Essar Steel Heavy Plates

for Speciality Applications

Contents

3
Essar Group

5
Essar Steel

13
Plate Applications

Shipbuilding
Line Pipe
Yellow Goods
Boilers and Pressure Vessels
Defence
Wind Engineering
General Engineering / Fabrication
Construction

Heavy Plates
for Speciality
Applications

12
Salient Features
of Plate Products

32

International
Grades
Available

Essar Plate Mill

Process

34

36

Testing
Facilities

Contact Us

35
Ordering

Essar Group
The Essar group is a multi-national conglomerate and a leading global player
in the sectors of steel, energy, power, communications, BPO, shipping, ports
& logistics, and construction. With operations in more than 20 countries
across five continents, and over 60,000 employees, the groups annual
revenues are over USD 15 billion. Essar began as a construction company
in 1969 and has now diversified into manufacturing, services and retail.
Over the last decade, it has captured new markets and discovered new
sources for raw materials either through strategic global acquisitions and
partnerships or through greenfield and brownfield development projects.
It is also building a strong presence in sectors like mining & minerals.
Today, the group continues to expand its global footprint by focussing on the
Asian, American, African and European markets. Essar invests significantly
in forward and backward integration of its businesses, and on leveraging
synergies between businesses. It also focuses on in-house research,
innovation and on embracing the latest technology to remain a low-cost
manufacturer with high quality products and innovative customer offerings.
Along with its ambitious business pursuits, Essar has ensured that it also
delivers on its social responsibility. The group runs community outreach
initiatives in all its plant locations with a focus on education, healthcare,
environment, agricultural development, and self-employment.
The Essar group is widely regarded as a responsible and conscientious
global employer. It has experience in managing businesses in different
geographies with a culturally diverse workforce. This is why its people
practices are sensitive to cross-cultural nuances. The groups people
strategy is focussed on promoting a learning culture that continually
enhances the professional skills of its employees.

Essar Steel
Essar Steel is a global steel producer with a strong presence in intensive
steel consuming markets like Asia and North America. Its goal is to reach a
global production capacity of 20 25 million tonnes per annum (MTPA) by
augmenting its current capacity of 14 MTPA. Essar Steel is a fully-integrated
operation from mining to retail, with strong downstream capability and a
worldwide network of processing and distribution facilities, and distribution
outlets known as Hypermarts.
Global Operations
Essar Steel Algoma in Canada has a current capacity of 4 MTPA. Essar
Steel Minnesota USA (with iron ore reserves of over 1.4 billion tonnes) is
developing a 6 MTPA pellet plant, an ore concentration plant and a direct
reduced iron plant. In Indonesia, Essar Steel is the largest private steel
processor and operates a 400,000 tonnes per annum (TPA) cold rolling
complex with a galvanising line of 150,000 TPA.
Essar Steel is the largest steel producer in western India, with a capacity
of 10 MTPA at Hazira, Gujarat. The steel plant is backed by an iron ore
beneficiation and a pellet unit that ensures supply of quality raw material.
The Essar Steel complex at Hazira has a complete infrastructure setup
including a captive port, and power, lime and oxygen plants.
It has set up a 1.5 MTPA plate mill and a 0.6 MTPA pipe mill at Hazira to make
further value-additions to its product portfolio. Essar Steel has the countrys
largest steel processing capacity of 2.7 MTPA at its seven processing and
distribution facilities, located at key automotive and industrial hubs. In India,
it has the distinction of being one of the largest galvanisers, as well as being
the largest producer of cold rolled and colour coated products. Additionally,
it is setting up a 12 MTPA pellet plant in Paradip, Orissa.
Products and Services
Essar Steel produces highly-customised products catering to a variety
of product segments. It is Indias largest exporter of flat products to the
highly demanding US and European markets, and to the growing markets
of South East Asia and the Middle East. It invests in world-class research
& development and has technology collaborations with global steel
majors to develop enhanced value-added products and grades that find
wide acceptance in sectors like automotive, white goods, construction,
engineering and shipbuilding. With investments in downstream capabilities,
Essar Steel has evolved from being a product-based company to a valueadded service provider with an extensive product portfolio.

Heavy Plates
for Speciality
Applications
Widening horizons of the future
The demand for thicker, wider and ultra high strength steel plates has
been increasing due to rapid industrialisation across the world. Key
industry players across different segments in India, have concurred
that availability of thicker and wider width plates will result in enormous
savings on fabrication and welding, and also lead to an improvement in
yield, quality and durability.
Recognising the growing needs and potential of the plate market in India,
Essar Steel has recently commissioned a state-of-the-art plate mill at
Hazira. The 4 Hi Rolling mill has a roll separating force of 10,000 metric
tonnes and can produce plates with a width of up to 5 metres. Other facilities
include Normalising, Accelerated Cooling / Direct Quenching, Hot and Cold
Levelling and Quenching and Tempering.
Coupled with advanced steel-making facilities, the mill can produce plates
with extremely low sulphur content and tramp elements which guarantee
extremely high toughness values of up to -80C. The special feature of
Accelerated Direct Cooling (ADCO) enables designing of products for
specific wear resistance applications.
Essar plates are supported by the best manufacturing practices and testing
facilities including the Scanning Electron Microscope with EDAX, to ensure
clean steel with low inclusion. Essar plates conform to all international
standards including API, ASTM, EN, JIS and IS. They are also supplied in
customised grades as per client-specific requirements.
Plates undergo close process metallurgy and chemistry that is
customised to the specific requirements of different application segments.
The Essar Steel mill is capable of producing high strength and high
toughness plates that can cater to niche segments with an optimised
thickness-to-strength ratio resulting in weight reduction.
Essars quenched and tempered plates are designed to meet the demands
of strength, toughness and wear resistance for specialised applications
earth moving machinery, heavy earth movers, submarines, shipbuilding,
anti-ballistic plates and extremely low temperature storage tanks. The
normalised plates are produced using cutting-edge technology suitable for
critical use in nuclear reactors, hydrogen reactors, supercritical boilers and
high pressure vessels for oil and gas.
Each final plate has a unique identification mark that ensures proper
traceability right from the stage of heat making to the final product. The
port location of the plant gives Essar Steel a logistical advantage thereby
ensuring timely production and delivery of orders across the world.

Essar Plate Mill

World-class Processes, Ultra-modern Facilities

Digital Reheating Furnaces

With a capacity of 1.5 MTPA, the plate mill is equipped to

produce steel plates with widths of up to 5 metres. Superlative
toughness, excellent weldability and perfect flatness make
these plates comparable to the best in the world.

The digital furnaces are equipped with side burners having an

independent on / off control for each burner, thus helping to
reduce excess scale formation. The furnace is split into different
control zones for uniform heat transfer through homogeneous
heat elimination of hot spots.

Plate Capacity
Thickness

Up to 150 mm

Width

1,100 to 4,950 mm (in mill edge condition)

900 to 4,850 mm (in trimmed condition)

Length

3,000 to 25,000 mm

Rolling Mill
The reversible rolling mill along with cross rolling facilities has a
roll separating force of 10,000 tonnes. This force helps in highshape factor rolling and thus reduces the internal discontinuities.
The rolling mill is supported by high-speed automatic gauge control
for accurate dimensions, plan view rolling for proper crosssection and shape, profile and flatness gauge for ensuring
premium quality in plates.

State-of-the-art Technology, World-renowned Suppliers

Equipment

Supplier

Rolling mills, ADCO facilities,

roller tables, cooling beds, hot
and cold levellers, including
automation and control systems

Siemens VAI, France

Extensive heat treatment

facilities covering austenitising
and normalising, quenching and
tempering furnaces

LOI, Germany

Digital reheating furnace

Stein-Heurtey, France

Shot blasting and painting

Wheelabrator, Germany

Roll grinder

Waldrich, Germany

Thermo-Mechanical Controlled Rolling (TMCR) and

Accelerated Direct Cooling (ADCO)
TMCR and ADCO facilities help in producing high-tensile steel
grades with lower carbon equivalent and high toughness, good
formability and better weldability. ADCO ensures controlled
cooling with edge masking facilities for achieving uniform
properties along the cross-section. It also has the capability of
direct quenching for achieving high strength and high hardness
grades. This process is used for producing high-tensile steel
plates with high toughness and good weldability for all major
structural applications.

4 HI MILL

Plate Process Flow

RECEIVING
SLAB

PRIMARY
DESCALER

ADCO
COOLING

SLAB
YARD

DOUBLE SIDE
TRIM SHEAR

CROP SHEAR
FULL BODY UST

QC LAB

SLAB RE-HEAT
FURNACES

SLITTING
SHEAR

CHAIN TRANSFER &

TURNOVER DEVICE

DIVIDING
SHEAR

Hot Leveller

Heat Treatment

The hot leveller, with a capacity of 4,000 tonnes, provides

excellent flatness and residual stress-free plates. A plastification
ratio of up to 80% can be offered depending on the tensile
strength and thickness. The unit has automatic gauge control
and shape system to ensure a high level of flatness.

The mill is equipped with heat treatment facility with

austentising and normalising, and quenching and tempering
furnaces for acheiving the desired texture of steel plates. The
plates are shot blasted and an inert atmosphere is maintained
in the furnaces with indirect radiant type heating to ensure that
no scales are formed on the surface of the plate.

Shearing Units

Marking and Traceability

The shearing units in the mill can cut plates of up to 50 mm

thick. The mill is equipped with heavy duty shearing units like
crop shear for cutting the improper shapes of as-rolled plates,
double side trim shear for cutting improper shapes into wider
sections, slitting shear for trimming and dividing shear for length
and width trimming.

In addition to a hot paint marker, a plate marker & stamper

are provided to mark or stamp each final plate with a unique
identification mark. This ensures proper traceability right from
the stage of heat making to the final product.
Logistics

Ultrasonic Testing
The ultrasonic testing unit is an on-line test equipment for
automatic inspection and evaluation of the full body of the
plates. A hundred probes ensure accurate examination of all
flaws. As a result, on-line inspection of up to 50 mm covering
100% of the plate body and edges is done. Indications are
recorded and evaluated to ensure precise monitoring of the
internal quality of heavy plates cut in the shear lines.

Essar has a captive port which can accommodate vessels of

up to 60,000 DWT, enabling Essar to ship customer orders
directly without multiple handling.

THICK PLATE PROCESSING

HOT
PAINT
MARKER

HOT
LEVELLER

COOLING BED-1 > 50 MM

DISPATCH
FINISHED
PLATES

Cooling Bed-2 < 50 mm

STOCK &
SHIPPING
YARDS

PLATE
MARKER

CROSS
TRANS #2

PLATE PILER

CROSS
TRANS #3
CROSS
TRANS #4

HEAT TREATMENT
(NORMALISING AND Q&T)

COLD LEVELLER

SHOT BLASTING

PAINTING

10

Metallurgy of Plate Rolling

The Thermo-Mechanical Control Process (TMCP)

Shorter processing time as no heat treatment is required

Through TMCP, very fine and uniform ferrite microstructure

is obtained and results in higher strength and toughness.
The plate is also less susceptible to cold cracking and has
better weldability.

Normalising
The process of producing a stable microstructure by heating it
to the high temperature austenite and slowly cooling it.
Advantages

CONVENTIONAL
PROCESSING

THERMO-MECHANICAL
CONTROLLED PROCESSING (TMCP)

Refines and ensures homogenous structure

HEAT TREATMENT

HOT
ROLLING

Reduces residual stresses from rolling

ACCELERATED
ROLLING

Reduces the risk of "banding

QUENCHING & TEMPERING

SPRAY
WATER

AIR COOL

OOLED

AIR COO

C
WATER
AIR OR

OL

UENCH

AIR CO

OL

AIR CO

Q
WATER

TEMPERATURE,

NORMALISING

CONTROLLED
ROLLING

TEMPERATURE

Process for producing heavy plates

Quenching and Tempering

This is a conventional process used to harden or strengthen
steel. During the quenching step, the austenite is converted
to martensite. The quenched alloy is then tempered at an
intermediate temperature to transform the brittle martensite
into a very fine dispersion of cementite (iron carbide) phase in
an iron ferrite matrix.

AUSTENITE

PLATE ROLLING

STAGE I
POLYGONAL FERRITE
STAGE II
STAGE III

AI

AI

CO

OL

IN

AI

CO

OL

AI

CO

OL

IN

IN

TEMPERATURE,

DEFORMED ZONE

TEMPERING
QUENCHING

CO

OL

IN

FINELY DEFORMED
FERRITE

TIME
TIME

CONTROLLED-ROLLING

Concept of microstructure change during TMCP

Advantages

Quenching and Tempering process

Advantages
Increases hardness for better wear and abrasion resistance

Superior weldability due to lower carbon equivalent(Ceq)

Improves ductility and toughness

Better formability

Reduces cracking

Excellent mechanical properties (high strength and

toughness) attained through fine microstructure

Increases impact resistance

Salient Features of Essar Steel Heavy Plate

Clean Steel

Plate Characteristics

Essar plates are supported by state-of-the-art technology and

the best manufacturing practices to ensure clean steel (with
low inclusion) contents and low sulphur to avoid any hydrogeninduced cracking, fatigue failures, lower toughness, etc.

Better weldability even with higher strength plates

Good cold formability due to good homogeneity and micro structural cleanliness
Excellent hot forming characteristics due to normalising

Mechanical Properties
Mechanical properties of Essar plates conform to international
standards (ASTM, EN, JIS, and IS, etc.) and can be made to
any other mutually-agreed specifications.

Improved toughness for high heat input welding at a lower

temperature of -60C
Free of residual stress
High corrosion resistance due to micro addition of
special alloys
Superior abrasion and wear resistance due to micro addition
of special alloys and the quenching & tempering process
Shot blasted and painted for marine application

Unique Features
Facility

Product Quality

Edge masking for uniform cooling Consistent properties across the width and cross-section of the plate

12

ADCO cooling system

Superior hardness

Hot levelling (up to 100 mm)

Better flatness and residual-free plates

Cold levelling (for < 50 mm)

Acute dimensional accuracy, flatness and residual stress-free plates: minimal warpage

Shearing plate

Available for plates up to 50 mm

Shot blasting and painting

Biocompatible epoxy coating: both Sn and Pb based, suitable for marine application

Quenching and tempering

Ultra high strength and tough plates

Plan view rolling

Excellent shape and flatness

Plate Applications
Type

Application

Shipbuilding
Ultra high strength and tough steel plates

Merchant ships, cargo, bulk carriers, submarine hulls

Low-temperature applications

Line Pipe
High strength and ultra tough steel plates

Line pipes carrying different fluids, gases (including sour-gas)

Offshore structural application

Yellow Goods
Ultra high strength steel plates with superior toughness

Structures like
Truck body
Arm
Support structures

High abrasion and wear resistant steel plates

Shovels, quarries & mines equipment crushers, buffer bins,

buckets, dump trucks

Boilers and Pressure Vessels

High strength alloyed steel plates

Sub-critical to super-critical boilers applications

High strength steel plates

High pressure applications

Normalised steel plates

Low-temperature applications

Defence
High strength, hardness, toughness and anti-ballistics
steel plates

Armour tanks, mine protective vehicles

Ultra high strength and toughness, bulletproofs steel

Personal and vehicle protection

Special alloy steel plates

Naval warships, submarines

Wind Engineering
Higher width high strength steel plates

Conical sections of long wind towers

General Engineering / Fabrication

High strength steel plates with excellent weldability

General engineering / fabrication

Construction
Ultra high strength and tough steel plates

Dams, bridges, buildings, power plant structures, penstock

Atmospheric corrosion resistant steel plates

Offshore platforms, bridges

Seawater corrosion resistant steel plates

Bridges, offshore platforms, structures

13
9

Shipbuilding
Propelling the future
Applications

Challenges During Usage

Offshore structures

Plates for marine applications must endure adverse load

conditions like corrosion and large cyclical loads wave
loading, sea slap and slamming thermal excursions in tropical
and arctic seas, vibration and cargo buoyancy. Thus, steel
plates require high strength coupled with good low-temperature
toughness, through thickness properties, corrosion and fatigue
resistance, and tight dimensional tolerances. One of the most
important requirements is toughness in the base plate and in
the HAZ regions.

Bulk carriers
Tankers
Barges

Metallurgy
Composition / Treatment

Result

Proper alloy design having C, Mn, and other

micro-alloying elements

High strength and toughness

Addition of micro-alloying elements like Nb, V, and Ti

Improved strength and toughness

Clean steel, with very low S content

Avoid lamellar tearing

Addition of Cu and Cr

Improved all-weather resistance

Optimal carbon equivalent (Ceq) with low carbon

and micro-alloying elements

Good mechanical properties and good weldability

Normalisation of plates to remove secondary phases

Improved fatigue life and mechanical properties

Mechanical Properties
High strength
Good low-temperature toughness

Dimensions
Thickness

5 100 mm

Width

1,100 4,950 mm (mill edge)

900 4,850 (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per standard shipbuilding

norms

High corrosion resistance

Excellent high and low cycle fatigue properties
Excellent weldability due to lower carbon equivalent and
HAZ toughness
Supply conditions
As-rolled
Thermo-mechanically processed
Normalised rolling / Furnace normalised
Shot blasted and painted with biocompatible epoxy coating:
both Sn and Pb based, suitable for marine application

15

16

Line Pipe Steels

Fuelling the future
Applications

Challenges During Usage

Transport of oil, gas, water

Pipes are required to withstand very high hoop / circumferential

stress generated due to the transport elements. These are built
across different geographies, and thus would require good
corrosive resistance to Sulphide Stress Corrosion Cracking
(SSCC) and Hydrogen Induced Cracking (HIC), a high Ductile
to Brittle Transition Temperature (DBTT) and a good DropWeight Tear Test (DWTT) value.

Offshore structures

Metallurgy
Composition / Treatment

Result

Low C and very low S and P

High strength and toughness

Clean steel

Improved resistance to HIC and toughness

Addition of Micro-alloying elements like Nb, Ti, V

Reduced DBTT and increased DWTT

Addition of molybdenum in Nb containing steels

Improves the impact toughness and DWTT

Addition of Ni, Cr, and Cu

Improved corrosion resistance to HIC and SSCC

TMCR

Improved strength and toughness

Mechanical Properties

Dimensions

High strength

Thickness

From 5 50 mm for normal pipe

Good low-temperature toughness

Width

1,100 4,950 mm (mill edge)

900 4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per API standards

High corrosion resistance to HIC and SSCC

Good weldability

Supply Conditions
As rolled
Thermo-mechanically controlled
Furnace normalised

18

Yellow Goods and Mining Equipment

Excavating the future
Applications

Challenges During Usage

Mines and quarries

The plates used in yellow goods are subjected to land mines,

hard rocks, loading bulk material, shovels, crushing units, etc.

Agriculture machinery
Vehicle manufacturing
Cement works

The plates are therefore required to have high strength and

toughness and excellent abrasion and wear resistance.

Dump trucks
Front loaders
Crushers
Metallurgy
Composition / Treatment

Result

Low S, P and H

High toughness

Optimum alloy chemistry with C, Mn and other alloying elements

High strength and toughness

Alloying of special elements like Cr, Mo and Ni

Improved abrasion and wear resistance

Quenching and tempering

Desired mechanical properties

Mechanical Properties
High strength
High hardness

Dimensions
Thickness

5 150 mm (70 mm max for QT plates)

Width

1,100 4,950 mm (mill edge)

900 4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per relevant international standards

High abrasion and wear resistance

Good weldability

Supply Conditions
Thermo-mechanically controlled
Furnace normalised
Quenched and tempered
Shot blasted and painted

20

Boilers and Pressure Vessels

Powering the future
Applications

Properties Required During Service

Boilers:

Generally, steel plates are hot / cold formed to desired shape

for major boilers to withstand high temperature and pressure,
and adverse corrosive environments. Since the boilers and
pressure vessels carry high pressure and temperature fluids,
hold low-temperature fluids, the steel plates are required to
have high strength, toughness and ductility, and corrosion
resistance. Due to high temperature applications, the steel
plates should have excellent creep resistant properties.

Power plants
Process industries
Refineries
Coal gasifiers
Petrochemical exchangers
Pressure Vessels:
Process industries
Power plants
Nuclear power plants
Metallurgy
Plate Metallurgy - Composition / Treatment

Result

Clean steel with low S and P

Improved strength and toughness

Addition of micro-alloying elements like Nb, Ti, V

Improved strength and toughness

TMCR

High strength coupled with low-temperature toughness

Special alloying elements like Ni, Cr, Mo

Strength, hardenability and creep resistance

Furnace normalisation

Improved mechanical properties and fatigue resistance

Mechanical Properties
High strength

Dimensions
Thickness

5 150 mm (70 mm max in

furnace normalised condition)

Width

1,100 4,950 mm (mill edge)

900 4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per relevant international

standards

Good low-temperature toughness

High corrosion resistance, high resistance to HIC,
SSCC and embrittlement
High creep resistance

Supply Conditions
As-rolled
Thermo-mechanically controlled
Normalised rolled
Furnace normalised
Quenched and tempered
Shot blasted and painted

21

22

Defence

Protecting the future

Applications

Challenges During Usage

Armoured vehicles

The plates used for defence have to face battlefield

conditions like land mines, rockets, high momentum bullets
and other blast materials. They are therefore required to
have excellent toughness, high strength, high hardness and
good ballistic properties.

Mine protective vehicles

Protective buildings
Security vehicles
Metallurgy
Composition / Treatment

Result

Proper alloy design having micro-alloys such as Mo, Cr, Ni, B

and others

Desired toughness, strength, hardness and ballistic properties

Mechanical Properties
High strength, up to 1,500 MPa tensile strength
Good low-temperature toughness

Dimensions
Thickness

5 70 mm (QT plates)

Width

1,100 4,950 mm (mill edge) 900

4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per defence standards and

MIL specification

High corrosion resistance

Good weldability
NIJ Level-III for anti-ballistic properties
Supply Conditions
Thermo-mechanically controlled
Quenched and tempered
Shot blasted and painted

24

Wind Engineering
Harnessing the future
Application

Challenges During Usage

Conical sub-sections of wind towers

The plates used in wind engineering are subjected to high

wind, tower and buckling loads due to rotation of blades. The
plates are required to have high strength and toughness, good
weldability and formability.

Metallurgy
Composition / Treatment

Result

Clean steel with low S and P

Improved toughness

Optimal alloy design containing C, Mn, and other micro-alloying

elements like Nb, V and Ti

High strength and toughness

TMCR

Desired mechanical properties

Mechanical Properties

Dimensions

High strength, up to 690 MPa tensile strength

Thickness

5 70 mm

Good weldability

Width

1,100 4,950 mm (mill edge) 900

4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per relevant international

standards

Good corrosion resistance

Supply Conditions
As-rolled
Thermo-mechanically processed
Furnace normalised
Shot blasted and painted

26

General Engineering / Fabrication

Designing the future
Applications

Challenges During Usage

Equipment manufacturing

The plates are required to have high strength, toughness,

corrosion resistance and good weldability.

Forging and industrial fabrication

Kilns
Gates for hydro projects
Crane girders
Turbine runners
Metallurgy
Composition / Treatment

Result

Optimum alloy design and TMCR

High strength, high toughness and good corrosion resistance

Mechanical Properties

Dimensions

High strength

Thickness

5 150 mm

High toughness

Width

1,100 4,950 mm (mill edge)

900 4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per relevant international

standards

Good weldability
Good corrosion resistance

Supply Conditions
As-rolled
Thermo-mechanically controlled
Furnace Normalised
Shot blasted and painted

28

Construction
Building the future
Applications

Challenges During Usage

Civil structures

Plates used for this segment are pre-fabricated structures and

range from low strength to high strength depending on the
application. The plates must have good corrosion resistance,
toughness, weldability and dimensional tolerances.

Bridges
Dams
Highways
Power projects
Mega residential and commercial complexes
Telecom towers
Metallurgy
Composition / Treatment

Result

Optimum alloy design and TMCR

High strength and toughness

Low levels of S and P

Improved toughness

Furnace normalisation

Uniform mechanical properties

Mechanical Properties

Dimensions

High strength

Thickness

5 150 mm

High corrosion resistance

Width

1,100 4,950 mm (mill edge) and

900 4,850 mm (trimmed edge)

Length

3,000 25,000 mm

Dimensional
tolerances

As per relevant international

standards

Good weldability

Supply Conditions
As-rolled
Thermo-mechanically processed
Furnace normalised
Shot blasted and painted

30

Factory Welded Beams

Optimising Cost, Maximising Productivity
Applications

Key Benefits

Power projects

Shortens project time and maintains a clutterless project site

Bridges

Increases productivity due to zero rejection and zero scrap

Civil construction

Reduces capex, labour and working capital

Improves quality with tighter design tolerances and
weld strength
Eliminates pollution (no shot blasting, no painting,
no welding at site)

Facilities
High-quality steel from one of the largest plate mills in the world
at Hazira using the state-of-the-art Essar Steel processing and
distribution facility:

Plasma cutting under water

Web loading by magnetic tilting arms
Tandem arc welding

4-edge welding for better results

Shot blasting up to 250 Ra finish

Beam auto-straightening

Primer & final paint booth

Oxy-plasma profile cutting up to 60 mm

CNC drilling machine

Dimensions
Welded Beam Specifications
Web height

350 2,500 mm (flanges included)

Web thickness

10 40 mm

Flange width

250 1,000 mm

Flange thickness

8 63 mm

Max beam weight

1,500 kg / m

Beam length

6,000 18,000 mm

Conical beam

The difference in height between the two ends < 900 mm

Types of Beams
I / H beams

Wide flange beams

Non-symmetrical

L / Tapered beams Cross / Star

Custom-made, Ready-to-use Beams

Special beam shapes are available in an extensive range of
profiles, providing designers and construction engineers with
maximum flexibility in selecting the optimum structural steel
section for their specific application.

Asymmetrical C-shapes

Camber

T-shapes

Variable depth

Z-shapes
Symmetrical hybrid

Tapered

31

International Grades Available

Usage segment

Specifications
ASTM

Shipbuilding

JIS

KS

Others

ABS A, B, D,

NK

KR

NV, CR, BV, RINA, A, B, D,

AH32,

KA, KB, KD, KE,

RA, RB, RD, RE,

NV, RINA A27, D27, E27,

DH32,

Ka32, KD32,

RA32, RD32,

A32, D32, E32, A36, D36,

EH32,

KE32, KA36,

RE32, RA36,

E36, A40, D40, E40 CR, BV

Ah40

KD36, KE36,

RD36, RE36,

A, D, E32/36, A, D, E40,

KA40, KE40,

RA40, RD40,

KL24A,B, KL33, 37

KL24A, B,

RE40, RL24A,

LR Ah32, DH32, EH32,

Kl33, 37

B, Rl33, 37

AHS34, DHS34, Ah36,

DH36, EH36, Ah40 GL
A32, D32, E32, A36, D36, E36,
A40, D40, E40

Mechanical

A36(M)

JIS G 4051,

KS D 3752,

Structure

SAE1010

S10C~S58C,

SM10C~SM5

~SAE1060,

JIS G4105,

8C

SAE4150

SCM415~440

Boilers

A285 Gr A, B, C

JIS G 3103, SB410,

KS D 3560,

En10028

and Pressure

A515 GR 55, 60,

450, 480, SB450M,

SB 410, 450,

P265GH

Vessels

65, 70 A516

SGV410, 450, 480

480 KS D 3540

Gr 55, 60, 65, 70

JIS G 3115, SPV235,

SGV 420, 450, 480

A537 Class 1, 2

315, 355 SPV450, 490,

KS D 3521,

A387 Gr 11, 12

JIS G 3119, SBV 1A,

SPPV 235, 315,

SBV 1B, 2,

SPPV 450, 490

3 JIS G 4109,

KS D 3560

SCMV 1, 2, 3

SB 450M,SB 480M

Low-temperature

A662

JIS G 3126

KS

WDEhw 680

Pressure Vessels

Gr A, B, C

SLA235A, B

SLA235A, B

TTST41

A203

SLA325A, B

SLA325A, B

TTST45

Gr

SLA360

SLA360

BS1501-224

A, B, C, D, E, F

KS D 3586

KS D 3586

Gr 430A, B

A553-1

SL3N255,

SL3N255,

Gr 460A, B

SL3N275,

SL3N275,

SL3N440,

SL3N440,

SL9N590

SL3N590
SL9N590

32

Usage segment

Specifications
ASTM

JIS

KS

Line Pipes

Others
API 5L-A, B
X42, X46,
X52, X56,

X60, X65,
X70

Marine Structures

API-2H

Gr 42, 50
API-2W
Gr 42, 50, 60

Weathering &

A441

JIS G 3114

KS D 3529

Corrosion

A588

SMA400AW, AP

SMA41AW, AP

Resistant

Gr A, B, C, K

SMA400BW, BP

SMA41BW, BP

SMA400CW, CP

SMA41CW, CP

SMA490AW, AP

SMA50AW, AP

SMA490BW, BP

SMA50BW, BP

SMA490CW, CP

SMA50CW, CP

SMA570W,

SMA58W,

SMA570P

SMA58P

Structural

A283

JIS G 3101

KS D 3503

EN 10025

Applications

Gr A, B, C, D

SS330,

SS330,

S185

A36

SS400,

SS400, SS490

S235J2G3, 4

A572

SS490

KS D 3515

S275JR,

Gr 42, 50,

JIS G 3106

SM400A, B, C

J0, S355JO,

60, 65

SM400A, B, C

SM490A, B, C

J2G3, 4

A633

SM490A, B, C

SM490YA, YB

E295

Gr A, C, D, E

SM490 YA, YB

SM520 B, C

A678

SM570

SM570

A656

JIS G 3136

A514B, F

SN400A, B, C

A573

SN490B, C

Gr 58, 65, 70

33

Testing Facilities
Optical emission spectrometer
Scanning electron microscope with EDAX analyser
Universal testing machine with elevated temperature testing
with a capacity of 1,200 KN
Universal testing machine with a capacity of 2,000 KN
Cold bend tester with a capacity of 1,000 KN
Drop weight tear tester with a capacity of 80,000 J
Impact tester with a capacity of 450 J
Vicker hardness tester
Rockwell cum Brinell hardness tester
Metallurgical microscope with 1000 X Magnification
Typical microstructure of a normalised rolled plate

Marking
Paint marking
Mechanical stamping
Bar coding

34

Ordering
Attributes

Details to be specified

Remarks

Plate dimensions required:

thickness width length
out of squareness

Refer capability matrix

Other requirements in dimension

would be subject of Minimum Order Quantity
(MOQ) on an individual case basis (ICB)

Prescribed or
equivalent specification

In case specification required is different

please mention the equivalent specification

Plate marking

Marking will be on plate top surface.

Specify additional requirements if any

On mutually agreed terms

Trimmed / Untrimmed

In case flame cut requirements,

the tolerance would be subject to
mutual agreement

Applicable in case of plate sizes

above 50 mm thickness

As-Rolled / Normalised / QT

Specify relevant heat treatment

Supply conditions
Tolerance (close / skewed)

In case tolerance of required is closer than

the minimum mentioned, the same should
be mentioned against each attribute
and would be negotiable based on ICB
Skewed tolerances to be mentioned
clearly

On mutually agreed terms

Inspection by customer /
Third Party Inspection (TPI)

Kindly specify in case of inspection

requirement:
Inspection agency
Scope of inspection
Inspection required during rolling
or finishing or at both stages

Would be at an additional cost unless

man datory as per specification
The scope of inspection should be defined
at negotiation stage

TPI with Indian Boiler Regulation

(IBR) certification

In case normalising is not mandatory

but IBR certification required

For non boiler applications including

pressure vessels

Ultrasonic testing as per ASTM

ASTM A435
ASTM A578 Level A, B, C

As per ASTM A435 unless otherwise specified

(Other cases can be considered on mutually
agreed terms)

Impact proof certification

Please specify the temperature range

Z test

Sampling requirements if required

On mutually agreed terms

Flatness & waviness

As per ASTM A6. Any closer tolerance

would be be possible subject to
confirmation from our end.

On mutually agreed terms

Dual certification

Certification specifications

On mutually agreed terms

Copper extra

Percentage of Copper in LSA

On mutually agreed terms

Low sulphur

Sulphur restriction
0.005% Max

On mutually agreed terms

Inclusion rating

Rating

On mutually agreed terms

Shot blasting and painting

Supply conditions

On mutually agreed terms

Delivery

Lead time
Ship to
Sold to

On mutually agreed terms

35

Contact us
India Offices

India Offices

International Offices

Ahmedabad
Essar House,
Ellisbridge,
Ahmedabad - 380 006
Tel: +91 79 6608 6666

NCR
A-5, Sector-3,
Noida - 201 301
Tel: +91 120 6626 666

Indonesia
PT Essar Indonesia
BFI Estate, Inds 3 Kav B1,
Cibitung, Bekasi 17520,
West Java , Indonesia
Tel: +62 21 8980 152

Bengaluru
No. 2, 2nd Floor, RR Chambers,
11th Main, Vasanth Nagar,
Bengaluru - 560 052
Tel: +91 80 2220 2131
Chennai
Chennai House,
5th Floor, No. 7, Esplanade,
Chennai - 600 108
Tel: +91 44 2535 1271 / 73
Hyderabad
301, Sidhu Shree Vaishnavi Arcade,
Road No. 1, Banjara Hills,
Hyderabad - 500 034
Tel: +91 40 2337 0125 / 6677 0980
Indore
409, City Centre,
570 M.G. Road,
Indore - 452 001
Tel: +91 731 2538 825 / 2537 974
Kolkata
2nd Floor, Block: EP, Plot Y16,
Sector V, Saltlake City,
Kolkata - 700 091
Tel: +91 33 6612 6608

Essar House, 11 K. K. Marg,

Mahalaxmi, Mumbai - 400 034.
India
Tel: +91 22 6660 1100
Fax: +91 22 2353 2695

www.essarsteel.com

Mumbai
Essar Technopark,
# 2, L.B.S. Marg, Kurla (West),
Mumbai - 400 034
Tel: +91 22 6733 5000
Pune
408, City Tower,
17, Boat Club Road,
Pune - 411 001
Tel: +91 20 6620 9901 / 2
International Offices
Canada
Essar Steel Algoma Inc.
5515 North Service Road,
Burlington, Ontario,
L7L 6G4 , Canada
Tel: +1 905 331 3400
Dubai, U.A.E.
Emaar Business Park,
# 4, Sheikh Zayed Road,
P.O. Box 61078, Dubai, U.A.E.
Tel: +971 4364 9000 / 37

Give your business a

competitive edge.
Mail us at
plates@essar.com

Germany
Essar Steel Gmbh,
92 a, Konigsalee,
Dusseldorf 40489, Germany
Tel: +49 211 5403 9615
United Kingdom
Servo Steel
Pensnett Road, Dudley,
West Midlands DY1 2HA,
United Kingdom
Tel: +44 1384 471 371
Registered Office
27th KM, Surat Hazira Road,
Hazira - 394 270, India
Tel: +91 26 1668 2400
Corporate Office
Essar House,
11, K. K. Marg, Mahalaxmi,
Mumbai - 400 034, India
Tel: +91 22 6660 1100