7. Products 8

8. Process route of CRCA material 11

9. Shops 21

10. Project 24

11. Steel grades 32

12. Dimensions and executions 45

13. Tolerances 45

14. Work in slip sheet 49

1
 Acknowledgement
Here, I found this golden chance to acknowledge all those people who had blessed,
encouraged and supported me technically and morally through all the phases of my
training. I thank almighty God for giving me this opportunity to express gratitude
to all those who helped me in my training.

First of all, I pay my immense gratitude to principal Dr. M. L. Ohri,

Er. Sukh Chain SinghDilo HOD, Mechanical engg. Dept. for their valuable
guidance.

It is my proud to express my heartiest gratitude to my venerable guide to his

valuable guidance, proper advice and constant encouragement and Mr. Abhay
kumar (Bhushan steel limited ) without whose expert guidance and support, this
training period would have been compelling.

I also express my deep thanks to the faculty and staff of M.E.-Dept,

College of Engineering & Management, for their help, inspiration and moral
support, which helped me a lot in the successful completion of my training.

I extend my fort right thanks to my family and friends for their moral support and
encouragement throughout my training report.
Kr. Radha Raman
M.E. (5th SEM.)

7061113072

2
 Profile
Amongst the various reasons behind BSL's unprecedented growth and rapid
integration on the steel value chain, perhaps, the most important would be
its unwavering focus on acquiring the latest technology and know-how. The
 
most important reason behind this focus has been BSL's commitment to
provide its customers with the best quality products. The result, to say the
least, has been awe-inspring growth.
   
The Khopoli plant, commissioned in 2004 has been playing a remarkable
role not only in the growth of exports, but in the production of a much wider
variety of value added steel like Colour Coated Sheets, High Tensile Steel
 
Strappings, Hardened and Tempered Strips and Precision Tubes. In addition
to these, the Khopoli plant has recently launched the Galume value added
steel (Aluminium & Zinc Coated Sheet) for the first time in the country.
   

   
Operating with the most advanced technology, expressed through a large
fleet of latest equipment, machinery and systems, the Khopoli plant has
given a tremendous boost of 425000 MT per annum to BSL's total
 
production capacity Including 240000 MT of galvanised steel, which are
further forward integrated into Colour Coated Sheet, Galume and other
value added products.
   
Giving a tremendous volume-thrust to the production capacity of BSL is its
plant at Sahibabad, with a production of 475,000 MT per annum comprising  
products such as Automotive Grade C R Sheet and Galvanised Sheets.
   
As a strategic move to optimise the usage of resources and services, as well  
as to streamline the functioning of all systems and process within the
3
organisation, BSL has recently implemented SAP (the global leader in
Enterprise Resource Planning Systems). After all, with sales touching Rs.
3070 crores and installed capacity in the one million tonnes per annum
range, BSL is now India's 3rd largest Secondary Steel Producer after SAIL
and TISCO. BSL has the distinction of being the only producer In India of
the widest width CR Sheet, besides being a preferred supplier of automotive
grade steel sheets for inner and outer panels to all leading 4-wheeler and 2-
wheeler manufacturers in the country.
   
The most brilliant milestone in BSL's journey of excellence is the setting up
of a state-of-the-art Hot Rolling Steel & Power Plant in Orissa. This
 
Integrated Steel and Power Plant will, no doubt, put BSL firmly on the fast
track of progress.
   
Bhushan Steel Limited, is an ISO 9002,QS 9000 certified and a company of
 
Rs. 2868 crores ($650 million approx.).
   
As one of the prime movers of the Technological Revolution in the Indian
Cold Rolled Steel Industry, BSL has emerged as the country’s largest and
the only CR steel plant with an independent line for manufacturing Cold  
Rolled coils and sheets up to a width of 1700 mm, as well as Galvanised
Steel Coils & Sheets up to width of 1350mm.
   
The Company currently has capacity to produce ALMOST ONE MILLION
 
MT/Annum of Cold Rolled Steel at Sahibabad and Khopoli Works .
   
The Company is a “single-point source” for a wide variety of products such
as CRCA , Galvanized and Colour coated sheets, High tensile steel ttrapping,  
Hardened and tempered steel strips (HTSS) and Precision tubes.
   
   
EXCELLENT SURFACE FINISH  
   
Mill Clean System With A Synthetic Coolant To Avoid Any Coolant Mark On
 
The Strip
   
Electrolytic Cleaning Line To Remove Iron Fines From Strip , Which Helps In
Improving The Life Of Salt – Spray Test After Painting And Avoids Carbon  
Soot Completely . It Also Increases The Tool Life In Press Shop
   
Latest And Sophisticated Edt Machine To Provide Controlled Texture For
Better Paint Adhesion And To Achieve Surface Roughness To Close  
Tolerances
4
   
On- Line Tension – Levelling Equipment For Better Flatness And Controlled
 
Elongation
   
Computerized Inventory Control Management And Independent Skin- Pass
Mill To Avoid Any Unwanted Storage In Between Annealing And Skinpass  
Process.
   
Kathabar Storage System ” To Avoid Atmospheric/Rustiness Oxidation
 
Through De-Humidified Air..
   
Electro - Static Rust Preventive Oil Spray System For Controlled Oil Coating
On Crca Surface . Oil Coating Can Be Maintained In Between 0.50 Gms/M²  
To 2.00 Gms/M² Per Side.
   
EXCELLENT MECHANICAL PROPERTIES  
   
Practically , No Variation In Mechanical Properties Due To 100 % Hydrogen
 
Annealing Furnace
   
The Raw Material Selection Is Done By Computerized Program For Different
 
Applications
   
Close Tolerances On Thickness, Width And Length  
   
- X- Ray Thickness Gauge To Measure Thickness To A Fraction Of A Micron.  
- Radiometrie Thickness Checking Across The Width  
- Automatic Computerized Thickness Control..  
- Shim Less Tooling On Slitting Lines With Computerized Setting Ensures
 
Correct Width In Close    Tolerances .
- Precision Cut- To – Length Lines To 0.75 Mm.Ensure Length Tolerances
 
Better Than
- Automatic Electromagnetic Stacker On Shearing Lines To Produce Scratch
 
Free
 

Vision
5
  

 
Giving Definition To A Far-sighted Vision  

The vision of evolving into a totally integrate steel

producer, committed to achieving the highest
   
standards of quality through cutting-edge technology,
is being realised at Bhushan Steel Ltd.
    
  If you can anchor your organist sation with a single-  
mindedness of purpose, for providing-the best
service, technology and quality to customers and
stakeholders, then you can deliver higher value for
money wrthin schedule and budget, and continue to
thrive even in the face of rapid change and other
challenges besotting the Indian economy This is,
precisely, what BSL has been doing since its
   
inception: Acquiring the latest technology sourced
from the global leaders and maintaining global quality
standards; continually upgrading the steel plants and
efficiently implementing projects within schedule and
budget always meeting financial obligations on time
and yes, these are the hallmarks of BSL's Saga of
Excellence.
    
BSL's vision of total integration is a lot closer to realisation today.
Through seamless backward integration, BSL is consolidating its position
 
on the entire steel value chain - from iron ore to
specialised, value-added steel, the company is surging ahead.

Policies
6
 BHUSHAN STEEL  LTD, SAHIBABAD  
     
Integrated Quality, Environment, Occupational Health & Safety Management
   
System Policy
     
Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel
sheets of world class quality in a safe, healthy and clean environment by
  involving employees with continual improvements in system  
implementation, technological advancement, operational integration,
prevention of pollution & hazards maintaining
     
     
  Legal compliance and satisfying needs & expectations of Customers.  
     
 For Environmental Management System we have ISO 14001:2001
Certification
 For Quality System we have ISO/TS 16949:2002 Certification
 
 For Safety Management System we have OHSAS 18001:1999
Certification

Products
7
Finished Product List of Sahibabad Plant  
  1. Cold Rolled Coil  
  2. Cold Rolled Sheet  
  3. Galvanised Plane Coil  
  4. Galvanised Plane Sheet  
  6. Galvanised Corrugated Sheet

Cold rolled coil

BSL ( Formerly BSSL)is spearheading a technological revolution in
India’s Cold Rolled Steel industry and, in the spirit of a true leader, is
ceaselessly striving to raise the bar, achieve new milestones and set
new benchmarks in terms of quality of products and degrees of
customer satisfaction.

The most brilliant milestone in BSL’s journey of excellence is the

setting up of a state-of-the-art Steel & Power plant in Orissa. On
completion, the plant will be one of the largest integrated HR steel
and Power complexes of the nation.

BSL’s Galvanised Sheets, Color Coated Sheets, Coils, Corrugated

Sheets and Galume (Zinc and Aluminium coated) Sheets/Coils are
being accepted and appreciated across the world...

   
  S.n  
Parameters Technical details/specifications
o
1. Thickness(nun) 0.10t04.00
2. Width(mm) 10to 1700(Max)
3. Coil Weight(MT) Up to 30 MT (7 to 18 kg/mm width)
4. Surface Finish Super Bright, Bright, Dull&Matte. (RaValuewith
controlled Rmax on request).
5. Grades Specifications - As per JIS/BIS/ ASTM/EN
8
 Standards
Low Carbon CRCA Grades
Super EDD/EDD/DD/D (SPCX, SPCEN, SPCD,
SPCC) non-aging, IF-High
Strength steel(IF-HSS), High Strength Low Alloy
Steel (HSLA), viz., ST -42,
ST-45, ST-52, SAPH-400/41O, Steel for Porcelein
Enammeling, Corrosion
Resistant Steel, viz., Tin Mill Black Plate (TMBP)
Medium &High Carbon CRCA Grades
C- 30, C-40,MC -ll,EN - 8, for spring steel
application, C-55, MC-12,
EN- 9 C-62,C-60, C-80,HC-14,EN-42J
6. Strip widths mm ELECTRICAL Grades Elec -I, Elec-n, Elec-nI,
Semi Processed Elect. Steel
7. Chemical OTHER CRCA Grades
composition Case Hardening Steel- 15Cr3, SAE 1010, SAE 1012
(Coating) Through Hardening Grades- SAE 1040,SAE 1045,
1055, 1065, 1080, 1541
H.R PICKLED/ SKIN PASSED & OILED
8. Up to 3.00 mm           3.00 mm - 4.00 mm
Thickness
Above 4.00 mm
9. Max. Width for 1500 mm                   1250 mm
Cut Size 600 mm  
10. 50 mm - 1700 mm      50 mm - 1700 mm
Width for Coil
50 mm - 1700 mm

Cold rolled sheet

S.n  
Parameters Technical details/specifications
o
1. Thickness(nun) 0.10t04.00
2. Width(mm) 10to 1700(Max)

9
 3. Cut- to -Length Up to4500mm with tolerance of +2/-0
(mm) mm(Further close tolerance onrequest)
4. CoilWeight(MT) Up to 30 MT (7 to 18 kg/mm width)
5. Surface Finish Super Bright, Bright, Dull&Matte. (RaValuewith
controlled Rmax on request).
6. Grades Specifications - As per JIS/BIS/ ASTM/EN
Standards
Low Carbon CRCA Grades
Super EDD/EDD/DD/D (SPCX, SPCEN, SPCD,
SPCC) non-aging, IF-High
Strength steel(IF-HSS), High Strength Low Alloy
Steel (HSLA), viz., ST -42,
ST-45, ST-52, SAPH-400/41O, Steel for
Porcelein Enammeling, Corrosion
Resistant Steel, viz., Tin Mill Black Plate (TMBP)
Medium &High Carbon CRCA Grades
C- 30, C-40,MC -ll,EN - 8, for spring steel
application, C-55, MC-12,
EN- 9 C-62,C-60, C-80,HC-14,EN-42J
7. Strip widths mm ELECTRICAL Grades Elec -I, Elec-n, Elec-nI,
SemiProcessed Elect. Steel
8. Chemical OTHER CRCA Grades
composition Case Hardening Steel- 15Cr3, SAE 1010, SAE
(Coating) 1012
Through Hardening Grades- SAE 1040,SAE 1045,
1055, 1065, 1080, 1541
  H.R PICKLED/ SKIN PASSED & OILED
9. Up to 3.00 mm           3.00 mm - 4.00 mm
Thickness
Above 4.00 mm
10. Max. Width for 1500 mm                   1250 mm
Cut Size 600 mm  
11. 50 mm - 1700 mm      50 mm - 1700 mm
Width for Coil
50 mm - 1700 mm
     
     
  PROCESS ROUTE OF CRCA MATERIAL  
     
   

   
10
       
   

Galvanised plane coil

   
 Galvanised Plane Coil  

Technical details/specifications
FGP
SKIN HILGP GPC
FAN
PLAIN PASSECORRUGATED PETROL/F BUSES/COA
BLA
D UEL TANK CHES
DE
Thickn 0.40
0.10 to 0.30 to 0.30 to
ess 0.12 to 1.60 to 0.60 to 1.60
2.50 2.50 2.50
(mm) 1.20
100
Width upto upto 602,762,800,90 200 to
to 100 to 1350
(mm) 1350 1350 0,1050 1350
1350
Surfac Matte Matte
 e Regular Matte,
with finish Matte, Bright
& Bright
Finish zero/mi Regular Spangle , No finish, No
mim.spa Finish, No
n. span spangle
ngle spangle
spangle gle
Coatin
g Mass 80 to 80 to 60 to
80 to 300 20 to 80 60 to 80
(gms/ 300 300 90
m2)
Grades Soft/Lock EDD,
EDD,
forming DD,D, SPCD
DD,D, SPCEN, SPCD,
SPCEN, Roofing ,
SPCEN, SPCC
SPCD,S SPCC
SPCD,SPCC
PCC

Galvanised plane sheet

Galvanised Plane Sheet  
   
Technical details/specifications
FGP
SKIN HILGP GPC
FAN
PLAIN PASSE CORRUGATED PETROL/F BUSES/COA
BLA
D UEL TANK CHES
DE
11
 Thickn 0.40
0.10 to 0.30 to 0.30 to
ess 0.12 to 1.60 to 0.60 to 1.60
2.50 2.50 2.50
(mm) 1.20
100
Width upto upto 602,762,800,90 200 to
to 100 to 1350
(mm) 1350 1350 0,1050 1350
1350
Cut to
upto upto upto
Length upto 4500 upto 4500 upto 4500
4500 4500 4500
(mm)
Surfac Matte Matte
Regular Matte,
e with finish Matte, Bright
& Bright
Finish zero/mi Regular Spangle , No finish, No
mim.spa Finish, No
n. span spangle
ngle spangle
spangle gle
Coatin
g Mass 80 to 80 to 60 to
80 to 300 20 to 80 60 to 80
(gms/ 300 300 90
m2)
Grades Soft/Lock EDD,
EDD,
forming DD,D, SPCD
DD,D, SPCEN, SPCD,
SPCEN, Roofing ,
SPCEN, SPCC
SPCD,S SPCC
SPCD,SPCC
PCC
    
    
 

Products > Colour Coated Coil  

    
  Introduction:  
Coil coating is the most advanced techniques used in the continuous
  application of an organic coating on to a flat metal substrate in the  
coil form
     
  Coil Coating Process:  
   CLEANING OF SHEET  
 CHEMICAL COATING
 DRYING
 PRIMER APPLICATION(ON BOTH TOP & BOTTOM)

12
  CURING OF PRIMER
 TOP COAT & BACK COAT APPLICATION
 CURING OF TOP & BACKING COAT
 GUARD FILM APPLICATION

  Cross Section of Coil Coated Metal  

    

   

  

Products > Colour Coated Tiles / Profile Sheet  

     
Pre-Painted GI / Galume Tile Profiled  
   
Steel Sheet -2
     
   Overal sheet width before  
profile is 1120 mm (+/-10)
 Overal width after profile is 980 mm
(+/-10)
 Effective covered width is 888 mm
(+/-5)
 Pitch is 178 mm (+/-2)
 Depth TP1 is 27 mm (+/-2)
 Depth TP is 2.5 mm (+/-2)
 Length of step is 203 mm

13
     
Pre-Painted GI / Galume Tile Profiled
   
Steel Sheet -1
     
 Overal sheet width before profile is
1200 mm (+/-10)
 Overal width after profile is 1006 mm
(+/-10)
 Effective covered width is 950 mm
  (+/-5)  
 Pitch is 190 mm (+/-2)
 Depth P1 is 27 mm (+/-2)
 Depth P2 is 2.5 mm (+/-2)
 Depth of step is 15 mm

       
Pre-Painted GI / Galume Trapezoidal Profiled Steel Sheet  
     
 Overal sheet width before profile is
1220 mm (+/-10)
 Overal width after profile is 1050 mm
(+/-10)
 Effective covered width is 1010 mm
   
(+/-5)
 Pitch is 250 mm (+/-2)
 Depth TP1 is 30 mm (+/-2)
 Depth TP is 2.5 mm (+/-2)

     
       
  Pre-Painted GI / Galume Trapezoidal Profiled Steel Sheet  
     
 Overal sheet width before profile is
1220 mm (+/-10)
 Overal width after profile is 1030 mm
(+/-10)
   Effective covered width is 930 mm
(+/-5)
 Pitch is 186 mm (+/-2)
 Depth 32 mm (+/-2)

14
 Products >Drawn Tubes of OEM Grade  

15
     
  Tube Range  
Special grade tubes like, SAE 1541, SAE 1010, SAE 1020, SAE 1030,
Medium Carbon Tubes and High tensile strength tubes for special
   
applications are also available as per customers requirements in ERW /
ERW Annealed / CEW / CEW Annealed conditions.
     
 
 
 Line  
Diagram
     
of Tube
 
Mill- ERW
 

  ERW TUBES       

     
  TECHNICAL DATA SHEET FOR PRECISION ERW TUBES  
     
Outer Diameter
12.70 to 114.00 mm.
(mm)
   
Thickness (mm) 0.40 to 6.00
Length upto 12 Mtrs.
     
  Process Flow Chart - ERW Tubes  
     
   
 
Applications
Automotive, Boiler & Heat Exchengers, Air Heater, Gen.
Engg., Bicycle & Propeller Shafts
 

   
  CEW TUBES
   

16
   TECHNICAL DATA SHEET FOR PRECISION CEW TUBES
   
Outer Diameter
09.00 to 110.00
(mm)
 
Thickness (mm) 0.80 to 6.00
Length upto 12 Mtrs.
   
  Process Flow Chart -CEW Tubes
   
 
 
Applications
Automotive, Boller, Shock Absorbers, Textiles, General
Engg. Propeller Shafts, Cylinder bore ttubes for special
applications & front fork tube for two wheelers,
   
 
 
 
 
 

Products >Hardened & Tempered Strip  

     
  Hardened & Tempered Steel Strips  
     
Hardened & Tempered Strips of Low, Medium & High alloy carbon steel is
Produced with a Unique proccesing faciltiy in introduced first time in
India. Land metal bath quenching with automatic computerised
  temperature control system is employed which is different from the  
conventionally used oil quenching process. The.£!:9cess to J;?roduce
Bainitic steel strips having unique combination of hardness with ductibility
that improves the toughness property.
     
The hardening and tempering furnace line is from world leader EBNER -
Austria. The strip grinding and polishing line to achieve the desired
surface finish are from BREUER - Germany. The edge profiling Machine to
   
provide desired shape to edge of the Hardened & Tempered Strip is from
JULIUS - Germany and slitting machine equipped with toolings from
NEUENKAMP - Germany is from DAEHYUN - Korea,
     
17
  Capacity (Per Annum):  
     
  Hardened & Tempered Steel Strips 20,000 TPA  
       
  Dimensions    
       
25 mm Min
  Width To 550 
mm Max
0.20 mm
Min To
  Thickness  
3.50 mm
Max
Custom
Tolerance
  Hardness 32 HRC 
Min To 55
HRC Max
Less than
0.025 mm
  Flatness of 25 mm 
(Width of
Strip)
       
Bright
Ground or
Polished
  Surface Finish  
Blue,
Brown &
Grey
       
One or
both edges
Round,
  Edges  
Square,
Chamfered
& Beveled.
       
Tempered
  Microstructure Martensite  
or Bainite.
       
  Chemistry C-1062, C- 
1075, C-
18
 1080, C-
1095, 75
NI 8 & 50
Cr v4.
       
Applications Flat
springs fro
automobile
clutches,
Wood
working
saws,
Massonary
   
and
Agricultura
l tools,
Gang saws
blades, for
marble
cutting,
Doctor etc.
   

Products >High Tensile Steel Stripping  

     
  HIGH TENSILE STEEL STRAPPING - FOR PACKAGING  
     
The Cold Rolled High Tensile Steel strapping is specially heat treated to
provide high strength and toughness for packaging application. On this
high speed and high precision online heat treatment line, the special strap
paints are applied for strapping and cured by infrared wave curing system
   
using quartz lamps. For tension transmission high gloss wax is applied and
cured by infrared wave curing system. The allied products such as whole
variety of metal st,(als and strapping tools are also available to our valued
customers
     
  Capacity (Per Annum) :    
         
High Tensile Steel Strapping:     Metal Seal: 45 Strapping Tools: 10,000
   
25,000 TPA million nos
     
  Strapping Specification: Confirming to International Standards ASTM D-  
19
 3953
     
ULTIMATE
ELONGATIO PAINT WAX
TENSILE
GRADE BENDS N ON 152 THICKNES THICKNES
STRENGTH
mm GL S UM S UM
kg/mm
0.40 to
  93 Min. 2 5 to 6.50% 1.75 to 5
0.50
    110 Min 1R 2.50% 1.75 to 5 Nil  
  130 Min. 1R 2.50% 1.75 to 5 Nil
0.40 to
  93 Min. 1R 9.00% 1.75 to 5
0.50
0.40 to
  77 Min. 2 Negligible 1.75 to 5
0.50
  77 to 130 Min. 1 R-2 As Desired 1.75 to 5 As Desired
     
Width Tolerance      +_ 0.127 MM.             Thickness Tolerance + 0.03
   
mm.
  Coil size     ID 406  +_ 1.60 MM.               OD 597 mm max.  
     
 The ribbon wound vary from 648 to 686 mm depending upon strap
size.
 Strap edges are blunted by Bevelled process to prevent strap cutting
in the fingers or hands while sttapping.
   Strapping is available in both Ribbon and Mill Wound to 50 kg  
weight.
 Jumbo Coils are also supplied at 220 kg weight
 Special requirements are undertaken on request

     
  Metal Seals:  
     
All variety of seals like, Snap-on seals, Push type seals, Nestack seals are
   
available for various applications with Customers Logo/Signature.
     
  Strapping Tools:  
     
All ManuallPneumatic/Power Strapping Machines are available from
 
FROMM, Switzerland

20
 Shops
Current Capacities  
   (tonnes per annum) 
   Products Sahibabad  
Cold Rolling
Widest (upto 1700
1. 350,000
mm)
2. Wider (upto 1200 mm) 100,000
3. Narrow (upto 550 mm)   25,000
Total Cold Rolling 475,000
Galvanised Sheets 225,000
Hardened & Tempered
-
Strips
Color Coated Sheets -
Drawn/Precision Tubes 15,000
High Tensile Steel
-
Strapping
Alloy Steel/Wire Rods 70,000

21
 Service Centre 300,000
Captive Power 24 MW
      
   
ACID Pickling Lines
    
 Two push pull type tickling lines of H. B. esmech bombay with
technical know how from pro–eco, canada 1720mm wide & 1400mm
wide
 Push pull pickling with low chloro technology
   
 To avoid over / under pickling.
 High speed turbulant pickling with five stage effective cascade rinsing
 For better cleanliness of sheet

 Cold Rolling Mill  

    
 Widest mill(1700 mm)suitable for automobile application. (first time in
india)
 Universal crown control for better shape control. (first time in india)
 Auto shape control on both sides of the mill while the mill is running
at 1200 mpm speed . (first time in india).
   
 Auto gauge control.
 Level ii computerisation (first time in india)
 X-ray gauges for better thickness control (first time in india)
 Mill clean system to minimise rolling oil quantity on strips..

   
    
 Electro Cleaning Line  
 High density current electrolytic - cleaning line
 For degreasing the strips before annealing.
   
 It helps in removing the oil completely and also removes iron fines.

    
 Bell Annealing Furnaces  
    
 100% hydrogen based batch type furnaces ebner make
 From ebner austria – the no.1 supplier in the world.
 Fully computerised high convection and fully sealed base technology
 Annealing cycle programs available in the computer for getting
 
optimum mechanical properties.
 Annealing cycle programs available in the computer for getting
optimum mechanical properties.

22
   
 
 
Kathabar Cooling System
   
 Coils Cooling And Storage System Technology By Loi Germany  
   Here coils after annealing are stored to avoid oxidation through
dehumidification to prevent rusting  

  

 C.R. Slitting Lines - From FIMI, Italy/ Daehyun Korea  

    
   Fully automatic operation including slitter blades setting by computer
and shimless setting to ensure burr free and scratch free operation..  

    
 

   

    
 Multi Blanking & CTL Lines  
    
   From henrich georg, germany / fimi italy / daeyhun korea
 Electro magnetic stacker for best surface quality standards (first time
in india)
 
 Fully computerised leveller for table top flat sheets from shuntz,
germany

23
    
 Roll Grinder-From Waldrich Siegen Germany  
    
   Cnc controlled fully computersied grinder to provide best quality rolls
for mills with automatic roll inspection system  

    
 Electro Discharge Texturing Machine  
    
   From waldrich siegen – Germany.
 Cnc controlled for uniform roughness on rolls  

    
 Galvanising Lines  
    
 Hot dip galvanizing lines  
   Furnaces based on the design of Stein Heurty, France. Non-Ox
furnace for cleaning of strip Inert medium of Nitrogen with 30%
Hydrogen to avoid oxidation. Coating control with air knives. Coating
 
checking with Radiometrie Skin passing to minimize spangle, tension
levelling for improved Shape, Chromatising to avoid zinc oxidation

    
 Testing Equipments  
    
   Spectrometer from hylger, u.k. ( four alloy base)
 Fully computerized universal testing machine from zwick, germany for
measurement of y.s u.t.s, %e, r value, n value, yes, u.e.
 Metallurgical microscope axiovert germany upto 500x magnification .
 Fully computerized micro hardness tester from zwick germany.
 Automatic surface roughness tester from hommel, germany.
 Rapid drawability tester, r module from tinus olsen u.s.a..

24
 Project
Cold Rolled Steels

Abstract
Cold rolled steels provide excellent press formability, surface finish, and thickness
and flatness tolerances. Steel companies manufacture three groups of low- or
ultra-low-carbon grades to meet a variety of customer formability requirements:
CS Type B, DS Type B, EDDS, and EDDS+. They also produce HSLA steels and
structural steel grades for those applications that require specified strength
levels.

25
Cold rolled steels provide excellent press formability, surface finish, and thickness
and flatness tolerances. Steel companies manufacture three groups of low- or
ultra-low-carbon grades to meet a variety of customer formability requirements:
CS Type B, DS Type B, EDDS, and EDDS+. They also produce HSLA steels and
structural steel grades for those applications that require specified strength
levels.

Cold rolled steels can also be specified as dent resistant or bake hardenable for
applications that require dent resistance after forming and painting. Each grade
can be processed with several surface finishes depending on customer
requirements. Lubricants can be applied to enhance formability and to avoid at-
press lubrication

Cold-rolled steel sheets

Production of semi material for steel sheets
The processing conditions of the preliminary metallurgical stages during the
production of the raw steel already determine the quality of the steel grade to be
produced. Salzgitter Flachstahl steel is produced using the process chain of blast
furnace, oxygen top-blowing converter and continuous casting. This advanced and
efficient process technology is backed up by a fully integrated energy supply
system. Coke and electricity are produced by the in-company coking plant and
power station. Thanks to an efficient combined energy utilisation system the
generated secondary energies are fed back into the steelmaking process, thus
saving.
The flat rolled steel is smelted in the Salzgitter Works in three 220 t L. D.
26
converters using the oxygen top-blowing process combined with state-of-the-art
bottom purging technology. This is followed by a treatment of the steel in a ladle-
metallurgical centre. Here fine alloying, fine desulphurisation and vacuum
treatment are carried out. Salzgitter Flachstahl  flat steel is entirely produced by the
continuous casting process. Both bow-type continuous casters are equipped with
modern alchimist cooling system, narrowest roller spacing strand guides and
several bending points. All this represents the latest state-of-the-art.

Cold-rolled and surface-coated products

The range of cold-rolled and surface-coated products includes high-quality steel
grades with the finest tolerances with regard to mechanical key characteristics and
dimensions. The manufacturing program comprises cold-rolled drawn, deep-drawn
and specially drawn steel grades, construction and fine-grained steel, as well as
higher-strength and multi-phase steel grade which can be supplied in either
coldrolled, electrolytically galvanized, hot-dip galvanized and/or organically
coated form.

Working in close collaboration with customers from further processing industries,

Salzgitter manufactures optimized steel products that are tailored to their
respective applications. For example, we develop higher-strength isotropic thin
sheets with very good forming properties for the automotive industry; these sheets
exhibit the same or improved impact strength as conventional sheet steel and allow
a reduction in sheet thickness. Lower vehicle weight translates as enhanced
passenger safety and reduced fuel consumption. PRETEX® surface- texturing
method is used to structure the surface of sheet steel, thus rendering them suitable
for further processing and coating. The manufacture of these highquality steel
products draws on leading edge steel production and processing technologies. Our
policy of committing major investments to plant technology ensures the continuous
improvement and upgrading of processing technologies, while enabling us to meet
the most stringent quality requirements.

Sheet qualities
Salzgitter sheet is typified by:

 Excellent cold formability

 High surface quality especially suitable for surface treatment
 Excellent weldability
27
  Excellent strip flatness
 Close dimensional tolerances

The manufacturing programme includes cold-rolled drawing, deep-drawing and

extra deep-drawing sheets, as well as structural steel grades and fine-grain steel
qualities and grades for conventional or direct porcelain enamelling. Specific
solutions can be offered, tailored to the particular demands of the application.

Great importance is attached to close relations with the customer. In this way a
whole series of new steel types for particular applications was developed in close
co-operation with the industries involved in further processing. This highly
customer-oriented steel development is one of the reasons why Salzgitter
Flachstahl sheet steel possesses optimum usage properties and is recognised as a
high-standard quality product.

When using steel sheets, extremely high – and in part very different – material
demands result from the wide range of possible later applications. A high standard
of quality can only be achieved by keeping the manufacturing parameters within
very close limits. In order to guarantee this quality standard an integrated Quality
Management System has been established in all process stages. In the steelworks
already the properties demanded from the material are determined by means of
preset analyses. lt is continued by close co-ordination with the subsequent rolling
and heattreatment stages.

Sheet production
Salzgitter Flachstahl has always answered customers’ requests for improved sheet
qualities by continental modernisation and improvement of its process technology.
Shortly after the start-up of the cold wide strip mill further development
programmes were initiated. The expansion and modernisation programmes of the
seventies were aiming at improving the economic efficiency, increasing the
specific performance, enhancing the sheet quality, and bettering the workplace
conditions.
The focus of the heavy investments during the eighties and the nineties was on the
field of quality improvement. The production sequence in the cold widestrip mill
includes the following: pickling line, tandem mill, annealing facility, skin pass
mills and coilslitting and inspection lines..

Pickling lines
28
In the continuous pickling line and the push-pull pickling line the strip is freed
from scale while passing through an acid bath. In order to improve the mechanical
breaking of the layer of scale, a stretcher leveller is installed in front of the
chemical treatment section. The newly installed turbulence pickler with flat
pickling baths reduces the energy requirements of the continuous pickling line by
20 % and thus contributes substantially to the saving of resources. With the new
rinsing section and the installation of a new process computer and optimisation
system, the quality of the pickled sheet has been further improved with regard to
surface cleanness and structure.

Both pickling lines are equipped with electrostatic oiling-machines. The pushpull
pickling line has a skin pass mill for thicknesses up to 7,0 mm.

Tandem mill
The central section of the cold-rolling mill is the five-stand tandem mill. The
pickled strip is rolled in a single pass to finished thicknesses between 0,35 and 3,0
mm. At this stage final rolling speeds up to 90 km/h are achieved. The first four
stands are in four-high design and the fifth stand in six-high design. This plant
design, in conjunction with a thickness and strip flatness control system operating
in a closed loop, brings about a considerabie improvement to the strip flatness and
profile consistency while adhering to the closest possible thickness tolerances.The
strip profile is monitored by a measuring roll.

29
A process computer processes the measured data obtained from the complete
rolling train and controls the roll gap and the strip profile using hydraulic roll
screwdown mechanisms by bending the work and intermediate rolls, shifting of the
intermediate rolls and controlling the roll cooling.
This control system selected for use at Salzgitter can effectively influence the strip
profile over a wide range as shown in the diagrams above and opposite. In addition
to the good strip flatness the surface cleanness of the cold strip is improved by a
separate rolling emulsion circuit for the fifth stand.

Results of surface cleanness after annealing

Annealing and sheet conditioning

After cold-rolling the coil is annealed in order to remove the strain hardening in the
material caused by the cold-rolling process. Salzgitter Flachstahl thus meets the
increasingly stringent demands of the customer in this respect. With the
introduction of high convection furnaces which were added to complement our
conventional stack annealing furnaces, the uniformity of the material properties
and the surface cleanness have been increased.

Skin passes rolling mills and finishing shop

The annealed coils are then transferred to the skin pass mills where they are passed
through roughened rolls at very low reduction degrees of approx. 0,5% to 2,0%
and provided with a predetermined surface roughness on the sheet. In this way
30
subsequent formation or the application of paint or other coating materials is
improved.

The skin pass mills possess hydraulic screwdown mechanisms and automatic
elongation controls.

Distribution of the skin passes degree

The elongation is measured by means of deflector rolIs which are installed ahead
of and behind the skin pass stand. The related automatic pressure and rolling force
control unit ensures a constant elongation along the complete coil length.
A tension leveller is directly connected to skin pass mill 1 so that both skin passing
and straightening can be carried out in a single process, if increased coil flatness is
required. In the conditioning line of the cold-rolling mill modern coil slitting and
inspection lines are available. Here the coil edges are trimmed or the coils are slit
to the ordered width, marked and electrostatically oiled to prevent corrosion. For
this purpose atomised ionised oil particles are deposited evenly on the coil in a
layer which can be accurately controlled.
In the conditioning lines the coil weight can be adapted to suit the ordered weight
using the efficient Preplap transverse seam welder. Salzgitter Flachstahl can supply
coils up to a max. Weight of 32 t.

Production equipment and facilities

31
Hot-rolled products
The processing conditions during the preliminary metallurgical stages are already
decisive for the quality of the hot-rolled coil. Salzgitter AG produces its steel
according to the process chain blast furnace, basic oxygen steel making and
continuous casting. This advanced, effective and efficient process is supported by a
fully integrated energy supply. Coke and electricity are available from own coke
plant and power stations. Fine-tuned combined utilities make it possible to re-
supply the arising energy to the metallurgical process.
Salzgitter AG is amongst the large European steel producers. We have decades of
experience in steel making and are equipped with the most up to date production
plants for producing quality products according to advanced manufacturing
technologies. We produce our rolled-steel products at three locations in the centre
of Europe. Our works have a combined capacity of about 4,7 million tonnes. The
Salzgitter Works produce hot-rolled coils, cold-rolled and surface-coated steel
sheets. The Peine Works cover the product sector sections. Heavy plate production
is concentrated at the Ilsenburg Works, while plate-processing is located at
Salzgitter.

Steel grades
 Mild non-alloy steels for cold-reducing
 Mild non-alloy steels for direct cold-forming
 Extra deep drawing grade DD14 Bor
 Extra deep drawing grade DD14 Ti
 Non-alloy structural steels
 Laser beam cutting grade Salzgitter 240
 Special grade for hydroforming S280IHU
 Special grade for hydroforming S320IHU
 Weather resistant structural steels
 Steels for the manufacture of simple pressure vessels
 Weldable fine-grain structural steels for pressure vessels
 Heat-resistant pressure-vessel steels
 Special steel grades for gas cylinders and gas vessels
 Fine-grain structural steels, normalised rolled
 Fine-grain structural steels, thermomechanically-rolled
32
  High-strength steels for cold-forming, normalised rolled
 High-strength steels for cold-forming, thermomechanically-rolled
 Case-hardened steels
 Quenched and tempered steels
 Boronalloyed quenched and tempered steel
 Dual-phase steels
 Hot-rolled coils for the manufacture of large-diameter pipes
 High-strength special steel grades
 Bainitic grade SZBS600
 Bainitic grade SZBS800
 Martensitic grade SZMS1200

Dimensions and Executions

Hot-rolled coils unpickled, mill edge – Tensile strength class A

33
Other dimensions available on request
Deep-drawn Structural Pressure-vessel Case-hardened/quenched and Pipe
steels steels steels tempered steels qualities
DD11 S185… P235… C10E L245NB
DD12 S235… P245… C15E L245NB
DD13 S260NC P265… C16E L290MB
DD14 S275… P275… C22E L290NB
DD14 Bor S315NC   C25E  
DD14 Ti Salzgitter 240      
St 22 S280IHU      
RRSt 23 S320IHU      
St 24        
St 25        
IF-Stahl        

Hot-rolled coils unpickled, mill edge – Tensile strength class B

34
Other dimensions available on request
Micro-alloyed Structural Pressure-vessel Case-hardened/quenched and Pipe
steel grades steels steels tempered steels qualities
S315MC E295 13CrMo4-5 16MnCr5 L360MB
QStE 340TM E335 16Mo3 20MnCr5 L360NB
QStE 380TM E360 P295… 22MnB5  
S355M… S355… P310… 26MnB5  
    P355… C30E  
      C35E  
      C40E  
      C45E   
      C50E  

Hot-rolled coils unpickled, mill edge – Tensile strength class C

35
Other dimensions available on request
Micro-alloyed steel Pressure-vessel Quenched and tempered
Pipe qualities
grades steels steels
S420M… P420M… C55E L415MB
S460M… P460M… C60E L450MB
    C67S  
    34CrMo4  
    42CrMo4  

Hot-rolled coils unpickled, mill edge – Tensile strength class D

36
Other dimensions available on request
Micro-alloyed steel Dual-/martensitic-phase Quenched and tempered Pipe
grades steels steels qualities
S500MC DP550 (≥ 3 mm) C75S L485MB
S550MC DP600 (≥ 3 mm) 51CrV4  
S600MC SZMS1200 58CrV4   
S650MC      
S700MC      
SZBS800      

Hot-rolled slit strip – Tensile strength class A

37
Other dimensions available on request
Deep-drawn Structural Pressure-vessel Case-hardened/quenched and Pipe
steels steels steels tempered steels qualities
DD11 S185… P235… C10E L245NB
DD12 S235… P245… C15E L245NB
DD13 S260NC P265… C16E L290MB
DD14 S275… P275… C22E L290NB
DD14 Bor S315NC   C25E  
DD14 Ti Salzgitter 240      
St 22 S280IHU      
RRSt 23 S320IHU      
St 24        
St 25        
IF-Stahl        

Hot-rolled slit strip – Tensile strength class B

38
Other dimensions available on request
Micro-alloyed Structural Pressure-vessel Case-hardened/quenched and Pipe
steel grades steels steels tempered steels qualities
S315MC E295 13CrMo4-5 16MnCr5 L360MB
QStE 340TM E335 16Mo3 20MnCr5 L360NB
QStE 380TM E360 P295… 22MnB5  
S355M… S355… P310… 26MnB5  
    P355… C30E  
      C35E  
      C40E  
      C45E   
      C50E  

Hot-rolled slit strip – Tensile strength class C

39
Other dimensions available on request
Micro-alloyed steel Pressure-vessel Quenched and tempered
Pipe qualities
grades steels steels
S420M… P420M… C55E L415MB
S460M… P460M… C60E L450MB
    C67S  
    34CrMo4  
    42CrMo4  

Hot-rolled slit strip – Tensile strength class D

40
Other dimensions available on request
Micro-alloyed steel Dual-/martensitic-phase Quenched and tempered Pipe
grades steels steels qualities
S500MC DP550 (≥ 3 mm) C75S L485MB
S550MC DP600 (≥ 3 mm) 51CrV4  
S600MC SZMS1200 58CrV4   
S650MC      
S700MC      
SZBS800      

Hot-rolled coils unpickled

Steel Outside Spec. lift
Execution Thicknesses Widths Inside dia. Weight Tolerances
grades dia. weight
  Mm mm   mm mm kg/mm T  
1) 1) 2) ca. 760 max.
mill edge max. 23,6 max. 32 EN 10051
± 7% 2.100
                 
max. 3) ca. 508/610 max.
Sheared max. 10,00 max. 23,6 max. 32 EN 10051
1.580 ±15mm 2.100
                 

1)   See dimensions

2)   See materials

Hot-rolled coils pickled, unoiled or oiled

Oil grades
41
Anti-corrosion oil: Fuchs Anticorit RP 4107 S

Emulsifiable rolling oil: Henkel Gerolub 6515

Hot-rolled coils pickled in hydrochloric acid (push-pull

pickling line)
Spec.
Thicknesse Steel Inside Outside
Execution Widths lift Weight Tolerances
s grades dia. dia.
weight
  Mm mm   mm mm kg/mm T  
Max. 1) ca. 610 Max. Max. Max.
mill edge Max. 12,50 EN 10051
1.520 ±15mm 2.100 23,6 32
                 
Max. 2) ca. 610 Max. Max. Max.
Sheared Max. 10,00 EN 10051
1.500 ±15mm 2.100 23,6 32
                 

1)  Tensile strength max. 1.200 MPa

2) Tensile strength to 400 MPa: Thickness max. 10,00 mm

     Tensile strength to 510 MPa: Thickness max. 7,00 mm 
     Greater tensile strengths available on request

Hot-rolled coils pickled in sulphuric acid (continuous

pickling line)
Spec.
Thicknesse Steel Inside Outside
Execution Widths lift Weight Tolerances
s grades dia. dia.
weight
  Mm mm   mm mm kg/mm t  
max. 1) ca. 610 max. max. max.
mill edge max. 6,00 EN 10051
1.880 ±15mm 2.100 23,6 32
                 

42
 max. 1) ca. 610 max. max. max.
Sheared max. 6,00 EN 10051
1.850 ±15mm 2.100 23,6 32
                 

1) Tensile strength max. 700 MPa

    C-steels to C45: thickness max. 3, 00 mm
Pickled and skin-passed hot strip:
Thickness from 1, 50 - 7, 00 mm
Max. Strength 600 MPa

Hot-rolled slit strip

Spec.
Steel
Thicknesse Width Inside Outsid lift Weigh Tolerance
Execution grade
s s dia. e dia. weigh t s
s
t
kg/m
  mm mm   mm mm t  
m
ca.
508/61 max. max. max.
unpickled 1) 1) 2)
EN 10051
0 2.100 23,6 32
±15mm
                 
pickled in
ca.
hydrochlori
1) max. 2) 508/61 max. max. max.
c acid, EN 10051
750 0 2.100 23,6 32
unoiled or
±15mm
oiled
                 
pickled in
ca.
sulphuric
508/61 max. max. max.
acid, max. 6,00 1) 3)
EN 10051
0 2.100 23,6 32
unoiled or
±15mm
oiled
                 

1) See dimensions hot-rolled slit strip

43
2) See materials
3) Tensile strength max. 700 MPa
    C-steels to C45: thickness max. 3.00 mm

Cut-to-length
Steel
Execution Thicknesses Widths Tolerances
grades
  mm mm    
max. 1)
Unpickled max. 6,00 EN 10051
1.850
         
pickled in hydrochloric acid, max. 1)
max. 6,00 EN 10051
unoiled or oiled 1.500
         
pickled in sulphuric acid, unoiled max. 2)
max. 6,00 EN 10051
or oiled 1.850
         

1) See materials

2) Tensile strength max. 700 MPa

    C-steels to C45: thickness max. 3,00 mm

Ordered weights for order position (Guidelines)

Ordered width 1 Coil 2 Coils 3 Coils more
Mm t t t t
1)
900-925   28 - 32 - above 602)
925-950 20 38 - 42 56 - 66 above 80
951-1050 22 44 - 48 60 - 72 above 90
1051-1150 24 46 - 50 66 - 78 above 100
1151-1250 26 48 - 54 71 - 84 above 105
1251-1350 28 53 - 60 76 - 80 above 110
1351-1450 30  53 - 60 76 - 90 above 120
above 1451 30 53 - 60 76 - 90 above 120

44
1)
by prior agreement
2)
only an even number of coils possible

Prime material - coil weights undivided and without welds;

in tonnes
Ordered width  min. max.
mm t t
900 - 950 16,2 20,0
951 - 1050 17,2 22,1
1051 - 1150 19,0 24,2
1151 - 1250 20,8 26,3
1251 - 1350 22,6 28,4
1351 - 1450 24,4 30,5
1451 - 1510 26,2 31,7

Remarks:
1. Coil unit structure subject to prior arrangement.
2. Division of coils is possible. Minimum coil weight: 5 kg/mm width.
3. Special weights only by agreement. 

Tolerances
Unless stated otherwise in the following, Salzgitter Flachstahl shall guarantee all
limit dimensions and shape tolerances according to EN 10051. Closer tolerances
available on request.

Thickness tolerance
Without any extra charges, we warrant for all tensile strength classes 50% of the
thickness tolerances listed in DIN EN 10051. Closer tolerances are subject to extra
charges and possible up to 20% of DIN EN 10051, whereas the lowest possible
tolerance limit is +/- 0.06 mm. From a thickness of 6 mm closer tolerances must be
agreed separatly.
45
Tensile strength class Additional tolerance factor
  %
A 0
B 15
C 30
D 40
Displaced thickness tolerances are possible, the resulting rolling thickness,
however, must be within the range of the delivery program. Closer tolerances
available on request.

Width tolerance
Steel strip in thicknesses ≤ 4,00 mm: -0/+1 mm

Steel strip in thicknesses > 4,00 mm to ≤ 8,00 mm: -0/+2 mm

All other executions: tolerance according to EN 10051.

  Technology

The Manufacturing process utilizes the latest technology and the most modern
equipment for cold rolling, for producing high quality cold rolled steel coils &
sheets. The process includes judicious selection of H.R. coils, that are sourced
from best in country or from imports and then providing them cold reductions
which are suited to develop. Desired mechanical properties & crystallographic
orientation subsequent to annealing & skin pass.

Pickling

-In semi-continuous pickling line surface oxide layer of H.R.

46
Coils are removed by the action of warm hydrochloric acid ,
which is subsequently rinsed by cold & hot water such that
pickled H.R. coils does not carry any acid & is neither under
or over pickled.

Cold Rolling

-The process consists of reducing

thickness of hot rolled coils to desired
thickness in several passes (according to
set pass schedule). This results in :-

a) Closer dimensional tolerance.

b) Improved shape.
c) Improved surface.

47
 Annealing
Steel after undergoing cold rolling
become very hard because of work
hardening & has got only limited use
e.g. galvanizing because of loss of
ductility. In order to restore Ductility,
Formability, C.R. coils are annealed in
protective Nitrogen - Hydrogen
atmosphere such as to attain desired
grain size and orientation. This process
results in improvement in formability
related properties & also in its
microstructure.

Skin Passing

-Skin passing of annealed cold rolled

steel coils is carried out for following:

a) To suppress the yield point

phenomenon which can cause stretcher
strains on formed component.
b) To remove the wrinkles & achieve
flatness that is caused due to annealing.
c) To impart matte or bright finish
cdepending on customers requirements.

48
In addition to this semi-processed
electrical steels are given about 7-8%
critical reduction such as to improvise
their magnetic properties.

Slitting and shearing

-After skin passing the coils are slit to

the required width, by the precision
slitting machine.

-The coils are further sheared to the

desired length facility.

-The coils / sheets thus supplied to

the exact sizes for end users improve
the yield of CR rolled steel and
sheets.

Oiling & Packing

-The coils are provided with an

uniform coating of special rust
preventive oil to guard against
rusting, atmospheric corrosion & to
allow storage for long duration.

-The oil can be easily removed in

normal degreasing.

-The coils/sheets are securely packed

in bituminoid polyethylene lined
Hessian and tied with steel straps to
avoid any damage in handling and
49
storage.

Work in slip sheet

Description
The slip sheet is used as a unit load support device in vehicle delivery and
transportation of products. When slip sheets are supported by a pallet board, roller
conveyor surface, flat load carrying surface, or a cart or lift truck, the structural
strength of the slip sheet supports the product loads weight. With the slip sheet
supported by one of these transportation devices the unit load can easily be
transported both internally within a facility and externally between two facility
locations.

50
Slip Sheet Types
There are several types of slip sheets that can be used for the transportation of a
unit load depending upon the desired use of the sheet. The slip sheet is shaped and
dimensioned to the size of the product or unit load. The type of slip sheet varies
depending on both the number of lip extensions and the material from which it is
manufactured.

The variation used would depend on the loading patterns, unit load parameters, and
desired maneuverability of the slip sheet/unit load. Normally, the thickness of the
slip sheet is less than 0.5 inches.

For most warehouses, plant functional material handling equipment, and the travel-
path clearances, this fraction of an inch height increase does not stage a problem.
When designing an in-house transportation path for the slip sheet unit load, the slip
sheet has a 4 to 6 in. lip (tab) that extends beyond one or more of the sides of the
slip sheet. The lip extensions permit a push-pull device to lift the slip sheet unit
load.

Single Lip Slip Sheet

The first type of slip sheet is the single lip (tab) slip sheet.With a single lip, the lip
faces the narrow part of the rectangular shaped unit load and the delivery truck
door. This slip sheet variation maximizes the delivery truck’s space utilization and
loading and unloading process productivity. Also, with a single lip, the travel path
clearance is minimized as the lip facing the unit load carrier.

Multi-lip Slip Sheet

The second type of slip sheet is the multi-lip slip sheet. This type of slip sheet is
generally used on a container placed onto a railroad car or an ocean delivery
vehicle due to the necessary loading/unloading patterns. This allows a loading
device to load the slip sheet unit load from one side and an unloading device to
unload the load from another side depending on the number and pattern of the
remaining lips.

Lip Handling Options

During the transportation of your slip sheet, there are several options for handling
the slip sheet’s lip.
51
  Leave the lip extended allowing for additional clearance for the travel path.
 Tape the lip against the unit load if additional push-pull activities are
required.
 Cut the lip from the slip sheet if no additional push-pull activities are
required.

Slip Sheet Materials

Corrugated Slip Sheet Material

The corrugated material consists of two kraft liner board outer surfaces with a
corrugated interior that is bonded together with adhesive or glue. This bonded
material provides the necessary strength for the push-pull device to clamp the slip
sheet once or twice. There are several disadvantages associated with this type of
slip sheet material including that it is not very durable, moisture resistant, resistant
to high humidity or usable in cold storage areas. The advantages associated with
this material are low cost, one-way use, and its ability to be moved by a conveyor
or lift truck with a slip sheet device.

Fiberboard or Solid Kraftboard Slip Sheet Material

The fiberboard slip sheet consists of several layers of solid fiberboard sheets
laminated together. The bonding of layers of several flat solid kraftboard sheets
increases the slip sheet’s non-tear strength. This, in return, allows the slip sheet to
be used several times and in different temperatures. In addition, some fiberboard
slip sheets are coated with a plastic coating to improve its use in humid
environments. The disadvantages to this type of slip sheet are that it has a medium
cost and is not very durable. The advantages with this material are its multiple
uses, ability to withstand humid and cold environments, and ability to be handled
by conveyors, AGV, or other power unit load transportation devices.

Plastic Slip Sheet Material

The plastic slip sheet is made of a combination of polyethylene materials. This

type of material allows for greater non-tear strength and an increased number of
uses in cold and humid environments. The only disadvantage to the plastic slip
sheet is the high cost. Yet, its advantages include longer sheet life, durable lips,
ability to be stored in cold or humid environments, and can be handled by a roller
conveyor, slip sheet lift truck, AGV, or powered unit load transportation devices.
52
Slip Sheet vs. Pallet
When considering the use of a slip sheet vs. a pallet, there are several advantages
and disadvantages asso€ciated with both.

Slip Sheet Advantages

 Using slip sheets instead of wooden pallets allows for 12-15% more
products in material handling containers.
 Slip sheets do not require maintenance, but can easily be replaced.

Significant reduction in material handling costs.

 Decreases loading/unloading time by up to 60%

Slip Sheet Disadvantages

 Pallets provide a greater clearance between the floor and the unit load. An
advantage when loading extra cargo into a container (provides extra cube).
 Slip sheet usage requires special attachments on transportation devices
such as a lift truck (but are fairly cheap).
 When used alone, pallets provide more structural support than slip sheets.
 Pallets are easily compatible with crane devices.
 Lift truck attachment reduces load capacity. Except when 'Roller Forks' are
used
 Slower handling. Except when 'Roller Forks' are used

Cold rolled steels have the following features:

 Excellent Surface Appearance. Cold Rolled Steels have manufacturing

controls in place assuring consistent surface quality to satisfy customer
requirements.
 Formability. Cold Rolled Steels can be used to produce parts containing
simple bends to parts with extreme deep drawing requirements.
53
  Paintability. Due to stringent surface roughness controls, Cold Rolled Steels
are readily paintable using essentially any paint system.
 Weldability. Cold Rolled Steels can be joined using virtually any accepted
welding practice.

Standard grades for cold rolled steels are:

 Commercial Steel (CS Type B). May be moderately formed; a specimen cut
in any direction can be bent flat on itself without cracking.
 Drawing Steel (DS Type B). DS Type B is made by adding aluminum to the
mol steel and may be used in drawing applications.
 Extra Deep Drawing Steel (EDDS). Interstitial Free (I-F) steels are made
Drawing Steel by adding titanium and/or niobium to the molten steel after
vacuum degassing and offer excellent drawability.
 Extra Deep Drawing Steel Plus (EDDS+). Interstitial Free (I-F) steels are
made by adding titanium and/or niobium to the molten steel after vacuum
degassing and offer excellent drawability.

Surface Finish
Cold rolled steels are manufactured with a matte finish obtained by rolling with
specially roughened rolls on the cold mill and the temper mill. This finish helps to
maintain effective lubrication during metal forming and improves the appearance
of painted surfaces. Non-standard matters finishes can be provided that optimize
the opposing effects of surface roughness on painted part appearance and
lubrication during press forming.

Surface Protection and Lubrication

To prevent rusting in transit and storage, cold rolled steels can be supplied with a
rust protective oil film or press forming lubricants. A pre-applied press forming
lubricant provides uniform lubrication and eliminates the housekeeping
problems.

A dry film (acrylic/polymer) lubricant can also be supplied by further processing

the cold rolled product through a coil coating facility. These specialty organic
coatings are easily removed with a mild alkaline cleaner.

54
Formability and Mechanical Properties
The formability of all steel products is a result of the interaction of many
variables, the main ones being the mechanical properties of the steel, the
forming system (tooling) used to manufacture parts, and the lubrication used
during forming.

Tight control over chemical composition, hot rolling parameters, amount of cold
reduction, annealing time and temperature, and the amount of temper rolling allow
the production of high-quality cold rolled steel products to meet customer’s
requirements. Commercial Steel (CS Type B) should be used for moderate forming
or bending applications. CS Type B products are produced from aluminum-killed
continuously cast slabs and, unless otherwise specified, have a carbon content of
less than 0.15%.

To prevent the occurrence of fluting or stretcher strains during forming, CS

products are tempered as a normal step in the mill processing.

For more severe forming applications, Drawing Steel Type B (DS Type B) should
be used. DS Type B has a controlled carbon content (<0.06%) and is produced in
such a manner that parts formed from DS Type B Steel should not exhibit stretcher
strain.

Extra Deep Drawing Steel (EDDS) or Extra Deep Drawing Steel plus (EDDS+)
should be used for the most demanding forming applications. These steels (also
known as Interstitial Free or I-F steels) are produced from a vacuum degassed,
titanium stabilized grade. EDDS and EDDS+ have the lowest carbon content
available (<0,010%) and have been specially formulated to be most ductile
products.

For high strength or structural applications, cold rolled steels are also available in
yield strengths up to 50 ksi.

Paintability
Cold rolled steels can be easily painted using a variety of paint systems provided
proper care is taken in preparing the material. Prior to painting, the surface
should be carefully cleaned with either a solvent or alkaline cleaner.

55
Cleaning should be followed by a pre-treatment prior to painting. Zinc or iron
phosphates give good results on cold rolled steels. Mild abrasion prior to pre-
treating may also be used to enhance mechanical bonding of the paint.

Cold rolled steels can be in general supplied as pre-painted or pre-primed.

56