Bar and Wire Rod Mills

Solutions made by SMS group

 Bar and Wire Rod Mills by SMS group
State-of-the-art and one step ahead, we are your partner

Your expectations Our solutions

Planning and building a new production plant or
revamping existing facilities requires a broad range of
knowledge, experience and reliable expertise.
SMS group offers you complete tailor-made bar and
wire rod mill solutions that include everything you
want: best technological solutions, comprehensive
support, integration in existing mills, logistics, and
sub-systems - all with cutting-edge technology.
We offer you tailor-made bar and wire rod mills, cover-
ing your expectations. Included in our full spectrum of
services are highly skilled project management, con-
figuration of project scope, basic and detail engineer-
ing, procurement and manufacturing, transportation
to site, comissioning and site management, construc-
tion, and/or installation services. All services in one
hand minimize interface drawbacks. We are with you
all the way.

We rise to the challenge by combining our leading

metallurgical technology more rapidly, flexibly, and
efficiently with our know-how in the construction of
bar and wire rod mills. „All under one roof“ is our mis-
sion statement to create the synergies that produce
innovative solutions for you. That is expertise from
one source for even better performance.

A sound basis for success given that demands world-

wide are changing and growing fast – along with your
expectations.

2
Wire rod mills 6
High speed wire rod mills 8
Wire rod mill for quality steel 10
Wire rod mill for high precision 12
Bar mills for quality and special steel 14
SBQ bar mill for straight bars and coils 16
Combined bar and wire rod mill for total range of steel grades 18
Rebar and merchant bar mills 20
Single-strand high speed bar mill 22
Slit rolling bar mill 24
Combined bar mill with vertical compact coiler VCC® 26
Merchant bar mill 28
Section mill for medium-light profiles 30

3
 Your benefits
You can rely on our overall responsibility for planning
and execution because we offer you a high degree of
know-how, flexibility, and an excellent track record.
As a turnkey contractor or leading partner in consor-
tia, SMS group draws on long experience in imple-
menting small and large bar and wire rod projects for
the industries.

Our in-house technologies and the engineering

expertise are state-of-the-art. Wherever your project
is based, you benefit from our worldwide network. It
includes strategic partnerships covering the whole
range of mill solutions for bar and wire rod mills, as
well as electric and automation and package unit.

The benefits for you are that SMS group works with
engineering companies, representatives, and local
partners all over the globe. They strengthen our posi-
tion in handling all aspects of your project

4
5
 Wire rod mills
Economic success with sophisticated solutions

PQA® - Product
Know-how transfer

Control and
Integrated solutions

Starting material Heating Rolling

n Billets/blooms of various material Heating and reheating furnaces nH  L stands
grades n Pusher-type furnaces nC  L stands
n Walking beam furnaces nH  igh-speed wire rod blocks
n Walking hearth furnaces n MEERdrive® technology

Life cycle

6
 Wire rod is a great all-rounder: from high-quality com-
ponents for the automotive sector, chemical industry
and mechanical engineering through to fasteners — it
is all based on wire rod. Accordingly, the solutions
SMS group offers for wire rod mills are just as versa-
tile: all sizes, materials and alloys can be efficiently
produced on the wire rod mills.
Complete wire rod mills, where all components are
perfectly matched — this is the success formula for
enhanced competitiveness. This guarantees that
technology, automation and the individual processes
work in perfect harmony. The result is top quality, high
productivity, lower capital and operational costs. SMS
group designs wire rod mills in close cooperation with
the plant owners based on the relevant requirements.
Regardless of which demanding grades are rolled
— the wire rod experts offer the precise technology
package to maximize the benefit to the customer. And
always with an eye on the overall process. Temper-
ature-controlled rolling and heat treatment in the
rolling line enable precise adjustment of the desired
properties.
The process control systems and process models
from SMS group help plant owners optimize their
processes, quality and productivity. Together with
transport systems, the advanced user-friendly control
system ensures a high capacity utilization of the
plants and makes it easy for the operators to find the
ideal settings. The SMS group service technicians
support the plant owners in exploiting the full poten-
tial of the systems.

quality analyzer by MET/Con

and production assistance

automation
- intelligently networked

Cooling and inline heat treatment Finishing Products

n Waterboxes – shiftable
n Loop technology: flexible cooling
and equalizing zone
n Thermomechanical rolling tech-
nology
n High-speed laying heads Wire rod with diameters between
n Loop cooling conveyor LCC® 4.5 and 27 mm in various material
n Three fan technology for LCC® grades
n Coil handling systems
n Coil compactors
n Tying systems

partnership

7
 High speed wire rod mills
High speed mills for high production

1- or 2-strand high speed wire rod mills from SMS
group roll small sizes with high production capacities
up to over 1,000,000 tons per year. Speeds up to
120 m/s are possible and enable high productions
also for small finishing diameters. Even at full speed,
the mills achieve a very good laying pattern.
The layout mainly consists of:
n Reheating furnace
n Roughing mill, with stands of housingless design, in
alternating horizontal-vertical (H-V) arrangement,
with the possibility of quick-changing device
n Intermediate mill, with stands of housingless de-
sign, in alternating horizontal-vertical (H-V) arrange-
ment, with the possibility of quick-changing device
n Pre-finishing stands of cantilever design
n Finishing block with group drive or MEERdrive®
design
n L aying head
n L oop cooling conveyor (LCC®)
n Coil handling system with coil compactor

10
12
11

1 Furnace
 5 4
 CL-stands in H/V
2 Roughing mill arrangement

3 Isolated free run out
6 2
 water boxes with

equalizing line
4 Intermediate
 mill
7 10
 stand high speed
wire rod block
8
 Loop laying head
Maintenance-friendly and flexible
The modern loop laying heads from SMS group reliably lay
uniform wire rod loops even at high speeds and irrespective
of the wire rod diameter. The difference compared with con-
ventional systems: SMS group loop laying heads easily handle
widely differing steel grades — even those that are rolled at low
temperatures in order to improve the metallurgical properties.
Depending on the application laying angles of 10°, 20° or 30°
are possible. The maintenance is quick, wear parts such as
the laying pipes can be replaced in a minimum of time. That
improves the profitability of the plant as a whole.

The next step – moveable

laying heads
n Changing between laying heads (increasing of
operating time)
n Changing between several laying pipe geometries
(form, diameter, material => e.g. between small to
medium/large dimensions)
n Possibility of offline-implementation of varying
laying angles
n Stabilization of laying pattern
n Reducing of downtime

7 5 1
4 3 2

8 6

8 Water
 boxes with 11 Coil
 handling system
equalizing line 12 Horizontal coil

9 Pinch
 roll unit, compactor
laying head
10 Loop
 cooling conveyor
(LCC®)
9
 Wire rod mill for quality steel
Thermomechanical rolling of the complete size range

The thermomechanical rolling of wire rod with small
dimensions at high production rates is not possible
with a conventional 10-stand finishing block. Due to
the number of passes required, heating is too high to
achieve the required metallurgical properties. Splitting
the wire rod block into a 6-stand and a 4-stand unit
allows wire rod of any dimensions to be finish-rolled in
a maximum of four passes. With sufficient cooling and
good temperature equalization over the cross-section,
thermomechanical rolling at high production rates is
also possible.
The layout mainly consists of:
n Reheating furnace
n Roughing mill, with stands of housingless design, in
alternating horizontal-vertical (H-V) arrangement
n Intermediate mill, with stands of housingless de-
sign, in alternating horizontal-vertical (H-V) arrange-
ment, with the possibility of quick-changing device
n Pre-finishing stands of cantilever design
n Cooling and equalizing line
n 6 -stand finishing block with group drive or
MEERdrive® design
n Cooling and equalizing line
n 4 -stand finishing block with group drive or
MEERdrive® design
n Laying head
n Loop cooling conveyor (LCC®)
n Coil handling system with coil compactor

10 9 8
11

12

1 Furnace 5 Cooling and equalizing

2 Roughing mill loop

3 Intermediate mill
6 6-stand
 wire rod block

4
7 Water
 boxes with
4  CL-stands in H/V
equalizing line

10
 Loop technology
The best way to optimum quality Multiline Loop then enables the wire rod block to be
With the loop technology from SMS group, wire rod changed over ready for the next size while production
producers can set the desired metallurgical proper- is still running. Nevertheless, wire rod producers can
ties of their products flexibly, precisely and reliably choose freely between hot and cold rolling.
– for any steel grade and any diameter. No matter
whether the material used has to be rolled at a high
Thermomechanical rolling
or low temperature, the variable equalizing sections
and cooling systems ensure that the steel is always at
the optimum rolling temperature.

For finish-rolling at low temperatures in wire rod mills,

the material entering the wire rod block is intensively
cooled. This is then followed by a sufficiently long
equalizing section to allow the desired metallurgical
properties to be achieved uniformly over the cross-
section of the finished product. That ensures a uni-
form temperature profile and hence a homogeneous
microstructure. For steel grades that have to be rolled
as hot as possible, the wire rod goes into the wire rod
block directly – without the detour via the equalizing
section. The loop technology thus enables mill owners Normal rolling
to react quickly and flexibly to widely differing order
requirements. In wire rod mills in which all sizes are
finish-rolled with MEERdrive®PLUS, the Multiline Loop
is an optimum variant. The mill operators guide the
wire rod via switches through various parts of the
equalizing section and cooling systems to achieve the
best results, irrespective of diameter and steel grade.
When rolling final sizes with larger sizes, the wire rod
block upline of the MEERdrive®PLUS is not used. The

7
5 4 1
3 2

8 4-stand wire rod block 11 Coil handling system

9 Pinch
 roll unit, 12 Horizontal
 coil
laying head compactor
10 Loop
 cooling conveyor
(LCC®)

11
 Wire rod mill for high precision
For closest tolerances and small lot sizes

The MEERdrive®PLUS technology from SMS group is a
high-precision and flexible solution for the finish-roll-
ing of wire rod. The 4-stand block is installed downline
of the wire rod block and finish-rolls all sizes between
4.5 mm and 26 mm diameter. With the special pass
design of the last two stands high precision rolling is
realized. With a gearbox in each block stand, MEER-
drive®PLUS covers a wide range of speeds. It permits
single-family rolling in the upline stands: Only one
groove size is used in each stand over the whole size
range. The required initial pass cross-sections for
the MEERdrive®PLUS block are created by inserting
or omitting two passes in each of the upline stands.
This arrangement with a cooling section in between
allows high-precision and thermomechanical rolling of
all sizes and significantly reduces the amount of roll
changing. Complemented with a quick change system,
also small lot sizes can be rolled efficiently.
The layout mainly consists of:
nR  eheating furnace
nR  oughing mill, with stands of housingless design, in
alternating horizontal-vertical (H-V) arrangement
n Intermediate mill, with stands of housingless
design, in alternating horizontal-vertical
(H-V) arrangement,
nP  re-finishing stands of cantilever design
nC  ooling and equalizing line
n8  -stand MEERdrive® wire rod block
nC  ooling and equalizing line
n4  -stand MEERdrive®PLUS finishing block
n L aying head
n L oop cooling conveyor (LCC®)
n Coil handling system with coil compactor

11 10 9 7 8 7
12

1 Furnace 5 Cooling and equalizing

2 Roughing mill loop

3 Intermediate mill
6 6-stand
 finishing block

4
7 Shiftable
 water boxes
4  CL-stands in H/V
with equalizing line

12
 MEERdrive® technology Advantages of MEERdrive®
A comparison of a conventional solution with MEERdrive®
More flexibility at lower cost
The MEERdrive® technology is a revolution in the field Conventional solution MEERdrive® technology
of wire rod blocks: It enables infinitely variable setting
of the diameter, close tolerances, very good metallur-
gical product properties and last but not least signifi-
cant cuts in operating costs. At the same time,
MEERdrive® reduces the energy consumption and
thus improves the environmental balance. Mechanical facts

With MEERdrive® technology the motors are con- n Heavy distribution gear
trolled relative to one another so that the stands n Longitudinal drive
behave like a conventional wire rod block and can shafts
also be set far more precisely. n Many bearings and
couplings
Together with the total flexibility in roll pass strategy n Bevel gears
a sizing system for wire rod can be realized. By a n Large motor with up to
4-stand MEERdrive®PLUS block, with an oval-round- 7,000 kW
round-round pass design and a minimized stand n Medium voltage supply
distance at the last two stands closest tolerances
for wire rod between Ø 5.5 mm and Ø 27 mm can
Operational facts
be realized. Only one switch gear unit is required per
stand for the speed range to realize a “One Family
Rolling” in the previous rolling mill. This generates n Fixed roll pass design
additional cost savings by reduced changing time in n Fixed reduction ratios of
the rolling mill. stands within the block
n Narrow limits for roll
adjustments to compen-
sate wear/varying
speed
nN  o distribution gear
n Individual short drive
shafts
nF  ewer bearings and
couplings
nO  nly spur gears
nS  mall individual motors
with 290 – 1,450 kW
n L ow voltage supply
n T otal flexibility in roll
pass strategy
n Infinite reduction ratios
due to electrical shaft
n L ess maintenance
nF  ree adjustment range

7 6

5
4
3 2 1

4-stand MEERdrive Loop cooling conveyor

8 ®PLUS 10
wire rod block (LCC®) with 3-fan
9 Pinch roll unit, technology

laying head 11 Coil
 handling system
12 Horizontal
 coil
compactor
13
 Bar mills for quality and special steel
Special quality solutions

PQA® - Product
Know-how transfer

Control and
Integrated solutions

Starting material Heating Rolling

n Billets/blooms of various material Heating and reheating furnaces nH L stands (H; V)
grades n Pusher-type furnaces n3 -roll PSM® sizing blocks
n Walking beam furnaces
n Walking hearth furnaces

Life cycle

14
 Typical applications for SBQ bars (Special Bar Qual-
ity) can be found in the automotive and mechanical
engineering industries. The closest tolerances and
maximum consistency are what is needed here – and
competition is intense, especially among sub-sup-
pliers. With bar mills from SMS group, rolling mill
operators can meet all their customer’s needs, both
flexibly and efficiently – giving them a real competitive
advantage.
For SBQ production SMS group has specifically
developed machinery and systems that enable plant
owners to offer customers products they can rely on
– even with small batch sizes special product require-
ments can be met cost-effectively.
quality analyzer by MET/Con
and production assistance
automation
- intelligently networked
Cooling and inline heat treatment Coil handling/Finishing
n Cooling and equalizing lines with n Pouring reel lines
waterboxes – shiftable n Saw and shear units
n Cooling bed with systems n Bundling equipment
- for retarded cooling
- for integrated fast transport
partnership
In terms of quality steel, in particular, every rolling
mill operator has different demands to meet in order
to deliver perfect products to customers. That is why
SMS group develops customized solutions for each
SBQ producer.
The dedicated process control systems and process
models supplied by SMS group are setting standards
in the market – in terms of both quality and costs. The
systems are based on a holistic approach: They mon-
itor the entire production process and automatically
intervene if potential for optimization is identified. By
adapting the programs individually and using learning
data bases, SBQ technology systems can deliver the
right product, no matter how specific the customer’s
requirements may be.
Products
n Round SBQ grades with diameters
of 13 mm to 160 mm
n Hexagonal SBQ grades with
diameters of 13 mm to 103 mm
15
 SBQ bar mill for straight bars and coils
All market requirements are met with flexibility and
precision

The 3-roll PSM® (Precision Sizing Mill) technology
from SMS group is a high-precision and flexible solu-
tion for the finish-rolling of bars and a core element of
a high quality SBQ mill. One of its outstanding princi-
pal features is its capability to adjust each roll under
load – fully automated and in real time. With the PSM®
one family rolling in the roughing and intermediate
mill as well as the infinitely variable production of all
finishing sizes by using the free size range is possible.
The high roll force capacity allows thermomechanical
rolling.
The subsequent equipment like a cooling bed as well as
a pouring reel line are consequently designed for scratch
prevention. The metallurgical aspects like fast or retard-
ed cooling are considered in the equipment. Walking
beam coil transport with blowers or hoods for the reeled
coils, or fast transport included in the cooling bed allows
an inline treatment of the high precise rolled bars.
The layout mainly consists of:
n Reheating furnace
n Roughing mill, with stands of housingless design, in
alternating horizontal-vertical (H-V) arrangement
n Intermediate mill, with stands of housingless
design, in alternating horizontal-vertical (H-V)
arrangement
n Cooling and equalizing line
n Precision sizing mill (PSM®)
n MEERgauge® true shape measuring system with
inbuild surface defect detection SurfTec
n Cooling bed with fast transport
n Finishing equipment
n Pouring reel line
n Coil handling system with cooling equipment

2 3 4 5

1
6

1 Furnace
2 Roughing
 mill
3 Intermediate mill I
4 Intermediate mill II
5 Cooling line
6 PSM

®

16
 PSM® Precision Sizing Mill
Best sizing technology - major improvements
through process transparency
One of the outstanding principles of a PSM® is its
capability to adjust each roll under load – fully auto-
mated and in real time. The adjustment under load
function is made possible thanks to the advanced
design of the 3-roll cassette in combination with
three hydraulic cylinders. It provides the operator with
the opportunity to optimize the bar shape during the
rolling process. The hydraulic cylinders can adjust all
three rolls concentrically. Where required the system
is also able to individually adjust one or all three rolls
independently. As a result, symmetrical as well as
unsymmetrical positioning adjustments of individual
rolls under load provide opportunities for final tuned
optimization of the net shape tolerances.
This is made possible thanks to the advanced closed
loop Technological Control System (TCS), which also
provides plant operators with full process transparen-
cy, including pass and roll position and on-line correc-
tion, as well as rolling force measurement and active,
fully automated overload protection.
Together with sophisticated control and automation
systems, this opens up unique possibilities for optimi-
zing products and processes. Furthermore, the system
is able to automatically compensate individual mill
spring, feeder variations and bar entry impacts. It is also
able to level out temperature variations along the bar.
A combination of the MEERgauge® true-shape measur-
ing system and the hydraulic adjustment under load
feature is another revolutionary milestone in advanced
3-roll technology, offering the measurement accuracy
to optimize and fine tune the product online during
rolling. The combination of the highly dynamic control
system and the true-shape measurement unit means a
fully automatic rolling operation of the 3-roll block can
be successfully realized independently of the operator.

12
10 11
7 8

7 Cooling bed with fast transport

8 Cooling bed with slow transport
9 Finishing area
10 Pouring reel
11 Walking beam with blowers or hoods
12 Coil
 handling
17
 Combined bar and wire rod mill for
the total range of steel grades
Total flexibility – tight tolerances

The demand for wire rod and bar steel is changing
continuously: Today structural steel for new buildings,
tomorrow wire rod for the automotive industry.
Manufacturers who can react quickly to market chang-
es, who are flexible in the product formats and can
produce varying lot sizes cost-effectively have a clear
advantage. That is why SMS group offers combined
mills in which both wire rod and bar steel can
be produced – cost-effectively and in high quality.
The individual components from the SMS group port-
folio for SBQ plants form a broad basis for combined
mills. SMS group links the components into plants
with a very high level of flexibility in the finished
product dimensions and metallurgical properties,
so generating added value for its business partners.
No matter whether wire rod or bar steel - SMS group
gives comprehensive advice and designs the plants
individually to the customer’s needs.
The layout mainly consists of:
n Reheating furnace
n Roughing mill, with stands of housingless design, in
alternating horizontal-vertical (H-V) arrangement
n Intermediate mill, with stands of housingless design,
in alternating horizontal-vertical (H-V) arrangement
n Cooling and equalizing line
n Precision sizing mill (PSM®)
n MEERgauge® true shape measuring system
n HSD® System
n Cooling bed
n Finishing equipment
n Pouring reel line
n Coil handling system with cooling equipment
n Wire rod line with MEERdrive® block and
MEERdrive®PLUS block
n Pinch roll laying head
n LCC® with three fan technology
n 2nd wire rod line for small sizes on cooling bed
n Coil handling system with compactors

5
2 3 3

1
4

1 Furnace
 4 PSM

®

2 Roughing
 mill 5 10-stand
 MEERdrive® block
Intermediate mill 4-stand MEERdrive block
3 6 ®PLUS

18
 High speed shear
Quick and cost saving
The high-speed shear provides in-line trimming of hot speed shear: one for speeds up to 85 m/s and one
and out of tolerance head and tail ends. The high-speed for speeds up to 120 m/s. With an installation imme-
shear is based on a simplistic design with minimal diately in front of the laying head ensures substantial
disturbance of the rod path. For different applications savings in operational costs are.
in the mill SMS group offers two types of the high-

High speed shear: Technical data

HSS 85 HSS 120*
Ingoing diameter 5.5 - 32 mm 5.5 - 25 mm
Shearing resistance 180 N/mm2
Shear force 6 - 130 kN 3.5 - 90 kN
Design speed 10 - 85 m/s 11 - 120 m/s
Rotor speed 300 - 2,800 min -1 350 - 3,820 min -1
Motor power approx. 315 kW chopping shear (similar to laying head)
Chopping length approx. 475 mm
Blade radius 300 mm
*HSS 120 can be realized as 1 or 2 shear system

9
10

6 7
8
11 12
13

14

7 Loop
 laying head 11 Quenching
 and tempering facilities
8 LCC

® 12 HSD

®
system
9 Pooring reel line 13 Cooling bed
10 Coil handling facilities 14 Finishing area
19
 Rebar and merchant bar mills
Solutions for a wide range of products

PQA® - Product
Know-how transfer and

Control and
Integrated solutions

Starting material Heating Rolling

n Billets Heating and reheating furnaces nH L stands (H; V, convertible)
n Pusher-type furnaces nC L stands
n Walking beam furnaces nF inishing blocks
n Walking hearth furnaces n2 , 3 and 4-strand slitting

Life cycle

20
 SMS group offers all types of merchant bar mills: For
bars and small sections, rebar mills with high-speed
delivery system (HSD®) or slit rolling technology as
well as machines for coiling rebar (VCC®) and billet
welding machines for endless rolling.
The smooth interaction between these machines is
what ensures very high productivity and availability
levels. A high degree of efficiency is also guaranteed
thanks to the technology systems, actuators and
quick-changing equipment: Size changes and adjust-
ments to the product lengths can be performed very
fast, while downtimes are reduced to a minimum.
The production process itself is fast-moving too:
for example, rebar rolling speed can reach up to
50 meters per second.
quality analyzer by MET/Con
production assistance
automation
- intelligently networked
Cooling and inline heat treatment Finishing
n Quenching and self-tempering n VCC® vertical compact coiler
facilities n Straighteners
n Cooling beds n Piling machines
n HSD® high-speed delivery system n Bundling and tying machines
partnership
High flexibility and reliability are the trademarks of
SMS group merchant bar mills. State-of-the-art mills
of this type are capable of producing various products
such as angles, squares, flats and small channel steel
sections in one plant. Rounds can be produced too.
SMS group rolling mills boast typical capacities of
around 300,000 to 800,000 tones every year. Rebar
mills can also be designed as high-performance plants
with a capacity of 1,400,000 tones per year - depend-
ing on the capacity requirements customers request
from rolling mill operators.
Products
n Rebars
nR  ound, flat, squares
nA  ngles, channels
21
 Single-strand high-speed bar mill
Limited investment meets high productivity

These mills ideally combine limited investment with
high productivity. A solution which guarantees the
fastest return of investment. Generally these mills are
sized for a medium range production up to 500,000
tpy. The typical product sizes range from 8 to 32 mm
diameter round and rebars, which are the predomi-
nant sizes in commercial bar rolling.
The layout mainly consists of:
n Reheating furnace
n Roughing mill, with stands of cantilever or housing-
less design, in alternating horizontal-vertical (H-V)
arrangement, with the possibility of quick-changing
device
n Intermediate mill, with stands of housingless de-
sign, in alternating horizontal-vertical (H-V) arrange-
ment, with the possibility of quick-changing device
n Finishing block
n Quenching and self-tempering facilities
n Single-strand HSD® High-Speed Delivery System
nC  ooling bed
nF  inishing facilities with cold shear, bundling system
with bar counter and wire tying machines

4
1

2 3

1 Furnace
2 Roughing
 mill
3 Intermediate mill
4 Finishing block

22
 HSD® High speed delivery system for straight bars
The main advantages of this process can be summarized as follows:
n Yield increase due to close tolerance on each nY
 ield increase due to better bar counting:
strand: When slitting, the “worst bar” determines Since the HSD® system delivers one bar per notch,
the size of all bars (in case of differential wear on bars can be kept separate throughout the finishing
the rolling passes it is very common to have one end greatly facilitating bar count and, with the SMS
bar in the correct size and the others slightly over- group bar counting system, limiting bar over-count
sized) to a maximum of one bar per bundle

n Cobble reduction: n For small diameters (8-10 mm), a two-strand HSD®

The slitting area is the most prone to cobbles. With system achieves a productivity increase of 70%
the HSD® system, the two bar slitting is performed compared to the three-strand slitting and a cost
on larger diameters and thus the bar is easier to advantage of up to 13 euros/t.
control

HSD®: Technical data

Size range for rebars/rounds 5.5 mm – 43 mm
Temperature range 500°C – 900°C
Speed range 2 m/s – 50 m/s
Cooling bed length 54 m – 102 m
Single HSD capacity
®
up to 120 t/h approx.
Double HSD capacity
®
up to 240 t/h approx.
Steel grades/standards DIN 488, NBR 7480, BS 4449, ASTM-A615-A706, GB 13014,
GOST 10884, KSD 3504, IS 1786

TMbaR Thermo-mechanical rolling of reinforcing steel

In order to meet the increasing quality requirements for reinforcing steel with regard to higher strengths and
a finer microstructure, SMS group combines the knowledge of rebar and thermomechanical rolling to TMbaR.
The advantage of this process is the drastic reduction of alloying elements such as manganese, combined
with higher-grade mechanical material properties.

7
5 6

5 Quenching and
self-tempering facilities
HSD system
6 ®

7 Cooling bed
8 Finishing facilities
23
 Slit rolling bar mill
Economical solutions for high rolling production

This bar mill operates at relatively low speed in mul-
tiple lines, normally consisting of 2 to 4 strands, with
a common starting material stock. Even though the
slit rolling process is employed only for production
of rebars, this process is a very economical solution
to achieve high rolling production, even for small
sizes. The annual production may vary, depending
on the number of strands, but tonnages in the range
of 1,000,000 tpy can be achieved with product sizes
from 10 to 50 mm.
The layout mainly consists of:
n Reheating furnace
n Roughing mill with horizontal-vertical (H-V) stands
either of housingless or cantilever design
n Intermediate mill with horizontal-vertical stands (H-V),
housingless design
n Finishing mill with horizontal, vertical and converti-
ble stands, housingless design and quick-changing
device
n Quenching and self-tempering facilities
n Drop wall roller way with lifting aprons
n Cooling bed
n Finishing facilities with cold shear, bundling system
and wire tying machines

6
7 5

8 8

1 Furnace
2 Roughing
 mill
3 Intermediate mill
4 Finishing mill

24
 The slitting process
Many steel producers operate mills based on mul-
ti-slit technology. The majority of those mills have
a size range of 10 or 12 to 40 mm. In some appli-
cations, 8 mm is also rolled. Depending on furnace
capacity and product size, 4-slit, 3-slit and 2-slit
operation is used.
Even if the design speed of the mills may be higher,
these mills run at rolling speeds ranging in most
cases from 13 to 18 meters per second.
The reason for such low speeds is the fact that opera-
tion is sensitive at small sizes and mill setting requires
fine accuracy. In this regard, the experience of the
rolling crew plays a key role. The design of the guiding
equipment inside the mill (even for looper arrange-
ment) and the cooling bed run-in system have to take
account of the special requirements of the multiple
running strands.

Benefits of slitting technology

n The possibility of producing also flats, squares and
hexes to complement rounds and rebar production
n A minor saving in total investment costs since the
cost of two high speed blocks, with associated
additional electrics, piping and foundations, is
avoided. This is partially offset by the need of two
additional convertible housingless stands.
n The high speed blocks require a higher degree of
mechanical knowledge from operators and mainte-
nance personnel.

4 3 2 1

5 Quenching and
self-tempering facilities
6 Drop wall roller
7 Cooling bed
8 Finishing facilities
25
 Combined bar mill with
vertical compact coiler VCC®
Highly productive and cost-efficient

A highly flexible and productive solution is the bar mill
combining 2-slit rolling via high-speed finishing blocks
and a double strand HSD® High-Speed Delivery Sys-
tem.
The presence of the finishing blocks allows a further
extension either for the production of wire rod (nor-
mally for 5.5 to 16 mm in coils) or for the production
of bar in coils with the VCC® Vertical Compact Coiler
line (normally for 8 to 16 mm in compact coils), which
is the most innovative way of producing rebar today.
The layout mainly consists of:
n Reheating furnace
n Roughing mill with horizontal-vertical (H-V) stands,
cantilever or housingless design
n Intermediate mill with horizontal-vertical (H-V)
housingless stands with quick-changing device
n 2 finishing blocks
n Quenching and self-tempering facilities
n Double strand HSD® system
n Cooling bed
n Finishing facilities with cold shear, bundling system
with bar counter and wire tying machines
n VCC® line (or wire rod line with laying head, con-
trolled cooling conveyor, coil forming and handling
line with compactor and wire tying)

2 3 4

1 Furnace
2 Roughing
 mill
3 Intermediate mill
4 Finishing block

26
 VCC® - Compact and torsion-free coils
SMS group’s VCC® is today’s state-of-the-art solution
for producing compact and torsion-free coils, and is
now increasingly in demand by rebar post-processors.
The VCC® concept combines the best elements of
modern mechanical engineering for rolling mill appli-
cations: industrial design standards, including heavy
duty service factors, focus on maintenance minimi-
zation, easy erection and start-up, effective safety
features and a design that perfectly suits the overall
production process.
One of the most important features of VCC® is its
method of coiling the bar directly in the vertical posi-
tion. Plant operators can therefore eliminate the need
for turning manipulators and at the same time reduce
the process cycle time, as all coils are formed in the
final position. The coils are ready to be stored imme-
diately once coiling has been completed and the coils
have cooled down. Reduced handling also minimizes
the overall risk of damaging the coil.

VCC®: General characteristics

Product range Plain rounds diameter 8 mm – 50 mm,
rebars diameter 6.3 mm – 40 mm, as well flats, squares and hexagons
Coil weight up to 8 t
Temperature range 450°C – 900°C
Speed up to 40 m/s
Winding temperature 550°C – 850°C
Coil dimensions internal diameter 700 - 850 - 900 mm
height 700 - 800 - 900 mm, external diameter 1,500 mm max.
Steel grades/standards DIN 488, NBR 7480, BS 4449, ASTM-A615-A706, GB 13014, GOST 10884,
KSD 3504, IS 1786

6 7
5

5 Cooling line
Vertical coil compactor (VCC )
6 ®

7 Unloading device and

strapping machine
8 Cooling and transferring device

27
 Merchant Bar Mill
A wide range: from rounds to angles

A modern merchant bar mill has the capacity to
produce a variety of products such as angles, squares,
flats and small channels. Round bars can naturally be
produced, too. Such a mill is characterized by great
flexibility and has an annual capacity of 500,000 to
600,000 tpy producing a broad product mix including
plain rounds and rebars from 16 to 40 mm, flats up to
100 mm, tees up to 80 mm, angles and channels up to
150 mm and I-beams up to 120 mm.
The layout mainly consists of:
n Reheating furnace
n Roughing mill with horizontal-vertical (H-V) stands,
cantilever or housingless design
n Intermediate mill with horizontal-vertical (H-V)
housingless stands
n Finishing mill with horizontal and convertible (H-V)
housingless stands with quick-changing device
n Drop wall roller way with lifting aprons
n Cooling bed
n Multi-line straightener
n Finishing facilities with cold shear, stacker and
strapping or tying machines

6
7

1 Furnace
2 Roughing
 mill
3 Intermediate/finishing mill
4 Finishing mill

28
 The HL housingless stand
The housingless design stands, in short HL, are the backbone of modern rolling mills. The modular design allows
the use of the HL stand cartridges in all possible configurations: horizontal, vertical, convertible and universal.

Thus the HL concept is suitable for roughing, intermediate and finishing mills. Mill stand sizes vary in accord-
ance with the required dimensions of rolls and necks, the pattern of pass, the groove design as well as the
transmission and drive characteristics. SMS group design department models all load data to determine all the
process variables and select the correct stand size.

The HL stands operate in bar mills, wire rod mills,
section mills and combined plants. The main features
of the HL design are:
n Conservative component sizing criteria and general
philosophy in order to achieve rigidity and com-
pactness of each unit
n Low roll deflection modulus (favorable ratio of roll
neck to roll working diameter)
n Long life multi-roller bearings with chocks
self-alignment under load
n Balancing of backlash between chocks
n Rest bars designed to allow easy and fine adjust-
ment of guiding devices
Hence, these are the mayor benefits during operation:
n Finished product matching required tolerance on
geometry and size, thus stricter weight control
n Time savings during stand changing with off-line
roll replacement
n Flexibility of operation, same stand unit used in
horizontal, vertical, convertible and universal con-
figurations, thus minimization of spare parts inven-
tory
n Highly reduced maintenance time and costs, due to
a reduced number of components and easy access
n Automated gap adjustment
n Integration in fully automatic control

4 3 2 1

5 Drop wall roller way

6 Cooling bed
7 Multi-line straightener
8 Finishing facilities

29
 Section mill for medium-light profiles
Solutions to suit all production volumes

A continuous section mill with high flexibility and the
capacity to roll beams, angles, channels and flats of
small and medium size has a capacity of 600,000 to
700,000 tpy of sections with a product ranging from
100 to 200 mm. Continuous mills are also possible for
beams up to a web height of 350 mm.
The layout mainly consists of:
n Reheating furnace
n Roughing mill with horizontal-vertical (H-V)
housingless stands
n Intermediate/finishing mill with horizontal, converti-
ble and universal stands with quick-changing device
nD  rop wall roller way with lifting aprons
nC  ooling bed
n Straightener
n L ayer transfer facilities
nF  inishing facilities with saws, stacker and strapping
machines

5 6

1 Furnace

2 Roughing
 mill
3 Intermediate/finishing
 mill
4 Drop
 wall roller way
30
 Electrical tying machine
Final packaging is a key operation in modern produc-
tion facilities: it is the business card with which steel
producers introduce themselves to their customers.
Long product rolling mill operators also have to pay
particular attention to the form and quality of the
bundles as, after this operation, the bundles of bars
is delivered to the market. Each and all single bundles
produced in the mill are bound by a tying machine.
In standard tying machines essentially hydraulic oper-
ations are used. Yet hydraulics always require special
maintenance – for hoses, valves, pumps and there
is always a risk of oil leakage. The electrically driven
system of the SMS group tying machine guaran-
tees cleaner, safer and more reliable operation than
hydraulics – especially in the severe conditions of a
rolling mill.

This operation is critical on several levels and must be: The benefits are:
n Safe: bundles have to be tied securely and n Oil-free operation
consistently n Clean and safe technology
n Reliable: any problem at the tying machines n High-precision operation and repeatability
requires the whole operation to be stopped n Significantly reduced maintenance
n Aesthetic: bundles should be neatly tied and
free of oil

3 2 1
4

5 Cooling
 bed
6 Straightener

7 Layer
 transfer facilities
8 Finishing
 facilities
31
 W3-311E · Published on 10.03.2018 · Circulation XXX · Printed in Germany · KD

SMS group GmbH SMS group S.p.A.

Business Unit Long Products Business Unit Long Products

Ohlerkirchweg 66 Via Udine, 103

41069 Mönchengladbach 33017 Tarcento (Udine)
Germany Italy

Phone: +49 2161 350-1724 Phone: +39 0432 799-253

Fax: +49 2161 350-1753 Fax: +39 0432 792-058
barandwirerodmills@sms-group.com
www.sms-group.com

The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these charac-
teristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal
effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.