Steel Mill Segment Assembly and Fabrication for Continuous Casting, Plate Mills, Hot Strips, and Melt Shops
Electric Arc Furnace Gantry | Beam Blank Segment | Electromagnetic Ruler Braking Molds | Bearing Chock Assemblies | Down Coiler and Automation Design Engineering and Fabrication
We specialize fabricating steel mill equipment modules and assembled segment parts used in melt shops, continuous casting lines, hot strip lines, plate mills and section mills. Known as the market leader of beam blank segment technology in South Korea, we boast not only fabrication, but also engineering and design capabilities for gantry systems for electric arc furnaces, copper molds and oscillators, and down coiler lines for hot strip mills.
Our manufacturing-to-print portfolio includes new and retrofit projects for global engineering firms such as Fives ST, SMS Group, Danieli, Primetals and SPCOSG. Our quality is the backbone of our over 35-year history working with steel mill clients in Asia. Our notable Asia-based clients include POSCO, Nippon Steel, Hyundai Steel, Dongkuk Steel and Dongbu Steel.
Located just 1.5h from Busan Port, one of the most productive ports in the world, our manufacturing plants are equipped with a large sized planer, CNC machining centers, and several cranes capable of handling up to 50 tons, each.
Steel Melt Shop, Continuous Casting Line and Plate Mill Equipment Component Segment and Assembly Fabrication
Since our main manufacturing facilities opened in 1987, we have transitioned from being a domestic segment and assembly manufacturer for South Korea’s steel industry to being an engineering and manufacturing partner for major global steel mill projects. Throughout this period, we have maintained our expertise and consistent quality in fabrication and assemblies of equipment components for continuous casting lines, hot rolling and cold rolling mills, including plate rolling, strip rolling and section rolling mills, cooling and leveling mills.
A significant portion of our business is dedicated to repairs, refurbishments and upgrades of existing equipment and lines in iron and steel mills operating in Asia.
Continuous Casting Line Equipment Component Fabrication Projects
We serve two main types of clients: steel mills and engineering & design companies. For steel mills, we provide fabrication, as well as design and engineering services for mold oscillators, beam blank segment, electromagnetic ruler braking mold and EMBr oscillator for continuous casting lines. In turn, this benefits our engineering and design clients, who find added value in our engineering expertise when we work as their manufacturing partner.
We fabricate and manufacture-to-print new and refurbished products for continuous casting equipment that produce carbon steel and stainless steel billets, blooms and slabs of various thicknesses and widths:
- Discharge Roller Tables
- Beam Blank Segment (400cm x 520cm x 140cm)
- Pinch Roll Assembly
- Apron Assembly
- Withdrawal & Straightening Equipment
- Slab Segment
- Slab Dummy Bar
- Electromagnetic Ruler Braking Mold
- EMBr Oscillator
- Mold & Oscillator Design and Fabrication
Heavy Plate Rolling Mill Component Fabrication
We fabricate plate mill segment frames, heavy plate mill bloom turners and assemblies for roller feeders, and roller tables for plate mills. Our hot leveler cassette assemblies minimize downtime for tool changes.
Our projects for heavy plant rolling mills include 120-ton car assembly, table gear box, plate roller table, roll coupling and chock, turn table roller, slab cutting roller table, hot leveler cassette assembly, and feed roller assembly.
Hot Strip Mill Equipment Component Fabrication
We manufacture finishing mill online roll profiler frame assemblies and side frame assemblies for hot strip mills producing flat steel strips. Finisher scale breaker frame assemblies and work roll changing device assemblies are two of our main strengths, as well. Our fabrication project portfolio includes roughing stands, transfer tables, finishing stands, cooling sections and down coilers.
We design, engineer, manufacture and automate entire down coiler lines for our large mill clients.
Mill Stand Technology Reduces Roll Surface Defects
Our capacity to develop roll grinding apparatus inside the mill stand offers the unique advantages of extending roll life, reducing vibrations, and minimizing surface defects of the roll.
Scale Breaker Technology for Roughing and Finishing Section Mills
Our scale breaker is designed to descale water pressure and roller force to help achieve consistent surface finish with minimum scaling for roughing and finishing mills.
Section Mill Equipment Component Fabrication
Our portfolio for section mills includes roughing and finishing trains, V-chock assembly, descale roller assembly, bar mill cross traverser, exit car, tilting roller table, and cooling bed turner.
Electric Arc Furnace Fabrication and Assembly Projects
We are a global leader in fabricating parts for electric arc furnaces for mini melting mills. Our recent projects include parts for furnaces with capacities of 80 tons – 150 tons and with annual tonnages exceeding 1,000,000 metric tonnes. We manufacture upper and lower furnace shells, furnace gantry systems, rockers, rocker rail, tilt cylinder & tilting platform and laminated hooks of up to 120 tons.
Amongst our EAF components we boast our design and engineering capabilities for gantry systems of up to 80-ton capacities, which sets us apart from our competitors, who only offer fabrication services.
With successful projects for large- to mini-mills in Korea, Japan, Thailand, and China, we are an ideal partner for your large-sized fabrication, refurbishing, and assembly needs.
Steel Manufacturing Mill Project Experiences
Our clientele consists of major iron and steel strip, billet, plates, and casting producers, as well as Tier 1 turnkey steel mill producers that outsource the production and refurbishment of their equipment and components. Our long-term clients include POSCO E&C, Hyundai Steel and Hyundai Rotem, Nippon Steel, and more. Please see a list of our steel mill project references in the PDF below.
If you are looking for rolls for rolling mills, plate mills or any other segments, our consortium’s roll manufacturer offers a comprehensive range of rolls including furnace rolls, pinch rolls, bridle rolls and guide rolls. Please visit our Steel Rolls page to learn about our rolls.
For coil processing lines, including cut-to-length and slitting lines, please visit our Cut-to-Length and Slitting Lines page to learn how we can minimize knife-changing downtime with our robotic slitter line.
For custom AGCs, push-up cylinders, and mold oscillating cylinders, our Custom Hydraulic Cylinders page provides detailed specifications and engineering examples for your cylinder needs.
Mold & Oscillator for Continuous Casting
A project for fabrication of Mold and Oscillator, that was originally designed by SMS, was carried out at POSCO’s Pohang Iron & Steel in Gwangyang, Korea. The 10 months long project involved remodeling and fabrication of the mold and oscillator to accommodate ABB’s agitator with electromagnetic ruler braking (EMBR) technology for thin slab casting. The joint development efforts between LPR, ABB and POSCO delivered a highly cost-effective mold and oscillation solution with increased mold life, high homogeneity of cast steel, improved cast speed, and superior steel cleanliness.
EMBr Technology in Continuous Casting
When casting steel slabs, EMBr is an effective way to generate a laminar flow of molten metal within the mold. This laminar flow reduces several surface defects, including due to meniscus freezing, slag entrainment and other intermittent defects. EMBr assists in controlling flow by applying static or moving electromagnetic forces through the core of the strand. The electromagnetic field controls the flow by generating induction current in the strand which in turn generates force or “brakes” opposite to the original flow of the melt. EMBr also effectively doubles the life of the mold due to its ability to streamline the flow of the melt.
Weighing approximately 28tons, a set of 4 mold frames were redesigned in collaboration with POSCO and manufactured to accommodate the ABB EMBr flow control system. The project was undertaken by POSCO, with POSCO E&C being the co-designer and POSCO ICT the system designer, and LPR providing the comprehensive fabrication services.
Fabrication of mold is a challenging task, with numerous inbuild cooling channels and the need to handle excessive loads within its constrained dimensions. The cooling system within the mold needs to be designed such that almost 40% of the total superheat and 30% of the sensible heat is removed from the strands through the molds. To achieve this, sophisticated materials in combination with precision welding was used. Additionally, thorough post fabrication testing was conducted, including high pressure water pressure testing at 12 bars, before the molds are cleared for delivery.
LPR having extensive experience in fabrication of complex equipment, such as molds and oscillators for casting lines, takes pride in their state of the art facility, exceptionally skilled workforce, and testing facility. LPR completed the fabrication in time, budget and quality to meet our client’s performance expectations.