FLEXIBLE UNIVERSAL ROLLING TECHNOLOGY OF H-BEAM

AND PRODUCT DEVELOPMENT

BY
TETSUYA OOMORI*

SYNOPSIS:

27 years ago, we started manufacturing NS Hyper Beam® at Wakayama Work (Sakai Area)
of Nippon Steel & Sumitomo Metal Corp. To achieve production of NS Hyper Beam, We
have established innovative technology, “Flexible universal rolling technology”

In the manufacture of conventional H-beam, inside web height and flange depth cannot be
controlled because of technical constraints. Therefore synchronous change of beam depth and
width with its thickness is inevitable in a same size series. We’ve broken through constraints
with flexible rolling technology.

This technology includes 3 innovatory technical elements.

1. The skewed rolling mill and the free size finishing mill for flexible rolling inside web
height.
2. The free size edging mill for flexible rolling flange depth.
3. The free size roller straightening machine that has variable barrel length rolls.

The development of this flexible rolling technology has enabled us to manufacture uniform
depth and width in a same size series. In addition, it has opened possibility of manufacturing
a multi-size series, using only one set of rolls.

We are manufacturing 611 sizes NS Hyper Beam® and other cross section which
corresponding JIS, ASTM and EN H-beams standards.

Furthermore, we have been producing Hyper Beam VE® (Value Ecology & Economy) series
NSYP®345B (+20MPa yield stress), and H-beam which improve low temperature properties
for onshore and offshore plant fields (CVN spec -40°C >27J).

Keywords: H-beam, Hyper Beam®, universal mill, edging roll, skewed rolling mill,
finishing mill, roller straightening, NSYP®345, low temperature properties

* Technical Staff of Large Shape Mill, Shape Div, Wakayama Works (Sakai Area), Nippon
Steel and Sumitomo Metal Corporation, Japan
1. Introduction

Nippon Steel and Sumitomo Metal Corp. (NSSMC) Sakai Large Shape Mill started its
operation in October 1961 as a first large section mill in Japan employing universal mills.
Since then, a series of equipment renewals and remodeling as well as constant technical
development and quality improvement, we have succeeded in producing extra-thick
H-beam in 1967 as well as a large variety of high quality products such as H-beam, Steel
Sheet pile, and Unequal-sided angle. We have also produced and marketed: structural
H-beam, NSHYPER BEAMTM, with incremental depth and width of 50mm pitch; and
other innovative products that span the history of construction in Japan. Working
together with end users, we have also endeavored to spread the use of steel structures in
building construction and promoted the use of structural H-beam as well as developed
key technologies in design, fabrication and construction fields.

In this paper, the name of each part of the H-beam is defined as shown in Fig.1

Flange thickness
Flange depth
Flange width

Web thickness
Center of
Web-flange corner outside flange
Inside web height
Outside web height
Fig.1 The name definition of H-beam section

1.1 Introduction of NSHYPER BEAM

In the field of H-beam, with use of the epoch-making process, we commenced in

November 1989 the manufacture and marketing of innovative H-beam NSHYPER
BEAM, externally constant H-beam.
NSHYPER BEAM has several user-friendly characteristics at its cross-section.

First of all, NSHYPER BEAM is rolled H-beam to be replaced Built-up H-beam. This
feature means advantages on saving labor force and fabrication term as well as higher
quality due to elimination of welding operations.

Second, as shown in Fig.2, NSHYPER BEAM has uniform-outer-dimension, different

from conventional H-beam shown in Fig.3, the uniform-outer-dimension has the same
outside web height and flange width within a same size-series, regardless of the flange
and web thickness.

Third, there are many choices of series and sizes with NSHYPER BEAM.
For example, the depth and width of NSHYPER BEAM increase depth and width by
50mm (app. 2 inch) pitch. Furthermore, wider size availabilities are realized, the number
of availability is 47 series and 611 sizes (Regular sizes: 42 series, 328sizes, Available
sizes: 5 series, 283 sizes).
 For these reason, NSHYPER BEAM can help structural design optimize for less steel
weight and better cost performance.

uniform different

uniform different
Fig. 2 Uniform-outer-dimension H-beam Fig. 3 Conventional H-beam

2. Production Process of NSHYPER BEAM

2.1 Conventional manufacturing process of H-beam

In the general, as shown in Fig.4, universal rolling method is adopted in the conventional
H-beam manufacturing process.

Fig. 4 Conventional manufacturing process of rolling H-beam

Technical constraint of conventional manufacturing process is that the inside

web height and the flange depth are varied in the same size series, Because of
the determination of roll-profile, such as the flange depth defined by depth of
the edging roll, the inside web height defined by barrel length of the
horizontal roll. As the result, the flange depth and the inside web height
cannot be changed with same roll profile in conventional process. In order to
breakthrough this technical constraint, horizontal rolls in universal mills and
edger rolls have to be exchanged according to a product dimensions.
Therefore, we had to prepare many variety of roll profile, and exchange roll
frequently to be decided according to dimension of Rolling H-beam. For these
reasons, productivity and manufacturing cost became worse.
2.2 Flexible universal rolling process

These constrains of conventional manufacturing process have been resolved by

introducing our new rolling technology. As shown in Fig.5, the new manufacturing
process of H-beam is composed new technology including four special equipments.

Variable depth of caliber Skewed rolling mill Free size finishing mill Free size roller straightener
Fig.5 New manufacturing process for NSHYPER BEAM

2.2.1 Free-size edging roll

Free size edging roll was developed for flexible flange-depth rolling.
The caliber depth of the conventional edging roll is constant, so the flange depth of the
H-beam is restricted by roll dimension. Whereas, the free size edging roll has variable
adjustment mechanism of caliber depth, to fit in the flange depth of rolling H-beam size
dimension. (Fig.6)
Conventional edging roll Free size edging roll

constant a A

Variable (a ⇔ A)
Fig. 6 Free size edging roll

Fig.7 shows the construction of a free-size edging roll having a variable edging calibre
depth. The free-size edging roll is composed with horizontal roll, eccentric ring,
web-restraining ring roll, and web-restraining ring roll positioning device.
In the free-size edging roll, flange-edge-rolling section is separated from the
web-restricting roll section, and the two sections are linked by an eccentric ring. By
turning the eccentric sleeve using the eccentric ring for positioning use installed outside
the horizontal roll, the distance between the flange-edging-rolling position and the web
restricting ring roll top position can be changed, thereby making the calibre depth
variable.
The advantage of using the free-size edging roll is that the calibre depth of an edging roll
is maintained close to the depth of the flange of a product in any pass in rolling, and
therefore products having improved web-center-off-ness can be manufactured as
compared to the case of using conventional edging rolls.

Fig. 7 Construction of free-size edging roll.

2.2.2 Skewed rolling mill

As methods for adjusting inside web height without changing rolls, technologies such as
partial inside web rolling, inside web stretching, and width direction web rolling have
been proposed. Nippon Steel and Sumitomo Metal have adopted the skewed roll type
rolling method, which is capable of efficiently adjusting inside web height in a wide
range with only one pass. The principle of this rolling method is shown in Fig.8, wherein
the centerlines of four rolls installed on in the left, right, top, bottom positions cross the
direction of rolling by an angle of a with a separation distance, L, between the left and
right roll. In this rolling mill, both edges of web which are rolled thicker than center
portion (additional thickness) provided in the foregoing stage are rolled in diagonal
direction, thereby expanding the inside web height. In this rolling, products with required
web height can be obtained by setting a and L to meet the required expanding condition
of the inside web height.

Fig. 8 Principle of skewed rolling

The deforming behavior of a material during the roll bite in skewed roll type rolling mill
is shown in Fig.9. Deforming behavior can be discussed in three separate stages. In the
first stage, on the entry side of rolling, although reduction is not applied to web thickness,
the roll side face contacts with the inner side of a flange and the whole of the web are
elongated in the width direction, and thereby, the inside web is expanded. In the second
stage, the web portion with additional thickness is rolled in the width direction and a
large increase in inside web height is provided. In the third stage, on the exit side,
although rolling reduction of the web is finished, the roll still remains contact with the
inner side of the flange and the whole of the web is stretched, and the expansion of the
inside web height is achieved. As mentioned above, an increase in the inside web height
in skewed roll type rolling method is brought about by stretching of the web and the flow
of an extra thickness portion in the web width direction.
The second area is the characteristic point in the skewed rolling mill method. In this area,
the shape collapses such as ditch at the center of the outside flange and necking at the
web-flange corner are prevented because reduction of δW helps metal flow toward
expanding the web thickness, and the radial rolling force can be decreased because δW is
reduced with stress toward expanding. Therefore, these advantages made it possible to
expand over 40mm without shape collapse.

Fig. 9 Deformation activities in the roll bite

2.2.3 Free-size finishing roll

In order to finish-roll by the finishing universal rolling mill after adjusting the inside web
height to a prescribed dimension by the skewed roll rolling mill, horizontal rolls of which
barrel length have to be adjusted within a short time on line are needed, and for the
purpose, the barrel length adjustable horizontal roll as shown in Fig.10 is used.
In the construction of the barrel length adjustable horizontal roll, a highly reliable roll
barrel length adjusting mechanism is completed with a highly rigid arbor mounted by roll
chocks and with a barrel length adjusting mechanism installed outside the work side roll
chock, thus maintaining the bending rigidity of the roll shaft.
 Fig. 10 Structure of free-size finishing roll

Rolls separated for barrel length adjustment are fitted to the arbor and an
intermediate sleeve respectively via interface-shrink. The intermediate sleeve
with an interface-shrink-fitted work side roll is fixed in the axial direction by
a thrust bearing built in the work side roll chock. On the other hand, the
arbor with shrink-fitted drive side roll runs through the inside of the
intermediate sleeve and is connected to the driving section of barrel-length
adjusting mechanism at its end. The work side roll is installed on a
double-structured roll shaft, and its rotational force is transmitted via a
spline. The barrel length is adjusted by changing the roll separation distance
between the left and right side rolls (inner and outer side rolls) with a screw
mechanism.

2.2.4 Free-size roller straightener

In order to straightening-roll by the multistage roll straightening machine after adjusting

the inside web height to a product dimension, horizontal rolls of which barrel length have
to be adjusted within a short time on line are needed. Furthermore, to straighten the
deformation of a product such as curvature on both up and down or left and right, angle
of flange and web, barrel length is adjusted each straightening roll independently. For the
purpose, the barrel length adjustable straightening roll as shown in Fig.11 is used.

Variable barrel length rolls

Fig. 11 Free size roller straightener

3. Current development of NSHYPER BEAM

3.1 Production technology and international size variation

Currently, as introduction of flexible universal rolling technology, constant outside-web

height H-beam of max 47 series, 611 sizes in the size range from 400 x 200 to 1000 x 400
is achievable. Furthermore, H-beam of various international standards is also produced
without changing rolls. Fig.12 shows corresponding standard and the shape, available
standards are not only JIS grade but also international standards such as ASTM, EN,
AS/NZS. For example, as shown in Fig.13, NSHYPER BEAM has comprehensive
size-series variation and cover European standards H-beam.

ASTM BS4 JIS G AS/NZS NSHYPER

A6 3192 3679.1 BEAM
ASTM A36 ✓ ✓ ✓ ✓
A572 Gr50 ✓ ✓ ✓ ✓
A992 ✓ ✓ ✓ ✓
JR ✓ ✓ ✓ ✓
S235 J0 ✓ ✓ ✓ ✓
J2 ✓ ✓ ✓ ✓
JR ✓ ✓ ✓ ✓
EN10025
S275 J0 ✓ ✓ ✓ ✓
-2
J2 ✓ ✓ ✓ ✓
Steel JR ✓ ✓ ✓ ✓
Grade S355 J0 ✓ ✓ ✓ ✓
J2 ✓ ✓ ✓ ✓
250 ✓ ✓
250L0 ✓ ✓
250L15 ✓ ✓
300 ✓ ✓
AS/ AS/NZS
300L0 ✓ ✓
NZS 3679.1
300L15 ✓ ✓
350 ✓ ✓
350L0 ✓ ✓
350L15 ✓ ✓
ASTM ASTM A6 ✓ ✓
Rolling EN EN10034 ✓ ✓ ✓
Tolerance JIS JIS G 3192 ✓ ✓ ✓
AS/NZS AS/NZS 3679.1 ✓ ✓ ✓
Fig. 12 List of corresponding to the standards and the shape
Flange width [mm]
200 250 300 350 400
400 IPE400 HE400
450 IPE450 UB457x191 HE450
Outside web height [mm]

500 IPE500 HE500

550 IPE550 UB533x210 HE550
600 IPE600 UB610x229 HE600 UB610x305
650 HE650
700 UB686x254 HE700
750 IPE750 UB762x267
800 HE800
850 UB838x292
900 HE900 UB914x305
950
1000 HE1000 UB1016x305 HL1000 UB1000x400

Fig. 13 Available H-beam series table

3.2 Size-series variation of NSHYPER BEAM

NSHYPER BEAM has a great deal of size variations as shown in Fig.14.

Availability
Regular Available
Series 42 5
Sizes 328 283

Fig. 14 Size variation of NSHYPER BEAM

Following are the advantages of size-series of NSHYPER BEAM toward European

H-beam from the analysis point of sizes, section properties and structural performance.
First, Fig.15 shows comparison of size-series structure between NSHYPER BEAM and
European H-beam, the vertical axis shows web height and the horizontal axis shows
flange width. NSHYPER BEAM has 274 regular sizes and 284 available sizes, European
H-beam has 103 PA common sizes, 58 PA uncommon sizes. This comparison shows that
users can choose optimum size for structural design.
Second, Fig.16 shows that plastic modulus as section properties analysis within a range
of outside web height up to 700mm. In the case of choice of H-beam having 11,000cm3
plastic modulus, Available web height of size-series is between 700mm to 1,000mm. The
benefit of the users is that NSHYPER BEAM provides more “economical” and
“intermediate” H-beam size alternative.
Finally, Fig.17 shows that buckling resistance moment as structural performance analysis.
In the offshore plant fields, a offshore structure has to be designed in consideration of a
twist of H-beam, therefore H-beam having wider flange width has advantage for
structure design. For example, shown in Fig.23, HE1000 x 249 (H 980 x 300 x 17x 26)
can be replaced to HY700 x 350 x 12 x 25, because it has the same strength, and 19.3%
steel amount can be reduced. From the above, NSHYPER BEAM provides more
economical H-beam size by utilizing its wider flanges of 350mm and 400mm.
 Fig. 15 Size structure analysis

HY700
HY750
HY800

HY850
HY900
HY950
HY1000

Fig. 16 Section properties analysis (Plastic modulus)

Fig. 17 Section profile analysis (Buckling )

 3.2 High strengthening NSHYPER BEAM

In recent years, the demand of high strengthening H-beam for structure have been
increased, whereby we launched NSHYPER BEAM VE® (Value Ecology &
Economy) series, NSYP®345B, which has 345MPa yield strength more
20MPa than SN490B. As shown in Fig.18, NSYP345B series has same
chemical composition and mechanical properties as SN490B except for the
upper and lower limit value of yield stress.
Chemical composition
Steel grade C [%] Si [%] Mn [%] P [%] S [%] Ceq [%] P CM [%]
NSYP345B
≤0.18 ≤0.55 ≤1.60 ≤0.030 ≤0.015 ≤0.44 ≤0.29
SN490B
Mechanical properties
Tensile property Impact property
Steel grade Thickness Yield Point Tensile strength Yield Ratio stretch temparature Charpy value
[N/mm2] [N/mm ] 2
[%] test piece [%] [̊C] [J]
NSYP345B 12≤t≤16 345 ～ 465 JIS grade 17≤
490～610 ≤80 0 27≤
SN490B 16<t≤40 325～445 No.1A 21≤

Fig. 18 Chemical composition and mechanical properties table

NSYP345B, uniform-outer-dimension H-beam, has more 20 N/mm2 design strength ,F,

than JIS grade SN490B.Design strength is defined as “the smaller of yield stress and
70% of tensile strength”, and in the case of standard steel, design strength is the
equivalent of yield stress. In the design of steel structure, structural design strength is
obtained by dividing design strength by safety factor, therefore NSYP345B increase
design strength, F, to 345 N/mm2 (more 20 N/mm2), and permitted to use 1.1 safety
factor. From the above, the steel amount using for construction can be reduced by
using NSYP345B.

3.1 NSHYPER BEAM with weldable structural steels for fixed offshore structures

The abundance of available size-series helps structure design optimize, that’s the reason
why NSHYPER BEAM was developed as replacement Built-up H-beam for Rolled
H-beam. Furthermore, we launched NSHYPER BEAM with EN10225-S355G11+M:
weldable structural steels for fixed offshore structures, which having size-series
advantage as well as low-temperature characteristics, fully complying with steel grade
and other specification based on PTS (Petronas Technical Specification). Fig.19 shows
chemical composition and Fig.20 shows mechanical properties for sections, stipulated by
EN10225-S355G11+M.
Chemical composition
Steel grade C [%] Si [%] Mn [%] P [%] S [%] Cr [%] Mo [%] Ni [%] Al(total)b
≤0.14 ≤0.55 ≤1.65 ≤0.025 ≤0.015 ≤0.25 ≤0.08 ≤0.50 0.015 to 0.055
S355G11+M Cu [%] N [%] Nb [%] Ti [%] V [%] Cr+Mo+Ni+Cu [%] Nb+V [%] Nb+V+Ti [%]
≤0.30 ≤0.012 ≤0.040 ≤0.025 ≤0.060 ≤0.80 ≤0.06 ≤0.08

Fig. 19 Chemical composition for sections

 Tensile strength Minimum yield strength RB Minimum on Minimum average CVN
Rm for thickness elongation A impact energy
t≤16 16<t≤40 RB/Rm gauge length Temp Energy
Steel grade
[N/mm2] [N/mm2] [N/mm2] maximum ratio [%] [˚C] [J]
S355G11+M 460 to 620 355 345 0.87 22 -40̊C 50

Fig. 20 Mechanical properties for sections

Fig.21 shows that adaptable CVN (Crack V-Notch test) specification manufacturing in
Wakayama Works (Sakai Area), Nippon Steel and Sumitomo Metal.

Availability: H400x200≤, H300x300≤

Test condition of CVN
○: OK △: Conditional ×: NG
Site of Test Material CE P CM Nominal thickness [mm]
test piece Temparature Grade [%] [%] Ft≤25 25<Ft≤40 40<
A992
Longitudinal 0̊C ○ ○ △
A572-G50
(Location : -20̊C EN S355 ≤0.43 ≤0.25 ○ ○ △
1/6F) SN490B
-40̊C SN490YB △ △ ×
Fig. 21 Available CVN spec table

There are 3 important advantages of NSHYPER BEAM with EN10225 -S355G11+M.

First, by using NSHYPER BEAM, shortening fabrication term is capable, such as
eliminating welding and inspection process, free from critical path on Built-H-beam.
Currently, the number of case, which modular construction method for offshore
construction is adopted, has been increasing in high advanced nations having expensive
labor cost, or polar regions and danger area being not able to maintain workforce. At the
case, Built-up H-beam is conventionally adopted, because large section to bear the load
of acceleration of marine and land transportation, and uniform-outer-dimension H-beam
having flexibility for frequent changing of structural design , is needed. NSHYPER
BEAM with low temperature properties has capability for shorter lead time and equal
properties compared with Built-up H-beam.
Second, quality improvement can be achievable without welding process (Fig.22), free
from heat damages and fatigue problems by welding. In a certain project, some problem
happened by using Built-H, such as welding quality: poor penetration, measurements
inconsistency. By using NSHYPER BEAM, these problems can be avoided.
Finally, welding cost on steel work can be reduced without Built-H-beam process.

Submerged Arc Welding Wire Top Flange

Welding Machine

Plate Girder

Bottom Flange

Fig. 22 Schematic of BH Welding process

4. Summary

We developed the manufacturing process that has realized the highly efficient production
of H-beam. In the intermediate rolling mill group, the material is rolled and finished to
the desired thickness, and further, by the use of free-size edging rolls installed in the
edging mill, the flange width of various sizes can be freely rolled
At the final stage of the process, the adjustment of the web height is achieved by the
skewed roll mill, and by using the barrel-length adjustable roll which is installed in the
finishing rolling mill. Furthermore, by using free-size roller straightener, H-beam can be
straightened on line without barrel-length changing.
By using these technologies, the highly efficient production of H-beam with constant
outside web height and flange width, as desired by customers, has become possible.
Currently, constant outside-web-height H-beam of max 47 series, 611 sizes in the size
range from 400 x 200 to 1000 x 400 is achievable. Furthermore, H-beam of various
international standards can be also produced without changing rolls.
By utilizing of abundant size-series structure of NSHYPER BEAM, we launched
advanced steel grade, and provided solution. As high strengthening H-beam for structure,
we launched NSHYPER BEAM VE® (Value Ecology & Economy) series,
NSYP®345B, which has 345MPa yield strength more 20MPa than SN490B.
Furthermore, we launched NSHYPER BEAM with EN10225-S355G11+M grade for
onshore and offshore plant fields, which having size-series advantage as well as
low-temperature characteristics.
The abundance of available size-series and development of various steel grade helps
structure design optimize.

Finally, one of our advantages for users in South East Asia, our geographical advantage
can help shortening lead time. As shown in Fig.23, Sakai Large Shape Mill is closer to
owners, EPC contractors, engineers and module fabricators in South East Asia. In general
case, compare with NSSMC and European mill, lead time from NSSMC of rolled
H-beam is shorter than from European mill, disparity in transport period of about 1
month. This our geographical advantages contribute shortening lead time to help “Fast
Track Projects”.

EUROPIAN
Shape AMERICAN
Shape
ASIAN
Shape

Extended
JIS Profile

W-Beam

UB, UC, HE, IPE

Fig. 23 Geographical advantage of NSSMC

References

1) Inagaki, A. et al.: Shinnittetsugiho. (343), (1992)

2) Saiki, E. et al : Shinnittetsusumikingiho. (401), (2015)
3) Matsuda, K.: South East Asia Iron and Steel Institute Report. 2012