Annexure - I

ROLLED PRODUCT DEFECTS, IDENTIFICATION VISUAL AND MPI

Its Remedies and Actions

All Shown defects to be rectified within size tolerance or product to reject as per guideline or
specification
 SCRATCH / LINE
Scratch: Defect generated due to rubbing action when
metal comes in contact with stationary part

Sources of Defects Remedies

Bar touching to entry guides EGH, stripper Ensure standard guide openings as per
& Delivery pipes guide schedule
Ensure roller condition for all roller entry
Jamming of entry guide rollers
guides in mill
Ensure conveying channel roller condition
Jamming of conveying channel rollers
healthy
Jamming of rollers of loopers, entry
Ensure roller conditions of loopers,
funnel, roll trestler, Cheek rollers & Bypass
funnels, trestlers, cheek & troughs
troughs
 LAP / FOLD
Lap: Defect generated due to folding of material rolled in
successsive stands

Sources of Defects Remedies

Overfill generated in intermittent stands got • Check & Ensure no overfill intermittent stock
folded in successive stands during rolling. by wood burning in finishing mill & visually in
Overfill due to roughing mill.
• Improper stock setting • Ensure standard stock setting as per guide
• EG Opening More schedule.
• Feeder round stock with heavy roll cross. • Looping should be taken care during grade
change.
• Improper twist
• Timely guide checking & replacement should
• Temperature variations done during minor stoppages.
• Guide out • Do not allow roll cross to any intermittent
• Interstand Looping stands
 SHAVING
Shaving: Defect generated due to cutting of material in
Intermittent rolling stages.

Sources of Defects Remedies

Shaving generated in intermittent stands due to

metal cutting rolled in successive stands during
rolling. Shavings comes due to
• EG Failure
• Guide Out
• Improper stand alignment
• Jamming of rotating parts.
• EG misalignment
• Checke & Ensure EG roller conditions during
stoppages.
• Ensure material flow in center of troughs and
guides.
• Ensure EG alignment by checking bar seams
through wood burning.
 SLIVER / CHIP OFF
Sliver: Defect generated due to initial billet flaws like
dents, cracks and seams which carry forward during
rolling. Sliver seems to be small chips removal on rolled
product.

Sources of Defects Remedies

• Grind billet to remove billet surface defect.

Sliver is generated due to Input Material flaws
like dent, seams and cracks. • Inspection and segregation of defective
billets.

Fin: Defect generated due to overstock or overfilling of
material called as fin.
Sources of Defects
Overfilling generated due to following
• Improper roll gap adjustment
• Excessive pass wear out
• Entry Guide opening more
• Abnormal spread of material
• Inter-stand looping.
• Improper twist
• Temperature Variation
FIN
Remedies
• Check & Ensure no overfill intermittent stock
by wood burning in finishing mill & visually in
roughing mill.
• Ensure standard stock setting as per guide
schedule.
• Looping should be taken care during grade
change.
• Timely guide checking & replacement should
be done during minor stoppages.
• Do not allow roll cross to any intermittent
stands
 DEPRESSION
Depression: Flatness generated on circumference /
periphery along the length of bar called as Depression. It
is due to pressing of hot material against stationary /
rotating equipment.

Sources of Defects Remedies

Depression generated due to

• Excessive Entry guide roller wear out, step
mark on rollers.
• Rubbing of material on edges during rolling
created flatness on rolled product
• Entry Guide roller condition to be checked
during stoppages and replace timely.
• Keep material flow in center of guide so that
edges should not been pressed by static guide.
 TWISTER MARK / WRINKLES
Twister Mark: Defect generated due to excessive wear out
of Twister Guide rolls make wrinkle mark on material
while twisting.

Sources of Defects Remedies

Twister marks generated due to

Twister roller conditions to be checked and to
• Excessive twister roller wear out makes net be replaced within life norms.
type pressing mark on material during twisting.
 DENT MARK
Dent Mark: Defect generated as a result of projection on
guide rollers, pass, conveying line rollers.

Sources of Defects Remedies

Dent marks generated due to

• Projection on guide rollers due to material
sticking.
• Projection on pass due to material sticking on
pass
• Timely checking & replacement of Finishing
Guides.
• Ensure proper roll cooling for passes as well
as guide rollers
 ONESIDE FIN/GUIDE OUT
Guide Out: Projection on cross section on either side, cross
section area shifts either side or unsymmetrical cross
section area called as guide out.

Sources of Defects Remedies

Guide Out due to

• Improper guide alignment with respect to • Check & Ensure seam width equal on both
pass side by wood burning.
• Roll cross in stand. • Check & Ensure roll cross in finishing stand
• Abnormal Loop formation. • Ensure proper loop formation.
 UNDERSIZE
Undersize: Any dimension along the circumference come
below tolarance limit called as Undersize

Sources of Defects Remedies

Undersize due to • Roll gap setting to be done as per standard

• Improper stock setting Rolling schedule of respective section.
• Improper setting of sampling stock. • Ensure no tension in mill during set up and
• Interstand Mill Tension. grade change.
• Inadequate Loop formation • Ensure proper loop formation.
 OVERSIZE
Oversize: Any dimension along the circumference come
more than tolerance limit called as Oversize

Sources of Defects Remedies

Oversize due to • Roll gap setting to be done as per standard

• Improper stock setting
• Improper setting of sampling stock.
• Interstand Mill Tension.
• More stock from feeder round
• More guide opening allowing material to flow
out of pass.
Rolling schedule of respective section.
• Ensure no tension in mill during set up and
grade change.
• Ensure proper loop formation.
• Check & ensure feeder round stock as per
standard rolling schedule.
• Guide opening should be kept as per standard
guide schedule.
 HIGH OVALITY
High Ovality / Out of Roundness: Deviation in dimension
along the circumference / periferi goes out of tolarance
then it is called as High Ovality / Out of roundness. It is
mainly caused due to roll cross.
Roll Cross: Deviation in center of top roll and bottom roll
grooves called as Roll Cross.

Sources of Defects Remedies

Roll cross is due to
• Check & ensure roll groove alignment during
• Roll gooved top/bottom not aligned with each set up.
other.
• Guide opening should be kept as per standard
• Material twisting due to more entry guide guide schedule.
opening.
• Check & ensure no twist from leader oval.
• Material twisting from leader oval
• Check & ensure feeder round stock as per
• Lower stock from feeder rounds generates standard rolling schedule.
twisting at finish pass
 CONVEXITY
Convexity: Thickness in center of Flat bars found more
than thickness on edges then it is called as convexity. All
flat bars should have concavity but convexity not allowed

Sources of Defects Remedies

Convexity generates whenever more
Minimise stock of feeder flat stand by
stock comes from feeder flat stand
adjusting roll gaps
before finishing edger
 FLUTTERING
Fluttering: Fluttering means overfill/underfill in side
dimension of bar at one place. overfill
underfill

Sources of Defects Remedies

• Adjust inter-stand tension/pushing

Fluttering caused mainly due to through R Factor at microlevel.
Hunting/ Vibration created due to
• Check actual vibration between VRM
inter-stand pushing and more feeder
stands by keeping small wire on bar.
round stock
• Minimize Feeder round stock
 PITTING
Pitting: Pitting means impression/dents on rolled bars
generated as scale rolled with material.

Sources of Defects Remedies

Pitting caused due to excessive scale
generation in Furnace. Reasons are
• excessive heating of material
• Over soaking - Long stay in Furnace
• Improper descaling
• Avoid Billet oversoaking and maintain
billet inside furnace as per discharge rate.
• Ensure descaler pressure 100-120 bar.
• Maintain oxygen level in furnace below 3
%.
 BURNING
Burning: Burning means cracks developed in rolled bar
due to excessive heating of material
Sources of Defects
Burning caused due to excessive
heating heating of material and
temperature not controlled properly in
case of long stay in furnace
Remedies
• Avoid excessive heating and higher
temperature rolling as per standard SOP
Heating & Rolling Parameters.
• Control Soaking Zone temperature in
case of long stay inside furnace as per
delay Management Programme.
 ROUGHNESS
Roughness: Net type impression on rolled prodct
generated due to pass wearout called as roughness

Sources of Defects Remedies

Roughness caused mainly due to
• Excessive Pass wear out.
• Over tonnage
• Higher Reduction.
• Improper roll cooling
• Pass changes should be done as per standard
pass life within norms.
• Reduction should be commonly distributed
within stands as per Rolling Schedule.
• Ensure proper roll cooling with sufficient
water flow
 FIRE CRACKS
Fire Cracks: Transverse impression crack type lines
generated on rolled prodct. Cracks generated on roll
pass shown in figure due to insufficient cooling.

Sources of Defects Remedies

Fire Cracks caused mainly due to • Reduction should be commonly distributed

• Higher Reduction. within stands as per Rolling Schedule.
• Improper roll cooling • Ensure proper roll cooling with sufficient
water flow
 PASS MARK
Pass Mark: Type of defect on rolled product generated
due to dent / projection on pass

Sources of Defects Remedies

Pass mark caused mainly due to
• Excessive Pass wear out.
• Chip off of pass
• step in pass.
• Pass changes should be done as per standard
pass life within norms.
• Reduction should be commonly distributed
within stands as per Rolling Schedule.
• Ensure proper front end behavior during
biting. Do not allow bend.
 RADIUS PROBLEM
Radius Problem: Type of defect on rolled product
generated due to wrong pass grooving. Edge radius not
within tolerance due to wrong or bigger size pass.
Radius not as per
tolerance

Sources of Defects Remedies

Radius problem caused mainly due to
• Wrong Pass dimension
• Small size rolled in Bigger pass
• Confirm & ensure with standard Rolling
Schedule, Roll card, groove no. prior to fix
pass in mill.
• Do not use bigger pass on smaller size.
• Strictly Standard rolling schedule to be
followed
 BEND
Bend: Type of defect on rolled product generated due to
uneven cooling rate. Most of the times bendness due to
distorshion properties of material chemistry.

Sources of Defects Remedies

Bend caused mainly due to
• Material charectericstics.
• Uneven cooling
• High cooling rate
• Fast tracking of bars on CB
• Check all bars on Cooling Bed, all should come
under canopy only to have uniform cooling.
• Check finishing temperature and if it is on
higher side try to lower down.
• Minimise furnace temperature to control
finishing temperature.
 WAVINESS
Waviness: Type of defect on rolled product which looks
like zigzag pattern / snaky bend.

Sources of Defects Remedies

Waviness caused mainly due to • Check interstand tension / pushing through

• Interstand pushing.
• More feeder stock
• Vibration of bars within VRM stands
Iba Analyser in VRM.
• Check and ensure feeder round stock and #21
stock as per standard rolling schedule.
• Minimise stock in mill by 0.2 mm/50 billets
rolled for smaller section rolling in VRM.
 TWIST
Twist: Type of defect on rolled product generated during
rolling as bar rotates along the length.
SEAM OF BAR
ROTATING CALLED
TWIST

Sources of Defects Remedies

Twist caused mainly due to
• Roll cross in finishing stands / Leader
stands. • Check & ensure roll cross in leader and
finishing pass.
• Uneven flow of material to finish stand
• Check & Ensure min. tension in mill.
• EG opened in running mill
• Check looper behaviour/loop formation
• Tension in mill
geometry.
• Abnormal Loop formation
 WATERMARK
Watermark: Water marks is the rusty or red colours
patched on coils due to oxidation generated on rolled
product.

Sources of Defects Remedies

Watermark caused mainly due to

• Higher rate of cooling water in GC line. • Check & ensure min. water flow in water box
• Uneven cooling rate. as well as GC conveying line.
• Moister flow with coils. • Ensure GC Blower should ON condition to
• Lesser equilising zone. avoid oxidation.
 BUBBLE
Bubble: Bubbles is the secondary scale formation on
rolled product .

Bubble

Sources of Defects Remedies

Bubble caused mainly due to

• Higher finishing Temperature.
• Uneven cooling rate.
• Lesser equilising zone.
• Check & ensure coil finishing temperature
840-860 Deg.C.
• Ensure GC Blower should ON condition to
avoid secondary scale generation.
 BURRS
Burrs: Burrs are projected portion of shearing ends.

Sources of Defects Remedies

Burrs caused mainly due to

• More clearence in shear blade .
• Improper separation during shearing due
to higher material temperature.
• Check & ensure Shear Blades clearence and
overlap as per standard.
• Avoid red hot material during cutting at CP4.
 SHEAR CRACK / BREAKAGE
Shear Crack / Breakage: Cracks formed at cross section
of sheared portion of bars. Bars some times used to get
break during shearing called as Breakage.

Shear Crack

Sources of Defects Remedies

Shear cracks / Breakages caused mainly
due to
• Bars cutting at lower temperatures.
• Breakages mainly occurs in hard • Hot cutting to be ensured.
material where carbon percentage is • Batch rolling to be carried out.
between 0.8 to 1.2 %
 BEND AT ENDS
Bend at ends: Bends generated at sheared ends during
cutting at cold shear.

Sources of Defects Remedies

Bend at ends caused mainly due to

• More clearence in shear blade .
• Check & ensure Shear Blades clearence and
• Improper separation during shearing due overlap as per standard.
to higher material temperature.
• Avoid red hot material during cutting at CP4.
• Two overlapped bars cutting at a time
• Avoid cutting two overlap bars at a time
 BULDGING
Bulging at ends: Bulging means spreading of material at
either side during shearing which goes beyond bar
tolerance.

Sources of Defects Remedies

Bulging at ends caused mainly due to

• Sections cutting in bigger size grooves . • Ensure section wise groove size in Shear
• Rounds cutting in flat blades Blades as per standard Procedure.
 BAD END
Bad ends: These defects happened at end of each billet
during rolling. These can not be avoided.

Sources of Defects Remedies

1. Inherently produced during hot rolling. • Ensure proper cutting at Cold inspection after
MPI.
 MINOR DEFECT INDICATION

Sources of Defects Remedies

• Check pass and pass life. If pass is rough and

Due to Rough pass
over used pass change it.