PERT Technical Book PDF

PERT
INNOVATIONS
IN ROLLING MILL
EQUIPMENT
www.pertengineering.com
BS STANDS:
Technical Features 05
Comparison Table With Common Stands 15
Energy Saving 19
PERT Restbars Solutions 04
PERT LLR rolls
®
27
Quality Improvement 31
PERT FINISHING BLOCKS:

Wide Range of PERT finishing blocks 07
FLUR® SYSTEM:
Techno-Economical Benefits 51
PERT ROLLING MILLS:

Evaluation of excavations,
civil works and building dimensions 11
PERTECO:
Water Treatment Plant for Rolling Mills 77
PERT
BS STANDS

Technical Features
| 05 TECHNICAL BOOK
/ PERT BS STANDS
SECOND GENERATION OF PERT BS STANDS
Since years, the first generation of PERT BI-SUPPORT rolling stands are working with success in the International
steel market. Thanks to the wish and the ability to innovate and to continuously improve its equipment and plants,
PERT has studied a new generation of BI-SUPPORT rolling stands. The revolution is in the concept of rolling stand
introduced with the new model of BI-SUPPORT stands, which immediately became a milestone in the field of rolling
technology for long products.
The conditions of the modern steel market, with always smaller profit margins and stronger competition, impose the
use of rolling mills with operational costs as lowest as possible but, in the same time, can assure a final product of
very high quality.
Fig 1. 3D view of a roughing mill in

H/V configuration
| 06
" TECHNICAL FEATURES"
Fig 2. PERT BI-SUPPORT Stand
Starting from these considerations, PERT has developed the second generation of BI-SUPPORT rolling stands,
which, maintaining the benefits of first generation stand, introduces new and innovative advantages:
XX Absence of spindles
XX Absence of piping on board
XX Absence of chocks
XX Use of rings instead of rolls (less grooves consumption per ton of production)
XX Smaller dimension for easy handling
XX High stiffness
XX - 85% spare parts
XX Increased bearings working life (min 50’000h)
XX Ring gap regulation starts from 5 micron
XX Horizontal and vertical stand with the same design, fully interchangeable
XX Mono-groove (roughing mill) and multi-groove (intermediate and finishing mill)
XX Roll gap regulation with eccentric system
XX Easy maintenance
XX Increased safety for changing and maintenance operations
| 07 TECHNICAL BOOK
/ PERT BS STANDS
The finality of second generation BI-SUPPORT stands development project is:

1. Improve the final product quality;
2. Reduce downtimes of the plant for the production changes and maintenance;
3. Reduce the investment for buildings, cranes and civil works;
4. Spare parts reduced cost.
5. Increase the safety of changing and maintenance operations
To satisfy these purposes, PERT has proceeded as follows:
1. Improve final product quality
1a – Reduction of reactions on constraints, as shown in the following diagrams:

PERT BI-SUPPORT stand under rolling load P = 1850 KN
Distributed rolling load on housing allows to reduce the stand mechanical yielding that assures Standard tolerance in
the final product. In the housingless stands, the rolling load is concentrate on the tie rods, so the adjusting screws are
subject to mechanical stress; this means wear and mechanical yielding.
1b – Constraints surface
The BI-SUPPORT stands have a reaction surface 5 times higher than housingless stands, so housing elongation,
under a load variation, is reduced to 1/5 compared to common housingless stands.
| 08
TRADITIONAL STANDS BI - SUPPORT STANDS = REACTION SURFACE
1c – Length of stress path

BI-SUPPORT stands have a stress path with a length of approximately the half compared to common housingless
stands, so also the elongations are proportionally reduced.
TRADITIONAL STANDS BI-SUPPORT STANDS
1d – Ring-holder shaft flexion

Constraints are very near to the rolling load, so the rigidity of the stand becomes higher and, consequently, also the
deflection of ring-holder shaft is reduced. In comparison with common housingless stands, flexion is reduced of
approx 3 times while in comparison with cantilever stand flexion is halved.
| 09 TECHNICAL BOOK
/ PERT BS STANDS
Considering the above mentioned points, we can demonstrate that the rigidity of PERT BI-SUPPORT stands is
approx 3 times higher compared with the other types of rolling stands actually proposed on the market and this
guarantees a very high quality to the final product.
2. Reduce the downtimes of the plant for the production changes and maintenance
Changing stands, from motor stop to restart, involves approx 10 minutes including the rings-holder shaft
changing. When a complete stand is available, as spare, changing times fall down to approx 2.5 minutes. So
reduced changing times are possible for the reason that the second-generation BI-SUPPORT Stand does not
include container and piping on board which are typical in housingless.
The rolling unit unlocking, lifting, replacement and re-locking is fully automated, both in horizontal and vertical
configuration.
3. Reduce the investments for buildings, cranes and civil works
Greater efforts have been turned toward the containment of total stand size and, as shown in figure (3), toward the
reduction of stand’s height in vertical configuration. As an example, BI-SUPPORT 650 vertical stand, doing part of
the roughing mill, has an height of just 4.30 m, against the average height of 7-8 m of common housingless stands.
Fig 3. Difference of dimension between housing less stands and

PERT BI-SUPPORT stand 650 in vertical configuration and with
rolling rolls/ring diameter of 650 mm
| 10
The advantages, that such a contained overall make possible, are:
XX The rolling mill building is lower in height, so it is possible to have a smaller and lighter steel structure;
XX Thanks to the reduced height of second generation BI-SUPPORT stand, the run ways of the cranes are just at
a height of +7.50 m and crane capacity is lower than 40% in respect of a standard mill.
XX The civil works for roughing, intermediate and finishing mill are reduced by 60%
XX For plants on the ground level, the building can be of concrete prefabricated type; this option allows to reduce
the initial investment and make faster the construction.
4. Reduce spare part costs
4a – The new BI-SUPPORT stands have no machined working parts directly in contact with water and scale
as it happens in common housingless stands (for example the tie rods). All moving parts are positioned into the
housing and are protected by adequate gaskets
(See figure 4).
Fig 4. Differences
between PERT BI-
SUPPORT stand and
housingless stand.
Adjusting screw for rolls

gap regulation is inside
the housing and protected
from water, scale and filth
infiltration
| 11 TECHNICAL BOOK
/ PERT BS STANDS
4b – BI-SUPPORT stands do not need operational intervention in rolling line, as the cantilever stands where the rings
change is made in the working area of the plant so the changing operations are very difficult and there is also the risk
to damage the stand shafts.
4c – BI-SUPPORT stand is composed by a number of components reduced to half in comparison with common
housing less stand. This allows to reduce drastically the number of spare parts and the total weight of the stand.
4d – In the BI-SUPPORT stands the rolling rings are installed on a heat-treated steel alloyed shaft, that ensures
the security against possible crack due to overload during rolling mill operations. Furthermore it will be replaced
only the worn rolling ring (grooves at the end life, no possibility of re-machining), as the steel shaft on which the
rings are installed can be re-used. In the housingless stands the whole rolling cylinder has to be scrapped.
Fig 5. BS Stand Typical

shaft and ring assembly
4e – The BI-SUPPORT stand bearings have a working life 2.5 times more (min. 50’000 h) in comparison with
common housingless stand, this because in the housingless stand the rolling load is always fixed than the external
ring of the bearing.
| 12
LOAD
DIRECTION FLOW
GRAPHIC OF LOAD DISTRIBUTION

IN EXTERNAL RING OF THE BEARING
LOAD
SUMMARIZED LOADS GRAPHIC
LOAD LOAD LOAD
DIRECTION FLOW
MAX GAP MIDDLE GAP MIN GAP
4f – The second generation of BI-SUPPORT stands have been designed and developed avoiding the use of
cardanic spindles. Instead of cardanic spindles, gear couplings have been installed, which, in aligned working
conditions, are not subject to the wear and therefore there is not the necessity of their replacement and spare parts.
4g - Lubrication system of BI-SUPPORT stands is very simple, it is like a lubrication system of a normal gear box.
BI-SUPPORT stands do not need special device for water removal from oil, such as cantilever stands.
5. Increase the safety of changing and maintenance operations
The design of BI-SUPPORT Stands allows, in case of cobble, a greater increase in operator safety in the rolling area,
as the rolled bar is contained by the stand, which prevents the material overflow.
In addition, the absence of on-board piping, avoid the risk of fire, due to the cutting of lubrication oil and grease pipes
by the hot bar, in case of cobble.
On the contrary of the other common stands, even the water splashes are avoided, thereby improving the conditions
of the working area of the rolling mill, increasing even more the safety and the easy maintenance
| 13 TECHNICAL BOOK
/ PERT BS STANDS
Water splashes in a
cantilever stand.
New BI-SUPPORT Stands have been designed to be used in rolling mill plants for the production of rebars, rounds
and sections in special quality bars (SBQ) steel grade, wire rod, light and medium section, and they are suitable for
special steel plants.
BI-SUPPORT Stands can be supplied in different configuration: horizontal, vertical or convertible, mono-groove
(roughing mill) or multi-groove (intermediate and finishing mill).
Finally, the multiple technical-economic advantages resulting from the use of second-generation BI-SUPPORT Stand
can be summarized as follows:
1. A net saving on initial investment due to the lowest costs for building and civil works
2. A saving in production costs due to the small quantity of spare parts
3. Increase the plant productivity thanks to the lowest changing times and plant’s downtimes
4. Very high quality of the final product
5. In general, the plant is more easier to be managed, with low maintenance and less manpower needs
6. Each group of stands (basement, gear box and stand), when assembled, is tested in our workshops to be
“ready to roll”
7. Reduction of costs concerning the machine tools for grooves re-machining
8. Reduction of costs concerning lubrication oil and grease consumption.
| 14
PERT
BS STANDS

Comparison table
between pert BS STANDS
and common stands
| 15 TECHNICAL BOOK
/ PERT BS STANDS
PERT BS HOUSINGLESS CANTILEVER

BISUPPORT Stands increase the advantages Miscellaneous rolling mill trains, equipped with housingless and cantilever stands, are not ideal,
of compactness and rapidity of ring change that in fact they represent a compromise that forces the Costumer to an unevenness of spare parts,
are typical of cantilever stands. In the same way operational stocks and to differentiate management of the rolling mill
they increase the advantages of housingless
stands, thanks to the adoption of a double
support on the ring shaft
Absence of spindles Presence of cardan spindles Absence of spindles
Absence of spindles Spindles as a spare part Absence of spindles
Absence of spindles Self-balancing spindle support Absence of spindles
Better mechanical efficiency due to spindles Spindles involve 5% of mechanical losses, hence Absence of spindles
elimination electrical power consumption is 5% higher
Absence of chocks Presence of chocks Absence of chocks
Absence of chocks Chocks as a spare part Absence of chocks
Absence of chocks Hydraulic chock balancing system Absence of chocks
No piping on board Piping on board Piping on board
Shiftable stand Shiftable stand Fixed stand
Vertical stands driven from the top, to avoid Vertical stands driven from the top, to avoid Vertical stands driven from the bottom, problems
infiltrations of water and scale into the gear box infiltrations of water and scale into the pinion of infiltration of water and scale into the gearbox,
stand premature wear of rotating components due to
scale infiltration
Height of BS Stand 650 → 4,3 meters Height of Housingless Stand with rolls diameter Excavation of 5 m depht
650 mm → 7-8 meters
Very simple civil works, - 70% of civil works Heavy civil works Heavy civil works, excavations….
regarding the rolling train
Roll gap regulation with eccentric system Roll gap regulation with adjusting screws Roll gap regulation with eccentric system
Bi-support Bi-support Cantilever
High stiffness due to bi-support and eccentric Bad stiffness due to high loads on adjusting Very bad stiffness due to cantilever rolls
roll gap regulation screws and tie rods
Suitable for light sections and special steel rolling Higher mechanical yield and higher deflection of Not suitable for light sections and special steel
mills due to smaller mechanical yield and smaller the rolls rolling mills
deflection of the ring holder shaft
Low number of components High number of components High number of components
- 85 % spare parts High number of spares High number of spares
Spares : rings and bearings Spares : rolls, bearings, spindles, chocks, Spares : rings, oil film bearings, complete
adjusting screws, complete stand mandrel unit
Robot for rings change is not needed Robot for rolls change Special tool for rings change
Only the worn ring will be scrapped, the ring The worn roll will be scrapped Only the worn ring will be scrapped, the ring
holder shaft will be reused holder shaft will be reused
Finishing stands equipped with carbide rings, Stands equipped with cast iron rolls, shorter Finishing stands equipped with carbide rings,
longer grooves working life grooves working life and more frequent roll longer grooves working life
changes
Multi – groove Multi – groove Mono – groove, 2 grooves in the finishing stands,
more frequent rings changes
Advantage Disadvantage
| 16
COMPARISON TABLE
PERT BS HOUSINGLESS CANTILEVER

Multi – groove, with worn groove , the rolling Multi – groove, with worn groove , the rolling Finishing stands have only 2 grooves, only the
axis can be realigned on new groove and the axis can be realigned on new groove and the inner groove is a working groove for deflection
production can proceed production can proceed reduction. With worn groove, the ring must be
turned.
Possibility of multi – slitting Possibility of multi – slitting No slitting, one strand rolling
Shorter stress path in comparison of housingless Longer stress path Longer stress path
and cantilever stands (- 50%)
Short barrel length due to the use of carbide Large barrel length due to the use of cast iron Short barrel length due to the use of carbide
rings instead of cast iron rolls rolls rings instead of cast iron rolls
Absence of deflection problems Deflection problems due to longer barrel length Deflection problems due to cantilever shafts
Practically no deflection problems. Deflection of rolls causes twisting in the flat bars Deflection of rolls causes twisting in the final
production products
Simple installation, BS stands are ready to roll Difficult installation, mostly for the vertical stands Difficult installation
Roll bearings Roll bearings In the roughing stands for high rolling loads, plain
bearings are needed
Roller bearings working life increased by 2,5 Shorter roller bearings working life due to the Plain bearings, more expensive and they involves
times in comparison with other stands fact that the rolling load is always fixed than the the use of a special device for water removal
external ring of the bearings from oil
Possibility of use rolls with a large diameter Possibility of use rolls with a large diameter Larger diameter of rolls means larger diameter of
in comparison with cantilever stands, hence in comparison with cantilever stands, hence roll neck and higher costs
reducing the bite angle reducing the bite angle
+50% of rolling load in comparison to cantilever +50% of rolling load in comparison to cantilever Lower rolling load in comparison to other stands
stands stands
Reduced lubrication point Complicated lubrication system Sophisticated lubrication system, due to the oil
film bearings
Reduction of lubrication oil and grease Higher consumption of lubrication oil and grease Higher consumption of lubrication oil and grease
consumption
Smaller bearings size Smaller bearings size For the same diameter of rolls, the bearings
size are bigger, it means more lubrication and
maintenance
Greater reliability of the gaskets-labyrinths anti Water and scale on tie rods and moving parts. Water and scale infiltration
water and scale, for the above lower diameter of
the ring holder shaft. The friction surface is lower
Fully automatic stand changing No automatic stand changing due to the No automatic stand changing
presence of piping on board
Complete stand changing time: 10 min Complete stand changing time: 20 min Rings changing time: 15 min
with stand as a spare: 2,5 min with stand as a spare: 10 min
Easy management of the rolling mill as Operational difficulties, longer changing times, Operational difficulties, high number of spare
BS Stands integrate all the advantages of high number of spare parts parts, bad quality of finished product
housingless and cantilever stands, without their
disadvantages
Number of remachining higher than cantilever Number of remachining higher than cantilever Lower number of remachining
stands stands
Reduction of costs concerning the machine Higher costs for the machine tools for grooves Reduction of costs concerning the machine
tools for grooves re-machining re-machining, due to the use of cast iron rolls, tools for grooves re-machining
that are bigger than rings
Not suitable for heavy section rolling mills Suitable for heavy section rolling mills Not suitable for heavy section rolling mills
Advantage Disadvantage
| 17 TECHNICAL BOOK
/ PERT BS STANDS
PERT BS STANDS
Advantages on Capital Costs Advantages on Operative Costs

Technology Advantages CAPEX OPEX
Less energy consumption

Better product quality Civil works reduction
-5%
Smaller buildings Less spare parts

Tight tolerances
dimension -85%
Less excavations for

Better surface finishing Less manpower
foundations
Increased bearings working life:

Easy maintenance
x2.5 times
Less lubrication oil

Easy rolling mill management
and grease consumption
| 18
PERT
BS STANDS

Benefits introduced
by the elimination
of cardanic spindles -
PERT BS Stands and
common stands
| 19 TECHNICAL BOOK
/ PERT BS STANDS
There are several advantages introduced by the elimination of cardanic spindles (replaced by gear couplings) for the
transmission of motion between gear box and rolling stand.
The most important are:
1. Better mechanical efficiency – Cardanic spindles have a mechanical efficiency equal to 95%, which means
that the electrical motor must provide 5% more electrical power to make up for mechanical losses due to the
use of cardanic spindles.
2. No spindles as a spare part – Spindles could be replaced after a certain working time. On the contrary,
gear couplings do not require replacements as they are not subject to wear. In any case, spindles as a spare are
needed, at least 2 for roughing, 2 for intermediate and 2 for finishing stands, for a total cost of approx 40’000 –
50’000 €.
This study takes into consideration the annual electrical power saving, introduced by the better mechanical efficiency
of the motion transmission between gearbox and rolling stand, thanks to the spindles elimination.
The electrical power consumption is heavily influenced by the inlet temperature of the billets, in fact “colder” billet
has an higher resistance to deformation, so the rolling load is higher and consequently also the electric power
consumption is higher.
Difference of 100 °C in the inlet temperature of the billet (from 1050 °C to 950 °C) involves an increase of power
consumption of 50% more.
Rebar rolling mill
Mill capacity: 50 t/h

Production per year: 360’000 t/y
Operating time: 7200 h
Number of strands: 2
Starting billet size: 130x130 mm
Inlet temperature: 1150 °C
Production mix:
Diameter of Production mix Hours of Real rolling Spindles Motor power
final product production per power* efficiency [kW]
[mm] year [h/year] [kW]
2x8 10% 720 3097 0.95 3260
2x10 15% 1080 3412 0.95 3592
2x12 20% 1440 3002 0.95 3160
14 20% 1440 3342 0.95 3518
16 15% 1080 2922 0.95 3076
18 5% 360 2787 0.95 2934
20 5% 360 2477 0.95 2607
25 4% 288 2077 0.95 2186
28 2% 144 1768 0.95 1861
32 2% 144 1733 0.95 1824
36 2% 144 1539 0.95 1620
* This is the value of the real rolling power calculated with PERT roll pass design software
| 20
BENEFIT OF BS STANDS
In a rolling mill equipped with common housingless stands, which uses the cardanic spindles, the electrical power
delivered by the motor, will be:
Real rolling power/0.95
In a rolling mill equipped with PERT BS Stands, conversely, the electrical power delivered by the motor is equal to
the real rolling power, without mechanical losses.
Summary table:
Diameter of final Total motor power Total motor power Difference Electrical savings
product [mm] – Common Stands – BS Stands of power per year [kWh/
[kW] [kW] consumption [kW] year]
2x8 3260 3097 163 117’360
2x10 3592 3412 180 194’400
2x12 3160 3002 158 227’520
14 3518 3342 176 253’440
16 3076 2922 154 166’320
18 2934 2787 147 52’920
20 2607 2477 130 46’800
25 2186 2077 109 31’392
28 1861 1768 93 13’392
32 1824 1733 91 13’104
36 1620 1539 81 11’664
Total Electrical savings per year:

1’128’312 kWh/year
Assuming the cost of electrical energy of 0,08 €/kWh (European cost)

Total cash saving per year:
1’128’312×0,08= 90’265 €/year
Corresponding to:
0,25 €/ton
Table of savings regarding different rolling mill capacities:

ANNUAL CAPACITY [tons/year] ANNUAL SAVING [€/year]
150’000 37’500
250’000 62’500
350’000 87’500
500’000 125’000
800’000 200’000
1’000’000 250’000
| 21 TECHNICAL BOOK
/ PERT BS STANDS
The reduction of energy consumption and the use of low-impact facilities, are now issues that every steel producer
faces, since plants that pollute generate high costs and a high degree of mistrust on behalf of civil society, that
perceives these works as a threat to its health.
This technical analysis takes into account the electricity consumption resulting from the use of different types of
rolling stands currently on the market, as well as the environmental impact due to their operation and considering the
different technical characteristics of each type of stand.
As well as introducing several advantages at a technical and economic level (reduction of CAPEX and OPEX) the new
revolutionary PERT BS stands also lead to considerable savings in electricity, drastically reducing consumption.
To date, the most commonly used rolling stands are the housingless and cantilever ones.
In the first analysis, we take into account the greater difference between BS and housingless — i.e. the absence of
spindles with regards to the BS.
From the point of view of energy saving, it is clear that the elimination of spindles involves a considerable simplification
of the kinematic chain that allows the transmission of motion from the electric motor to the rolls.
Fig 1. Simple scheme of the

spindles of Housingless Stand
This simplification results in considerable saving of electric power as the elimination of a component of the
transmission kinematic chain, also involves the elimination of losses due to the component itself.
In our case, the cardanic spindles used in common housingless stands, have an efficiency that varies between η =
0.94 - 0.95 each, this is because spindles should work in an inclined position (as shown in Figure 1) in a range from a
minimum of 3° and a maximum that varies between 5° and 6°, depending on the rolling load and speed of the rolls, in
order to meet the adjusting needs of the gap between the rolls.
Working constantly in an inclined position, losses on various components of the spindles, especially on journal
cross, are very high and increase as the angle of inclination to which the spindles works increases, hence the overall
efficiency of a transmission with 2 spindles is quite low.
In the BS stands instead, the spindles are replaced with a conventional gear couplings, working always aligned on the
axis of the rolls (FIG 2).
Fig 2. BS Stand – Gear

couplings are always aligned
with the rolls, due to the
eccentric gap regulation
| 22
There not being components working in an inclined position, the kinematic chain that goes from the rolls to the gear
box is basically made from a single component that, besides having no wear, has a yield nearly equal to η = 1.
As shown earlier, the BS stands allow considerable savings in energy and CO2 produced, on an annual basis, hence
big savings in economic and environmental costs. Improving the transmission of motion from motor to rolls does this.
From this point of view, the existing cantilever stands also have similar characteristics, i.e. they do not use spindles.
For this reason only, they are today considered as a stands which reduce the energy consumption.
Comparing BS stands with cantilever ones, we can immediately notice that major differences are in the rolling unit
itself and not on the transmission of motion.
The various solutions adopted in BS stands, allow additional energy savings compared to cantilever, for one fundamental
reason:
BS do not use oil film bearings, but roller bearings
Indeed, having regard to the cantilever configuration of the rollers and the high rolling loads (especially on the roughing
mill), the cantilever stands should mount oil film bearings and not roller bearings, vice versa the BS are bi-support,
therefore they mount multi-roll bearings.
The presence of oil film bearings involves innumerable problems from a technical and consumption point of view:
1. Oil film bearings efficiency is very low compared to that of roller bearings
2. The use of oil film bearings involves using a large lubrication unit besides a device that removes water from oil
3. The oil used for lubrication is much more viscous.
These problems are reflected not only costs, but also on an increase of energy consumption, in fact in cantilevers, if
on one hand the motion transmission is very efficient, the technical solutions adopted on the rolling unit significantly
reduces the advantages acquired by the elimination of spindles.
As mentioned, BS have roller bearings while cantilevers mount oil film bearings, well the yield of a roller bearing is
approximately η = 0.01 while that of a oil film bearings is in the order of η = 0.06, therefore 6 times greater.
Furthermore in cantilevers, the diameters of the roll necks, with the same diameter of the rings, are greater than those
of BS or Housingless.
With the same rolling load, the reaction diameter of the oil film bearings is greater than the roller bearings (also needed
to decrease the specific pressure on the oil film bearings).
As can be seen from the diagram in figure 3, the braking torque resulting from the rolling load on the oil film bearings
of the cantilevers stand, is very high compared to the one on the BS bearings, this is because:
The efficiency of the oil film bearings is very low, in fact, the friction is sliding and not rolling like on roller bearings, in
addition the high viscosity of the lubricating oil (which must also maintain high hydro-sustenance, otherwise the oil film
bearings can seriously be damaged) results in an increase of the coefficient of friction itself.
The reaction diameter of the cantilever oil film bearings is very high since the rollers are cantilevered (that is the
diameter of the necks is greater than the bi-support stands). This means that the load on the nearest constraint to the
rolling axis is very high, even higher than the rolling load.
In the BS stands, conversely, having a better distribution of loads on supports, normal multi-roll bearings can be
mounted that allow to decrease the reaction diameter and hence the reaction distance that generates the braking
torque. In addition, being the friction of rolling type and the oil used for lubrication with low viscosity, even the
coefficient of friction is dramatically reduced.
Moreover, the rolling load on constraints will in any case be smaller than the rolling load, something that does not
happen in cantilever stands.
| 23 TECHNICAL BOOK
/ PERT BS STANDS
Fig 3. Braking load diagram

for cantilever stand and BS
stand
Referring to Figure 3, the total braking torque of cantilever stand is:

Tot. Braking Torque= (4725+23085) x2= 55620 Nm
The total braking torque of BS stand is:

Tot. Braking Torque= (1250+1250) x2= 5000 Nm
Being the brake torque in the cantilever stands 10 times greater compared to the BS, the electrical power delivered by
the electrical motor to win such force is also 10 times greater than that delivered by using the BS stand.
Hence the cantilevers do allow a great saving in terms of energy due to the absence of spindles, but instead use
technical solutions that increase consumption, compromising much of the advantages of a simplified kinematic
motion transmission. Ultimately, cantilever stands cannot be considered as a stand that allow large savings in terms of
energy or environment.
Friction Load on Reaction Braking torque Lubrication unit

constraints distance (rr)
(RA, RB)
CANTILEVER High High, even higher than High given the greater High, due to greater Huge
(µ = 0.06) the rolling load diameter of the necks friction, increased load
on constraints and
greater torque arm
BS STAND Low Low, given the bi- Low given the minor Low given less friction, Small
(µ = 0.01) support diameter of the necks less load on constraints
and torque arm
| 24
The lubrication of oil film bearings is very complex; it must be as efficient as possible, so as to avoid burning and
damaging the same oil film bearings.
For this reason the lubrication unit is much greater in size, oil capacity, filtering devices and pump power (about 45%
more), compared to the one used for the BS stands.
Lubrication oil is also very viscous, which implies extra power needed to make it circulate in the circuit.
For all these reasons, a lubrication station serving, for instance, a group of 6 cantilever stands in roughing mill, has an
installed capacity of approximately +65% to which the power of the unit removing water from oil must be added (see
fig. 4). In comparison, the BS stands use a lubricant oil that is the same used in gear boxes, it has low viscosity and
high cooling is not required, therefore the lubrication unit is quite reduced and has a much lower installed power.
BS stands do not require the unit for the removal of water from oil, like the cantilevers, because water and oil are not in
contact with each other, as all lubricated parts are protected and inserted into the housings.
Fig 4. Difference between

Oil viscosity Tank capacity Installed Water from BS and cantilever
power oil removal lubrication unit
device
Cantilever stand 460 CST 15.000 litres +45% compared to Yes
lubrication unit BS lubrication unit
BS stand lubrication 220 CST 2.000 litres low No

unit
Energy saving, as well as being important to reduce energy consumption and environmental impact, is also a
significant economic saving for the user of the equipment, because it reduces a major item in operating costs.
From an environmental point of view, we must also take account of the cost of oil disposal and of all devices used to
minimise environmental impact resulting from contact between oil and cooling H2O, that, by using cantilevers, are
greater than using housingless and BS, because there are much larger lubrication units and therefore much greater
capacities. This translates into many extra litres of oil to be disposed of.
In summary, analysing today's typology of rolling stands as a whole, we have seen that the BS are the ones that at a
saving level, guarantee the best performances.
In fact, the housingless have good efficiency with regards to the rolling unit but are the opposite with regard to the
motion transmission from the motor to the rolls.
The cantilevers, on the contrary, have a good efficiency in terms of transmission of motion, but much of the savings
due to this advantage is lost with a low yield from the proper technical side of the rolling unit operation.
The BS stands were created to combine all the advantages of the Housingless and cantilevers but without their
disadvantages and, as seen, this is also valid from the energy saving point of view, making BS stands the real
eco-friendly rolling stands.
| 25 TECHNICAL BOOK
/ PERT BS STANDS
| 26
PERT
BS STANDS

Rest bars solutions
| 27 TECHNICAL BOOK
/ PERT BS STANDS
ON BOARD REST BAR
A new typology of stand needs a new typology

of rest bar.
In order to solve the problems introduced
using common solution of rest bars, PERT
has developed and patented a new rest bar
concept.
In the common rest bars, the guide-holder is
shiftable in order to permit the aligning of the
guide on the new groove. On the contrary, thanks to the shorter barrel length of PERT BS stands, the guide-holder is
fixed and the entire rest bar is shiftable in order to align the guides to the grooves, this means that the moving parts of
the rest-bar are located far from the rolling axis, so contact with scale and water is drastically reduced.
Thanks to the fixed guide-holder, the aligning operations for the guides are very easy and simple, above all in the
vertical stands where with common solutions, the weight of the guides, when disconnected from the rest bar in order
to permit shifting of the guide, does not allow a proper alignment, and the wedge of the guide can occur.
The main advantages of PERT rest bar are:

XXPerfect and easy alignment of the guides.
XXNo water and scale on moving parts.
XXIt is avoided the removal of the rest bar for rolls/rings changing operations, in fact the rest bar remain fixed on
one housing. The changing times due to rolls replacement are drastically reduced.
XXNew and innovative clamping system for an extremely simple rest-bar removal.
XXRest-bar shifting operations made by adjusting a warm screw by a simple spanner.
The entire rest bar is movable, as shown in figure
| 28
OPENABLE
1 - Hydraulic clamps
2 - Hydraulic cylinder for open close
movements
3 - Steel supporting frame
The “movable” type rest-bar is installed on the stand basement, and can be used both for PERT BS Stands and other
common stands (housing, housingless).
The rest-bar is connected to the stand basement by a set of hydraulic clamps, designed in order to withstand to high
rolling loads.
The rest-bars are openable in order to allow the stand take-off.
Great results can be achieved in the roughing mill, where the aligning of the guides is more difficult due to its weight.
In addition the guide is fixed respect the rolling axis, so the alignment of groove and guide is made by shifting only the
stand.
The main advantages introduced by PERT

openable rest bars are:
Rest bar fixed respect the rolling-axis
XX
All the hydraulic and water piping

XX
(cooling water collectors) can be 1 2

incorporated on the rest-bar supporting
steel structure, so the stand is
completely with-out on board piping
Stand changing operations are
XX
drastically reduced.
Simple aligning operations, mainly for
XX
vertical stands.
3 4
1 - Rest bars in working position

2/3 - Rest bars in open position, stand hydraulic clamps
in open position
4 - Stand ready for replacement
| 29 TECHNICAL BOOK
PERT
BS STANDS

LLR ROLLS®
| 31 TECHNICAL BOOK
PERT LLR ROLLS®
Introduction
PERT has developed and patented a new concept for the composite rolls for long product rolling mills, called LLR
Rolls® (Long – Life Rolling Rolls).
PERT LLR Rolls®, allows mounting of carbide rings on a shaft made of special alloyed steel, in order to increase the
grooves working life and to decrease, consequently, the plant downtimes for rolls changing.
LLR Rolls®, merge an increased groove wear resistance with high strength and toughness of the ring-holder shaft,
and ensures higher rolling loads even at low speeds (for example in the roughing mill).
LLR Rolls® can be installed on housing and housingless stands, as well as PERT BS Stands.
The new and patented ring locking system, is the main advantage introduced by LLR Rolls®, as the using of
traditional hydraulic locking system, is avoided. In fact, a mechanical coupling between rings and shaft is used, so the
rings changing operations are extremely easy and faster to perform.
When designing and manufacturing of LLR Rolls®, a major concern is to create a safe and reliable locking of the
rolling rings, ensuring that the ring will never slip. With common hydraulic systems, during usage, roll flexion creates
local deformations between the different roll components, which together with other deteriorations, like corrosion, will
cause the locking load to decrease and eventually the rolling ring could slip.
PERT has developed and patented a new locking system, precisely for avoiding the ring slippage and to make faster
and easier the ring changing operations.
PERT LLR Rolls® for a

roughing stands (rings
diameter 690 mm)
The LLR Rolls® could be supplied in two different typology, according to the methodology adopted for the anti –
slippage system of the rings:
With keyways
Adopted mostly for LLR Rolls® of roughing stands, but suitable also in intermediate and finishing stands
Without keyways
Patented locking system, adopted for LLR Rolls® of intermediate and finishing stands
PERT LLR Rolls® consist of:

Heat treated ring – holder shaft, made of alloyed steel
XX XX Rings spacer
Patented ring locking system
XX XX Rolling ring (cast iron or carbide)
| 32
INTRODUCTION
Ring – holder shaft (with

keyways)
Advantages
The main advantages introduced by using LLR Rolls®, are:

XXPatented coupling between rings and shaft
XXMechanical locking system instead of hydraulic system
XXLonger grooves working life
XXLower plant downtimes
XXIncreased productivity of the rolling mill and excellent surface finishing of final products through precise
dimension control during rolling
XXThe shaft can be reused, only the worn ring must be replaced. Conversely, the worn cast iron roll, must be
entirely scrapped
XXReduced number of grooves regrinding
XXImproved quality and tolerances of the final products, thanks to the use of carbide rings
XXReduced number of rings as a spare (compared with cast iron rolls)
XXReduced space for spare parts
XXFree from ring slippage even under high rolling torque
XXSimple assembling and disassembling operations for rings changing
Comparative table between cast iron rolls and LLR Rolls®
CAST IRON ROLLS LLR ROLLS®

Time for Rolls/Ring changing per year ~ 500 h/y ~ 150 h/y
Increased yearly Production +35’000 t/y
Yearly Consumption 0.508 Kg/t 0.172 Kg/t
Cost per Ton 0.38 €/t 0.09 €/t
* Referred to 100 t/h rebar mill
| 33 TECHNICAL BOOK
PERT LLR ROLLS®
LLR Rolls® for finishing

stands (dia. 275 mm)
Comparative table of productivity between cast iron rolls and PERT LLR Rolls®, for finishing stands:
Groove life cast iron rolls: 80 tons

Plan productivity: 100 t/h
Number of grooves: 24
Groove life carbide rings: 800 tons
Product size: 8 mm
Number of grooves: 8
The graph shown the different working life regarding the carbide rings in comparison of the cast iron rolls.
Is evident that the higher life of the carbide rings, allows the grooves/ring changing less frequently respect the
common rolls, which means less plant shutdown hours and increased mill productivity.
From the graph, it can be noted that, for each redressing operation of the carbide rings, using cast iron rolls, must
need at least 2 more redressing operations.
In one working week, are avoided at least 7 shutdown times for rolls changing, practically one per day, if we consider
a shutdown of 0.5 h per day, in one year the changing hours are reduced by 150 h, which means, for a 100 t/h rolling
mill, an increased production of 15’000 t/y.
| 34
PERT
BS STANDS

Quality improvement
| 35 TECHNICAL BOOK
PERT LLR ROLLS®
Thanks to the extremely high stiffness of PERT BS Stands, we introduce the concept of “sizing stands” not only in
special steel rolling mills (SBQ or alloyed steel), where the tolerance of the final products must be very tight, but also in
rebar or wire rod rolling mills.
This means a very high final product quality and a better product marketability, in fact the quality improvement does
not involve higher production cost, even better, using PERT BS Stands, the operational cost are reduced.
As mentioned, evaluating the high stiffness of BS Stands, we can consider them as a “sizing stand”.
In a special steel rolling mill, installing BS Stands with a shorter barrel length (monogroove) and tungsten carbide
rolling rings in the finishing mill, it can be achieved final tolerance of ¼ DIN. Furthermore, an evolution of PERT
2x TECHNOLOGY Convertible block, can be used as a sizing block, in Horizontal – Vertical – Horizontal
arrangement, with a dedicated roll pass design made of oval – round – round sequence.
In rebar mills, using BS Stands, the final rolled stock can be produced at the lowest allowed tolerance set out by
International Standards (DIN, ASTM, GOST…), so, in the markets where the bars are sold by a preset number request
from the Customer, it can be earned up to 40 Kg of steel for each billet. That means approx. 10’000 t/y of more steel
sold by the Producer (referred to a 100 t/h mill, billet size 150x150x12000mm).
In the modern market, the flexibility in the production range becomes a relevant factor for the increase of market
shares or even for the survival of the plant. Precisely for this purpose, PERT BS Stands gives the best flexibility to
the rolling mill, in fact a rolling mill which was born for rebar production, could be easily upgraded and converted in to
a special steel rolling mill, for the production of high valued steel grades.
In wire rod mills, it is very important that the entry round bars stock in a fast finishing block, must have the required
section and the required diameters as per roll pass design, but especially they must have a constant section along
the whole bar. This is a key factor for the final quality of the wire rod, in fact if the section of the entry round bar is not
constant, the oval sequences in the finishing block may not be filled in the right way, resulting in a poor quality which is
not acceptable especially if the wire rod will be processed in a drawing lines.
The stiffness and the rigidity of the BS Stands are due to:
XX Shafts mounted on double support
XX Eccentric gap regulation, which allows the gap setting every 5 µm
XX Rolling load distributed on stand housing (monolithic), so the reaction surface is increased respect other
common stands (no tie rods or cantilever rolls)
XX Shorter stress path
XX Flexotorsional problems practically eliminated, due to the double support and the patented ring-holder shaft design
XX In the special steel rolling mills, for increasing even more the stiffness of the BS Stands and achieve strictly
tolerances on final products, the finishing stands has a shorter barrel length and they are monogroove.
Of course the rigidity of BS Stands means the achievement of very tight tolerance on the rolled stock, but it involves
other advantages, such as:
1. Final product tolerance up to ¼ DIN
2. For each billet, the rolled bar incoming and outgoing of each passes has almost the same section, also if
the starting temperature of the billet is different (colder billet causes higher mechanical yielding and section
changing), so the stress of the guides is reduced and their working life will be increased.
3. Possibility of performing thermo-mechanical rolling
4. Increased head-to-tail tolerance
5. Possibility to produce more added value products even in a rebar rolling mill
In addition, the use of carbide rings in the finishing stands of PERT rolling mills, involves:
1. Increased dimensional tolerance
2. Better surface quality
3. Increased grooves working life (approx. 10 times more than cast iron rolls).
| 36
WIDE RANGE OF
PERT FINISHING
BLOCKS FOR REBAR
AND WIRE ROD MILLS
| 37 TECHNICAL BOOK
PERT LLR ROLLS®
PERT is the sole plantmaker all over the world which has developed and designed 8 different types of finishing
blocks, both for rebar and wire rod mills.
PERT range of finishing blocks consist:
1. PERT Wire Rod Fast Finishing Block
2. PERT 2xTECHNOLOGY® Finishing Block
3. PERT 2xTECHNOLOGY® Convertible Finishing Block
4. PERT 2xTECHNOLOGY TwistFREE® Fast Finishing Block
PERT Wire Rod Fast Finishing Block and PERT 2xTECHNOLOGY TwistFREE® Fast Finishing Block could be
designed in 90° or 45° arrangement, equipped with roller bearings (for lower speeds) or with plain bearings (for higher
speeds).
The wide range of PERT finishing blocks, allows “taylor made” solutions for every type of rebar or wire rod mill, from
small capacities rolling mills (100’000 t/y) up to large capacities rolling mills (1’500’000 t/y).
Summary table:
TYPOLOGY ARRANGEMENT N° OF STRANDS CONFIGURATION MAXIMUM TYPOLOGY OF FINAL
OF FINISHING SPEED BEARINGS PRODUCT
BLOCK
PERT WIRE ROD H/V 1 90 ° 40 m/s Roll bearings Rebar and wire rod
BLOCK
80 m/s Plain bearings Wire rod
45 ° 120 m/s Plain bearings Wire rod
PERT 2X H/H 2 / 35 m/s Roll bearings Rebar

TECHNOLOGY®
BLOCK
PERT 2X H/H 2 / 35 m/s Roll bearings Rebar

TECHNOLOGY®
CONVERTIBLE
BLOCK H/V 1
PERT 2x H/V 2 90 ° 40 m/s Roll bearings Rebar and wire rod
TECHNOLOGY
TWISTFREE® 80 m/s Plain bearings Wire rod
BLOCK
45 ° 120 m/s Plain bearings Wire rod
| 38
PERT FINISHING BLOCKS
PERT REBAR BLOCK
Fig 1. PERT Rebar Block
XX VMAX = 35 m/s XX 90° configuration

XX One strand XX Possibility to mount carbide, cast iron, steel rolling
XX Roller bearings rings
XX H/V XX Drastically reduced maintenance
XX Nominal rolling rings diameter= 250 mm XX Drastically reduced rolling rings changing times,
XX Stands center to center distance= 635 mm thanks to the FLUR™ System
This block (Fig. 1) with cantilevered rolling rings has been designed for high speed rebar production and is installed in
plants of small and medium capacity (up to 400’000 – 450’000 tpy).
The Distinctive trait of this block is that it uses roll bearings instead of oil film bearings, which is possible because of
the relatively low maximum working speed (35 m/s) and implies the great advantage of using a normal and simple
lubrication unit instead of a complicated lubrication unit and related station for separating water from oil, which would
be necessary when using oil film bearings.
Therefore also the use of high viscosity lubrication oil is avoided (high-priced and of difficult disposal), utilizing the
same lubricant used for the gear box of the rest of the plant.
The configuration is 90° to allow maximum accessibility to operators who will have to replace the rolling rings, which
are all placed in the front position; a much more complicated operation if the block was configured at 45°, since there
would be right and left modules and what is more, inclined.
The first stand is in a vertical position to have the last horizontal, so as to maintain axial stability of the ring holder
shafts and consequently maintain the caliber in a correct position eliminating the displacement of one of the 2 shafts
due to the rolling axial load.
Having the first stand in a vertical position ensures that all ovals are upright, so significant temperature reductions due
to contact with the cooling water of the rolling rings are avoided, since the contact surface is much smaller and there
are no effects due to stagnation of the water itself.
Moreover, transitions with the upright oval give more stability to the rolling bar lowering its flexion between one stand
and the other.
In addition to rebar production, this block is used as pre-finishing in wire rod mills, to be installed before the fast
finishing block, so as to avoid the usage of cantilevered stands which imply a bigger lubrication unit, equal to the ones
| 39 TECHNICAL BOOK
PERT LLR ROLLS®
used for fast blocks since both mount oil film bearings; and also rolling rings substitution of the cantilevered stands is
more complicated and needs dedicated hydraulic tools.
PERT REBAR BLOCK, like all other PERT blocks, mounts a fast changing rolling rings patented system, called
FLUR™ System, which allows rolling rings substitution in about 1 minute each, without using any hydraulic equipment.
All the on board piping is completely re-designed and incorporate in the steel framework, in order to supply a very
compact block with a reduced footprint. The maintenance operations will be facilitated due to a better accessibility
and quick disconnections joints.
| 40
PERT WIRE ROD BLOCK
Main features:
XX VMAX = 120 m/s XX Stand center to center distance = 700 mm
XX One strand XX All on board piping is incorporated and protected
XX Oil film bearings in the carpentry, inspectable and accessible for
XX FLUR maintenance through the removal of simple panels.
XX Nominal rolling rings diameter 200/160 mm - H / V XX Reduced maintenance
XX 90° or 45° Configuration
PERT WIRE ROD BLOCK can be supplied in 2 configurations, at 90° up to the speed of 80 m/s and at 45° for
higher speeds up to 120 m/s and is installed in one strand wire rod mills from 150.000 to 600.000 tpy.
The 90° Configuration can be adopted up to 80 m/s so as to grant also in this case good accessibility of the rolling
rings and therefore speed up and simplify rolling rings replacement operations.
For higher speeds a 45° solution is necessary, not so much for vibration problems, but to have a better gravity
condition so as to help the discharge of the oil film bearings lubrication oil as much as possible.
Another important characteristic is that the center-to-center distance between the stands is limited, only 700 mm,
thus implying less vibration of the roll, less strands and less vibrations of the block itself.
Less vibrations and an excellent balance of the gears involve an increase of the quality of the finished product, in fact in a
block where vibrations are nearly non-existent, it is easier to maintain the stringent final allowances, plus there will also be
less noise, which is reduced to minimum levels, avoiding annoying and deafening whistles while the block is working.
Given the highly elevated work speed of the PERT WIRE ROD BLOCK, the latter has been designed so as to
minimize damages caused by possible malfunctions or emergencies such as cobbles, motor failures etc. In fact,
thanks to the reduction to the minimum of the inertia of the gears of the block, it stops in minimal time.
The diameter of the rolling rings can be of 200 mm in the first stands and 160 mm in the last ones, depending on the
need, to grant an adequate and reduced relation between the rolling ring and the finished product’s diameter, so as to
have very tight tolerances and high quality.
In addition the shaft length is reduced, to have less cantilever “length” and therefore reduce vibrations.
Fig 2. PERT 2xTechnology® block
| 41 TECHNICAL BOOK
PERT LLR ROLLS®
PERT 2xTECHNOLOGY®
Main features:
XX 1 or 2 strands
XX FLUR®
XX Vmax = 35 m/s
XX Double-support stands
XX Air/oil lubrication
XX Configuration H / H
XX Nominal rolling rings diameter = 275 mm
XX Possibility to mount carbide, cast iron, steel rolling rings
XX No on-board piping
The ease, simplicity of use and maintenance make 2xTECHNOLOGY® block (fig. 2) the best solution for rebar mills
of medium-low capacity (up to 350.000 t/y), above all in countries with scarcity of skilled labor or for customers that
invest for the first time in a steel making plant.
This block is formed by 4 or 6 stands deriving from the PERT BS Stand, controlled by only one motor and mounted
on only one basament.
The main peculiarity of this block is that it can simultaneously roll 2 strands for the smallest diameters, which means
satisfy the furnace productivity also with them and at relatively restrained speed.
With respect to 1 strand rolling, rolling at 2 strands allows cutting the production speed in half, on equal terms of
production per hour of the furnace, thus facilitating less experienced operators.
Stand substitution is completely automatic, since no cardan spindles are used and the stands have no on-board
piping; with stand as a spare, substitution time is reduced to less than 10 minutes for all the stands of the block.
The stands rigidity, due to the double support of the ring holder shafts and to the gap regulation with eccentric
system, is highly elevated and grants high quality of the finished product.
The operating costs of the 2xTECHNOLOGY® block are really minimal as spare parts are almost eliminated, since
there are no cardanic spindles, chocks, container unit, etc. typical of common housingless stands. Moreover the
lubrication unit is standard and utilizes the same lubrication oil used for the stands of the rolling mill.
Since there are no spindles, up to 5% of electricity can be saved; in fact the gear couplings used instead of
the spindles never work in inclined position but are always aligned to the axes of the ring holder shafts, so the
performance of the transmission from the distributor to the rolling rings is nearly equal to 1.
Besides operating costs, investment costs are also cut down; in fact the foundations for the 2xTECHNOLOGY®
block are very simple and restrained; the amount of space is also really reduced: is should be remembered that the
height of the block, including the basement, is a little less than 0.9 m.
The flexibility of the 2xTECHNOLOGY® block is also very important, in fact productivity of the plant where it is
installed can be easily increased without significant interventions, just think that the maximum reachable speed is 35
m/sec per strand (equal to more than 80 t/h of 8 mm rebar).
| 42
2xTECHNOLOGY® CONVERTIBLE:
Main features:
XX As in 2xTECHNOLOGY® block
XX Configuration H/H (2 Strand) and H/V (1 Strand)
The 2xTECHNOLOGY® CONVERTIBLE block has essentially the same characteristics of the 2x TECHNOLOGY™
but in addition it has the possibility to use a H-H/V configuration, i.e. even stands can be used both in the horizontal
and in the vertical disposition.
This allows to roll the smallest diameters in the H/H configuration with 2 strand fitting so as to produce full capacity of
the reheating furnace, and larger diameters in the H/V configuration so as to avoid torsion of the rolling bar.
The convertible stands could be driven either from the top or from the bottom.
The 2xTECHNOLOGY® CONVERTIBLE block proves to be particularly suitable for small-medium plants (up to
350.000 t/y) for the production of bars and wire rod; in fact when wire rod is produced, the 2xTECHNOLOGY®
CONVERTIBLE block is configured horizontally and vertically and therefore the bar does not twist during rolling, thus
obtaining excellent wire rod quality, since all rolling mill is torsion-free.
Given the high rigidity of the stands, a further application for this block is the usage as sizing block in H-V-H
configuration for the production of specialty steel bars, round, square or hexagonal shaped, in a range from 16 mm up
to 100 mm (stand individually driven).
The use of carbide mono-groove rolling rings assures further increase in the rigidity of the stand, which guaranties
tolerances up to 1/6 DIN on the finished product.
| 43 TECHNICAL BOOK
PERT LLR ROLLS®
PERT INTERMEDIATE BLOCK
Main features:
XX 1 Strand XX Possibility to mount carbide or special steel rolling
XX 4 stands rings
XX H/H configuration XX Nominal rolling rings diameter = 420 mm
PERT INTERMEDIATE BLOCK has the same characteristics as the 2xTECHNOLOGY®; in fact 4 rolling units
controlled by a single motor and installed on a basement in common form it.
The stands have a nominal diameter of the rolling rings of 420 mm therefore the block is suitable to be used in the
intermediate or before the PERT REBAR BLOCK.
The employment of innovative steel rolling rings, whose duration is comparable to carbide rolling rings, allows using
only one motor for all 4 stands, since grooves consumption is far less and mainly uniform, with respect to cast iron
rings.
The utilization of PERT INTERMEDIATE BLOCK simplifies low productivity plants lay-out (see fig. 4) at the most,
drastically reduces the space needed for installation, investment cost and spare parts.
PERT 2xTECHNOLOGY TWISTFREE®
Main features:
XX Vmax = 120 m/s for wire rod XX Cantilevered
= 50 m/s for rebar XX H/V configuration
XX FLUR® XX Oil film bearings
XX Reduced maintenance XX 90° o 45°
XX 2 strands XX Nominal rolling rings diameter Ø200 mm or Ø160 mm
Fig 3. 3D view of the PERT

2xTECNOLOGY TWISTFREE
mandrel units
| 44
PERT 2xTECHNOLOGY TWISTFREE® block (fig. 3) represents a revolutionary innovation for the long products rolling
mills and is the first block in the world capable of rolling 2 strands simultaneously, in Horizontal/Vertical configuration and
at a speed up to 120 m/sec..
PERT 2xTECHNOLOGY TWISTFREE® has been designed for high capacity plants (up to 1.500.000 tpy) for the
production of both rebar, in 90° configuration, and wire rod, in 45° configuration.
This block involves countless advantages, in effect it substitutes plants using 3 or 4 or 5 strands multislitting technology
(higher number of guides, higher possibility of cobbles, low finished product quality, H/H sequence, operating
complications, higher specific operating costs for smaller diameters, higher number of short bars) and the plants using 2
finishing blocks with high speed 2 strands slitting (bigger space, longer plant, more civil works, an additional block, two
extra quenching lines, an extra shear…) as with 2xTECHNOLOGY TWISTFREE® one single block is sufficient.
A noticeable saving in equipment and civil works is also obtained in 2 strands wire rod mills, having all the same one
block less and a reduced working platform.
Since 2xTECHNOLOGY TWISTFREE® is also equipped with rapid FLUR® locking /unlocking system of the rolling rings,
the whole block can be set up in less than 20 minutes, using only a team of 4 workers, so downtime is reduced and
plant productivity increases.
| 45 TECHNICAL BOOK
WIDE RANGE OF PERT
FINISHING BLOCKS
FOR REBAR AND WIRE
ROD MILLS

Different finishing mill
configurations using
PERT Finishing Blocks
| 47 TECHNICAL BOOK
PERT LLR ROLLS®
REBAR ROLLING MILL
Mill capacity: 20 t/h up to 50 t/h

Production per year: 100’000 t/y up to 300’000 t/y
Number of strands: 1 or 2
The finishing mill of a small capacity rolling mill could be equipped with different types of PERT blocks, depending
of the final speed of the products, the number of strands desired, the stands arrangement and the different
management of the mill.
POSSIBLE CONFIGURATIONS:
1. PERT Wire Rod Fast Finishing Block
It could be used for rebar finishing on one strand with final speeds up to 40 m/s. The finishing block will roll rebars
from 8 mm up to 18 mm, while rebars from 20 up to 40 mm will be rolled on intermediate stands.
Smaller rebar sizes will be discharged at high speed onto the cooling bed trough a twin channel system, while bigger
sizes rebars will be discharged trough lifting aprons. For rebar finishing, this block is equipped with roller bearings,
which means that the water removal from oil device, is not needed. The number of stands could be 2, 4 or 6.
Advantages:
XX One strand
XX No twist of the bars (H/V arrangement)
XX Possibility of reuse the same block for future wire rod production (adding stands)
XX No water removal system due to the use of roller bearings
XX 90° configuration
XX Fast changing of the rings due to PERT FLUR® SYSTEM

It could be used for rebar finishing on two strands with finishing speeds up to 35 m/s. All the rebars sizes will be
discharge onto the cooling bed trough lifting aprons, because the final product speeds is lower than 18 m/s.
The number of stands could be 4 or 6.
Advantages:
XX Lower speeds due to slitting process
XX No water removal system
XX Two stands in less due to 2-slit process
XX Simple future upgrading of the mill (increasing motor size)

It could be used for rebar finishing on two strands with finishing speeds up to 35 m/s. Smaller rebar sizes will be rolled
on two strands in Horizontal/Horizontal arrangement, while bigger sizes will be rolled on one strand in Horizontal/
Vertical arrangement. All the rebars sizes will be discharge onto the cooling bed trough lifting aprons, because the final
product speeds is lower than 18 m/s.
Advantages:
XX No twist for rebar sizes from 12 mm up to 40 mm
| 48
DIFFERENT FINISHING
4. PERT 2xTECHNOLOGY TWISTFREE® Fast Finishing Block (90° Configuration)

It could be used for rebar finishing on two strands with final speeds up to 40 m/s. The finishing block will roll rebars
All the rebars sizes will be discharge onto the cooling bed trough lifting aprons, because the final product speeds is
lower than 18 m/s. For rebar finishing, this block is equipped with roller bearings, which means that the water removal
from oil device, is not needed. The number of stands could be 2, 4 or 6.
Advantages:
REBAR ROLLING MILL

Production per year: 400’000 t/y up to 1’000’000 t/y
The finishing mill of a large capacity rolling mill could be equipped with different types of PERT blocks, depending of
the final speed of the products, the stands arrangement and the different management of the mill.
For this kind of rolling mills, PERT propose finishing mills equipped with fast finishing blocks that rolls two strands
contemporary, to avoid the use of 3-slit or 4-slit process for the smaller rebar sizes, in order to have the best quality
for the final product.

It could be used for rebar finishing on two strands with finishing speeds up to 35 m/s. Smaller rebar sizes will be
discharged at high speed onto the cooling bed trough a double twin channel system, while bigger sizes rebars will be
discharged trough lifting aprons. The number of stands could be 4 or 6.
Advantages:
XX High productivity due to high speed 2-slitting process
XX Simple upgrading of the mill
XX No need of two fast finishing blocks in the finishing mill (As per common mills)

It could be used for rebar finishing on two strands with finishing speeds up to 35 m/s. Smaller rebar sizes will be rolled
on two strands in Horizontal/Horizontal arrangement, while bigger sizes will be rolled on one strand in Horizontal/
Vertical arrangement. Smaller rebar sizes will be discharged at high speed onto the cooling bed trough a double twin
channel system, while bigger sizes rebars will be discharged trough lifting aprons.
| 49 TECHNICAL BOOK
PERT LLR ROLLS®
Advantages:
XX High productivity due to high speed 2-slitting process
XX Simple upgrading of the mill
XX No twist for rebar sizes from 16 mm up to 40 mm
3. PERT 2xTECHNOLOGY TWISTFREE® Fast Finishing Block (90° configuration)

It could be used for rebar finishing on two strands with final speeds up to 40 m/s. The finishing block will roll rebars
Smaller rebar sizes will be discharged at high speed onto the cooling bed trough a double twin channel system, while
bigger sizes rebars will be discharged trough lifting aprons. For rebar finishing, this block is equipped with roller bearings,
which means that the device for water removal from oil, is not needed. The number of stands could be 2, 4 or 6.
Advantages:
XX Simple future upgrading of the mill
WIRE ROD ROLLING MILL

Production per year: 100’000 t/y up to 350’000 t/y
Finishing mill of small capacity wire rod mills will be equipped with one 10 – stand fast finishing block.
1. PERT Wire Rod Fast Finishing Block (90° configuration)

It could be used for wire rod finishing on one strand with final speeds up to 80 m/s. For wire rod finishing, this block is
equipped with plain bearings.
Advantages:
XX Easy changing of the rings due to the 90° configuration
XX Lower cost

It could be used for wire rod finishing on one strand with final speeds up to 120 m/s. For wire rod finishing, this block is
equipped with plain bearings.
Advantages:
XX Max speed achievable, 120 m/s
XX Higher productivity for smaller wire rod sizes
| 50
DIFFERENT FINISHING

Production per year: 400’000 t/y up to 1’000’000 t/y
Number of strands: 1 or 2
Finishing mill of large capacity wire rod mills will be equipped with one or two 10 – stand fast finishing block,
depending on the production rates.

It could be used for wire rod finishing on one strand with final speeds up to 120 m/s. For production higher than
700’000 – 800’000 t/y must be provided 2 wire rod lines equipped with one fast finishing block each.
For wire rod finishing, this block is equipped with plain bearings.
Advantages:
XX Max speed achievable, 120 m/s
2. PERT 2xTECHNOLOGY TWISTFREE® Fast Finishing Block (45° Configuration)

It could be used for wire rod finishing on two strands with final speeds up to 120 m/s.
For wire rod finishing, this block is equipped with plain bearings.
Advantages:
XX Max speed achievable, 120 m/s on two strands (it means 240 m/s)
XX Only one finishing block, instead of two, which feeds two laying heads

Production per year: 1’200’000 t/y up to 2’000’000 t/y
Finishing mill of very large capacity wire rod mills (PERTGigaMill®) will be equipped with two 10 – stand PERT
2xTECHNOLOGY TWISTFREE® Fast Finishing Blocks, in order to reach the high capacity required.
Using two PERT 2xTECHNOLOGY TWISTFREE® Fast Finishing Blocks, the wire rod mill will be equipped with 4
strands, so the productivity of the mill reaches levels never seen before.
Advantages:
XX Only two finishing blocks instead of four
XX Max speed achievable, 120 m/s on four strands (it means 480 m/s)
XX High productivity even for smaller wire rod sizes
| 51 TECHNICAL BOOK
PERT
FLUR® SYSTEM

Techno-economical benefits
for PERT FLUR® System -
PERT Fast Lock-Unlock
Ring System
| 53 TECHNICAL BOOK
PERT FLUR® SYSTEM
DESCRIPTION
PERT FLUR® Fast Lock-Unlock Ring SYSTEM allows changing of the rolling rings on our fast blocks in about 1
minute per ring (it means 20 minutes for the complete changing of the rings of a 10-pass block employing 3 persons,
less than 15 minutes employing 4 persons).
This changing does not need special equipments and can be carried out also by non-skilled personnel without a
special expertise.
This solution represents a further innovation in the field of the fast finishing blocks, where PERT has reached
nowadays a level of absolute excellence.
FLUR® system is adaptable to all type of existing finishing blocks, as well as the cantilever stand.
The use of PERT FLUR® Fast Lock-Unlock Ring SYSTEM allows significant increases of production on annual
basis, this is because the changing times of the rings of PERT finishing blocks, are drastically reduced.
A significant amount of more hours of production becomes available, which without using FLUR® SYSTEM, it would
have been spent on above changes.
The result is a big increase of the utilization factor of the rolling mill.
As mentioned, the increase in annual production of the plant is a considerable advantage introduced by FLUR®
SYSTEM, especially for the existing rolling mills.
For the new rolling mills, less shutdown hours means more available hours of production, so, for the same annual
production, the hourly capacity of the reheating furnace could be lower than in a standard mill. This involves the
reduction of operating costs regarding the fuel consumption of the furnace, furthermore lower capacity of the
reheating furnace involves less changes of the rings (or grooves) due to wear, increasing even more the hours of
production per year.
THE USE OF FLUR® SYSTEM DOES NOT INVOLVE ANY OPERATIONAL COSTS.
THE USE OF FLUR® SYSTEM DOES NOT INVOLVE ANY CIVIL WORKS.
THE INSTALLATION TIME OF FLUR® SYSTEM IS VERY FAST.
FOR THE INSTALLATION, THE PLANT MUST BE STOPPED ONLY FOR A FEW DAYS.
PERT FLUR® FAST LOCK-UNLOCK RING SYSTEM IS COVERED BY AN INTERNATIONAL PATENT.
| 54
TECHNO-ECONOMICAL BENEFITS
TECHNICAL FEATURES
The first system used for the locking of the rings, was a mechanical locking system. In this system, the locking of the
ring was made by friction, but for an adequate locking, it needs at least 40’000 Kg of axial locking force. This value
cannot be reached with manual tight of the locking nut of the system, so, could occur the slippage of the rolling ring
respect the shaft. In addition, in case of cobble, the shaft can be seriously damaged.
For these reasons, today, the ring locking system is an hydraulic locking, but involves:
XX Use of hydraulic devices for the unlocking/locking of the ring

XX High changing times (more than 4-5 minutes per ring)
XX Rescue to damage the shaft
XX Unsafety changing operations, due to the use of heavy hydraulic devices
PERT FLUR® System, instead, is a mechanical coupling between the rolling ring and the shaft, the slippage of the
ring is avoided as PERT technicians has studied a particular connection, covered by international patent, between the
ring and the shaft (without feather key).
PERT FLUR®, is a self – locking system, which exploits the power of the incoming rolled bar for the mechanical
locking between the ring and the shaft. FLUR® is designed to withstand up to 300 Kg of locking force, that is 2 times
higher than the typical maximum force of a rolled bar of a fast finishing block designed for max. speed of 120 m/s.
In addition PERT have avoided the use of hydraulic system for the ring locking (we don’t need 40’000 Kg of axial
locking force), so, with a simple manual tool or pneumatic drill, once unscrew only one nut, the ring can be replaced.
The timing of this changing is only 1 minute per ring.
PERT FLUR® System can be adapted also for the tungsten carbide rings locking in the finishing stands of the rolling
mill (cantilever stands, housingless and PERT BS Stands).
| 55 TECHNICAL BOOK
PERT FLUR® SYSTEM
COMPARISON TABLE BETWEEN PERT FLUR® SYSTEM

AND OTHER COMMON SYSTEMS FOR INCREASING ROLLING MILL PRODUCTIVITY
Until today, the systems more utilized for substantially increasing the yearly production of the rolling mills are:
1. Multislitting technology
2. Billet welding machine
These technolgies allow to increase the production on yearly base, but this means also increasing the operational
costs and the difficulties in managing the plant.
In the table which follows, a comparison between the mentioned used systems and FLUR® are shown:
MULTISLITTING BILLET WELDING FLUR®

MACHINE
ANNUAL PRODUCTION Depends on the number of strands +5% +2,5% ÷ +11,5%
INCREASE
CAPITAL COST HIGH HIGH VERY LOW
OPERATIONAL COSTS Higher number of guides Higher maintenance NONE

Higher wear of guides Higher electrical power
Higher spare parts consumption
Higher electrical power Higher spare parts
consumption
ADVANTAGES Very high production increase No cobbles No civil works
No interbillet time No operational costs
No tail and head crops No changes in the mill configuration
Independent of billet size, steel
grade etc…
DISADVANTAGES Changes in the mill configuration Higher space required NONE
Low final product quality Higher capital cost
Higher numbers of cobbles Skilled personnel
PAY BACK 24 – 30 Months 18 – 25 Months 1 – 6 Months
For the elaboration of the graph, it was assumed

the same value of the increased yearly production,
both with Flur® and Billet welding. For the Billet
welding machine, it was assumed as a starting
stock, a billet size 150x150 mm, in case of smaller
sizes (130x130 mm ), the payback period will be
higher.
For rolling mills capacities exceeding 800’000 –
900’000 t/y, Billet welding machine cannot be
used, due to the fact that this rolling mills are
equipped for 2 strands rolling.
All the considerations above mentioned, are not
needed for the FLUR® System, because it can be
used independently of billet size, steel grade or
yearly capacity of the rolling mill.
| 56
From the graph, it becomes clear that the use of FLUR® System makes sense also in a small capacity rolling mills
(150’000 – 300’000 t/y), conversely the Billet welding machine has a payback period of about 3 – 4 years.
FLUR® System has its maximum efficiency in the medium – high capacity rolling mills, where the impact of the hours
spent for the stands/grooves changing, is higher.
For the Billet welding machine, must be take into account that, in addition to the starting investment, the rolling mill will
be at least 20 m longer, so also the buildings will be longer in the same way.
FLUR® System has no operative cost, conversely Billet welding machine involves higher power consumption, higher
maintenance, spare parts and consumables, contributes to the increase of noise and unsafely operations.
REFERENCE PLANTS ANALISYS
HIGH SPEED REBAR MILL

Number of shifts: 3
Standard mills are characterized by the high speed production of small rebar sizes ( 8 mm up to 18 mm) at rates of
80% of the total annual production. So in this case the annual production of the range of rebar from 8 mm up to 18
mm, is 400’000 t/y.
All the smaller rebar sizes are rolled on two strands contemporary through the two 6 - stand finishing blocks.
The finishing mill of PERT high speed rebar mill is equipped with one 2xTechnology TWISTFREE finishing block.
STANDARD MILL PERT HIGH SPEED REBAR MILL
Finishing mill configuration: Finishing mill configuration:
2 fast finishing block of 6 stands each PERT 2xTECHNOLOGY TWISTFREE finishing block
Total number of rings: Total number of rings:

n = 2 × 6 × 2 = 24 rings n = 2 × 6 × 2 = 24 rings
Ring changing time: Ring changing time:

4 min per ring (employing 6 people) 1 min per ring (employing 3 people)
| 57 TECHNICAL BOOK
PERT FLUR® SYSTEM
Operating time for 8 mm – 18 mm production, per year:

7200 × 0.80 = 5760 h corresponding to 240 days per year
Product mix:
PRODUCTS PRODUCT DAYS PER HOURS PER NUMBER
MIX YEAR OF YEAR OF OF FINISHING
PRODUCTION PRODUCTION STANDS
8 – 10 mm 45% 108 2592 6
12 – 14 mm 35% 84 2016 4
16 – 18 mm 20% 48 1152 2
Grooves working life for rings of finishing block stands:

Φ GROOVE LIFE [tons] GROOVE LIFE [hours]* RING QUALITY
8 – 10 mm 1000 12.5 Carbide
12 – 14 mm 1400 17.5 Carbide
16 – 18 mm 1800 22.5 Carbide
*referred to 80 t/h
Summary table:
STANDARD HIGH SPEED PERT HIGH SPEED
REBAR MILL REBAR MILL
Annual hours of production 7200 7200
Annual hours of production for range 8 mm up 5760 5760

to 18 mm
Reheating furnace capacity 80 t/h 80 t/h
Total hours for changes per year 482 h 121 h
Annual production 500’000 528’880
Hourly capacity of the furnace for the same 80 t/h 75 t/h

annual production
Increasing in annual production thanks to the use of PERT FLUR® with different hourly capacity of the rolling mill:
HOURLY ANNUAL INCREASED PAY BACK
CAPACITY CAPACITY PRODUCTION
80 t/h 500’000 t/y +28’880 t/y +5,8% 5 months
110 t/h 650’000 t/y +54’780 t/y +8,4% 2.6 months
130 t/h 800’000 t/y +76’310 t/y +9,5% 2 months
160 t/h 1’000’000 t/y +115’680 t/y +11,6% 1.2 months
Please note that cost for rolling such additional production are just energy consumption and wear
parts costs (equivalent to approx. 25% of the total transformation costs per ton, from billet to rolled
finished product) as costs for debt service, infrastructure and personal are not affected by the
increase of the production.
| 58
Summarized table of the less hourly reheating furnace capacity due to the use of PERT FLUR System.
REHEATING FURNACE CAPACITY – STANDARD REHEATING FURNACE

REBAR MILL CAPACITY – PERT REBAR MILL
80 t/h 75 t/h
110 t/h 103 t/h
130 t/h 120 t/h
160 t/h 145 t/h
BENEFITS:
1. +5,8% ÷ +11,6% increased annual production
2. Smaller reheating furnace due to the availability of more hours of production per year ( higher utilization factor of
the rolling mill)
3. Fuel savings due to the smaller capacity reheating furnace
4. Rings changing operation employing a team of only 3 persons instead of a team of 6 persons
5. Rings changing performed without hydraulic or special devices
6. Thanks to the use of PERT 2xTECHNOLOGY TWISTFREE Finishing Block, the use of 2 fast finishing block,
in the finishing mill, is avoided. The advantages are:
6a) Only one block instead of two
6b) Less civil works
6c) Only one quenching line
6d) Less spare parts
7. Easy maintenance
8. Safety changing operations, due to the elimination of hydraulic device for ring locking/unlocking
| 59 TECHNICAL BOOK
PERT FLUR® SYSTEM
REBAR MILL

Number of strands: 2/3
Number of shifts: 3
Standard mills are characterized by the multi-slitting technology applied in the finishing mill, for the smaller rebar sizes.
In this case we supposed a 2 – slit for rebar 8 mm up to 14 mm and single strand for 16 mm up to 18 mm.
The finishing mill of PERT high speed rebar mill is equipped with one 2xTechnology No Twist block.
STANDARD REBAR MILL PERT HIGH SPEED REBAR MILL

6 finishing stands – 2 or 3 slitting for smaller sizes PERT 2xTECHNOLOGY TWISTFREE finishing block
Complete stand changing time: Total number of rings:

20 min per stand (with crane) n = 2 × 6 × 2 = 24 rings
Grooves changing time: Ring changing time:
5 min per groove 1 min per ring (employing 3 people)
Operating time for 8 mm – 18 mm production, per year:

7200 × 0.80 = 5760 h corresponding to 240 days per year
PRODUCTS PRODUCT DAYS PER HOURS PER NUMBER

MIX YEAR OF YEAR OF OF FINISHING
PRODUCTION PRODUCTION STANDS
8 – 10 mm 45% 108 2592 6
12 – 14 mm 35% 84 2016 4
16 – 18 mm 20% 48 1152 2
Grooves working life for rolls of finishing stands:

STAND N° 8 mm – 10 mm 12 mm – 14 mm 16 mm – 18 mm ROLLS QUALITY
1 1500 tons 960 tons 720 tons Cast Iron
2 1500 tons 480 tons 360 tons Cast Iron
3 960 tons 960 tons - Cast Iron
4 480 tons 480 tons - Cast Iron
5 960 tons - - Cast Iron
6 480 tons - - Cast Iron
| 60
Grooves working life of rings of finishing block stands:

Φ GROOVE LIFE [tons] GROOVE LIFE [hours]* RING QUALITY
8 – 10 mm 1000 12.5 Carbide
12 – 14 mm 1400 17.5 Carbide
16 – 18 mm 1800 22.5 Carbide
*referred to 80 t/h
When the rings (or groove) of the last passes of the finishing block will be worn, all set of rings (or
groove) must be replaced with new ones.
Summary table:
STANDARD PERT HIGH SPEED
REBAR MILL REBAR MILL
Annual hours of production for range 8 mm up 5760 5760

to 18 mm

annual production
BENEFITS:
1. +6,4% increased annual production

2. Smaller reheating furnace due to the availability of more hours of production per year ( higher utilization factor)
3. Fuel savings due to the smaller reheating furnace
4. Rings working life longer than cast iron rolls working life
5. Thanks to the use of PERT 2xTECHNOLOGY TWISTFREE finishing block, the use of multi-slitting technology
is avoided (higher quality of the final product, less number of rolling guides, less cobbles, shorter shutdown
production hours, lower costs)
6. Easy maintenance
| 61 TECHNICAL BOOK
PERT FLUR® SYSTEM
WIRE ROD MILL

Number of shifts: 3
Finishing mill equipped with 10 – stand fast finishing block, finishing speeds up to 120 m/sec.
STANDARD MILL PERT WIRE ROD MILL

10-stands fast finishing block PERT 10-stands fast finishing block
Total number of rings: Total number of rings:

n = 2 × 10 = 20 rings n = 2 × 10 = 20 rings
Ring changing time: 4 min per ring Ring changing time: 1 min per ring
(employing 10 people) (employing 4 people)
Operating time for 5.5 mm – 18 mm production, per year:

7200 h corresponding to 300 days per year
Product mix:
PRODUCTS PRODUCT DAYS OF HOURS OF NUMBER
MIX PRODUCTION PRODUCTION OF FINISHING
PER YEAR PER YEAR STANDS
5.5 – 6 – 6.5 mm 60% 180 4320 h 10
7 – 8 mm 15% 45 1080 h 8
9 – 10 – 11 – 12 mm 15% 45 1080 h 6
13 – 14 mm 5% 15 360 h 4
16 – 18 mm 5% 15 360 h 2
| 62
Grooves working life for rings of fast finishing block:

N° GROOVE LIFE [tons] GROOVE LIFE [hours]* RING QUALITY
1 3000 37.5 Carbide
2 3000 37.5 Carbide
3 3000 37.5 Carbide
4 3000 37.5 Carbide
5 2000 25 Carbide
6 2000 25 Carbide
7 1800 22.5 Carbide
8 1800 22.5 Carbide
9 1600 20 Carbide
10 1600 20 Carbide
*referred to 80 t/h
Summary table:
STANDARD WIRE ROD MILL PERT WIRE ROD MILL

annual production
Increasing in annual production thanks to the use of PERT FLUR® with different hourly capacity of the rolling mill:
HOURLY CAPACITY ANNUAL CAPACITY INCREASED PRODUCTION PAY BACK
40 t/h* 250’000 t/y +6’000 t/y +2,4% 20 months
80 t/h* 500’000 t/y +22’960 t/y +4,6% 5,2 months
150 t/h** 1’000’000 t/y +81’000 t/y +8,1% 1,5 months
200 t/h** 1’300’000 t/y +142’000 t/y +11% 0,9 months
* referred to one strand wire rod line equipped with one 10-pass block
** referred to two strands wire rod line equipped with two 10-pass block (each block has a dedicated team of 4 persons for the changes
operations)
| 63 TECHNICAL BOOK
PERT FLUR® SYSTEM
Summarized table of the less hourly reheating furnace capacity due to the use of PERT FLUR System.
REHEATING FURNACE CAPACITY REHEATING FURNACE CAPACITY

– STANDARD WIRE ROD MILL – PERT WIRE ROD MILL
80 t/h 75 t/h
150 t/h 140 t/h
200 t/h 183 t/h
220 t/h 200 t/h
BENEFITS:
1. +2,4÷ +11% of annual production

2. Smaller reheating furnace due to the availability of more hours of production per year ( higher utilization factor)
3. Fuel savings due to the smaller reheating furnace
4. Rings changing operation employing a team of only 4 persons instead of a team of 10 persons
5. Rings changing performed without hydraulic devices or special devices
6. Easy maintenance
| 64
PERT FLUR® SYSTEM
Advantages on Capital Costs Advantages on Operative Costs

Technology Advantages CAPEX OPEX
Safely ring changing Small reheating Less reheating furnace

operations furnace capacity fuel consumption
No hydraulic devices
Less manpower
for rig changing Cheaper than others
common systems
for increasing yearly
productivity
Easy maintenance Less manpower
Easy fast finishing block Increasing yearly production:

management +2.5 up to +11.6%
| 65 TECHNICAL BOOK
PERT
ROLLING MILLS

Comparison about civil works
and building dimensions –
PERT Rolling Mill vs. standard
rolling mill
| 67 TECHNICAL BOOK
PERT FLUR® SYSTEM
FORWARD
Whoever will be the supplier of the mechanical part of the rolling mill, whether European, Chinese or another, none of
them is going to affect the costs related to civil works, excavations for foundations and buildings of the plant, since
the technology of the rolling train is the same. The new and revolutionary PERT BS Stand and in general PERT new
equipment, as well as introduce significant technical and economical advantages during the working of a rolling mill,
are also drastically reduce the costs related to civil works, excavations and buildings.
INTRODUCTION
This technical section was written to emphasize the savings in terms of civil works and buildings dimensions,
introduced by the use of PERT revolutionary equipment for long product rolling mills.
The philosophy used since the first issue of the layout of the rolling mill, has been to contain the buildings dimensions,
the length of the electrical cables and pipes for fluid distribution, as well as to ensure an optimal material flow
(charging and discharging of billets and final product, maintenance….).
The development and design of PERT equipment have been made accordingly to achieve and ensure the above
objects. A very important factor, which is often not given the right importance, is that PERT is not only a company
that designs and supplies complete plants for the Steel Industry, but it is first and foremost an engineering company
which covers the engineering field at 360°.
PERT has the capacities to manage the whole project not only in terms of process and equipment supply, but also
from the point of view of optimizing the layout, optimizing the electrical and piping distributions, the design of civil
works and buildings structure and the design and supply of auxiliary plants (water treatment plant…).
Knowing all the technical aspects and engineering of a rolling mill, PERT is able to study solutions tailored to the
Customer needs, also proposing unconventional approaches and solutions.
ADVANTAGES INTRODUCED BY USING PERT EQUIPMENT
PERT rolling mills are equipped with BS Stands, in the roughing and intermediate mill, while the finishing mill is
equipped with one of the finishing blocks that are part of the wide range of PERT finishing blocks.
Standard mills are equipped with common housingless or cantilever stands, involving the well-known problems of use
of this typology of stands. The advantages introduced by the use of PERT equipment regarding the reduction of civil
works and building dimensions, are:
1. PERT BS Stands in Vertical arrangement has an height of just 4.30 m, against the average height of 7-8 m of
the common housingless stands. Cantilever stands has a lower height, but requires an excavation of about 5 m
depth (the vertical stands are driven from the bottom). ( Referred to stands dia = 650)
EXCAVATION FOR CIVIL WORKS

FOUNDATIONS
PERT ROLLING MILL Less excavation for the foundations • Less civil works due to the smaller
dimensions of the stands
• Less civil works due to the different typology
of foundations
STANDARD ROLLING MILL Heavy excavation for the foundations Heavy civil works
| 68
COMPARISON
BS Stand size 420 (BS 420)
2. The compact dimensions of the BS Stands, both in Horizontal and Vertical arrangement, allows the use of very
simple foundations, practically all the rolling train rests on an unique concrete platform, which require smaller
excavations, lower quantity of reinforced concrete and involves lower times of erection.
EXCAVATION FOR CIVIL WORKS

FOUNDATIONS
PERT ROLLING MILL Less excavation for the foundations • Simple foundations
• Unique concrete platform
STANDARD ROLLING MILL Heavy excavation for the foundations • Different typology of foundation for each
machinery of the rolling train
| 69 TECHNICAL BOOK
PERT FLUR® SYSTEM
3. The use of the PERT finishing block in the finishing mill, allows a considerable reduction in excavations for the
foundations and civil works. Compared to a standard finishing mill, usually equipped with 6 finishing stands, the
civil works and the excavations are lower.
4. The lower height of the PERT BS Stands allows:
BUILDINGS
PERT ROLLING MILL • The run ways of the cranes are just at a height of +7.5 m
• The height of the building are reduced
• Lighter steel structure
• Columns with lower weight
• Less wall cladding
STANDARD ROLLING MILL • The run ways of the cranes are at a height of minimum +10 m
• Higher height of the building
• Heavier steel structure
• Columns with higher weight
• Higher wall cladding
5. The use of the finishing block in the finishing mill, allows a considerable reduction in the buildings length. The
PERT finishing blocks (6 stands), in fact, occupies no more than 8 m, while a standard finishing mill equipped
with 6 finishing stands, occupies up to 30 m. Finishing mill equipped with 2 finishing blocks, instead, may
occupy up to 50 – 60 m.
BUILDINGS
PERT ROLLING MILL • The length of the building are reduced
• Less number of columns
• Less covered surface of the building
• Less wall cladding
• Shorter run ways of the cranes
STANDARD ROLLING MILL • Higher length of the building
• Higher number of columns
• Higher covered surface of the building
• Higher wall cladding
• Longer run ways of the cranes
| 70
COMPARISON
Finishing mill (2xTECHNOLOGY

Finishing Block) overview in erection
phase. It can be noted that the
foundations are very simple and
small in dimensions.
6. The weight of PERT BS Stands, in comparison with others traditional stands, is lower, so the advantages are:
BUILDINGS
PERT ROLLING MILL • Smaller load capacity of the cranes (- 40%)
• Lighter steel structure
STANDARD ROLLING MILL • Higher load capacity of the cranes
• Heavier steel structure
Obviously the weight reduction is not going to affect the stiffness and rigidity of the rolling stand.
COMPARISON BETWEEN PERT ROLLING MILL AND STANDARD

ROLLING MILL - CIVIL WORKS AND EXCAVATION FOR FOUNDATIONS
Annual production: 500’000 t/y

Hourly capacity: 80 t/h
Starting billet size: 130x130x12’000 mm
Plant on the ground level
18 stands
2-slitting for smaller rebar sizes
STANDARD ROLLING MILL PERT ROLLING MILL

Roughing Mill: Stand size 550 mm x 6 Roughing Mill: Stand size 550 mm x 6
Intermediate Mill: Stand size 420 mm x 6 Intermediate Mill: Stand size 420 mm x 6
Finishing Mill: Stand size 320 mm x 6 Finishing Mill: 2xTECHNOLOGY Block size 250 mm (6 Passes)
| 71 TECHNICAL BOOK
PERT FLUR® SYSTEM
ROUGHING MILL - EXCAVATIONS FOR FOUNDATIONS AND CIVIL WORKS
STANDARD ROLLING MILL
Height of vertical stand: 7,4 m

Interaxis between the stands: 2 m
EXCAVATIONS FOR CIVIL WORKS

FOUNDATIONS
VERTICAL STANDS 64 m3 39 +29* m3
HORIZONTAL STANDS 58 m3 41 m3
TOT. 366 m3 327 m3
* the second number consider the concrete support structure.
PERT ROLLING MILL

EXCAVATIONS FOR CIVIL

FOUNDATIONS WORKS
VERTICAL STANDS
HORIZONTAL STANDS
TOT. 145 m3 126 m3
The foundations are the same, both for vertical and horizontal stands, it is a single concrete slab. The support
structure of the vertical stands, are made in steel carpentry instead of reinforced concrete, this means faster erection
of the rolling train.
| 72
COMPARISON
Typical foundations for a BS 650 in

vertical arrangement
INTERMEDIATE MILL - EXCAVATIONS FOR FOUNDATIONS AND CIVIL WORKS


FOUNDATIONS
TOT. 633 m3 480 m3
* the second number consider the concrete support structure.
| 73 TECHNICAL BOOK
PERT FLUR® SYSTEM
PERT ROLLING MILL
Height of vertical stand: 4 m


FOUNDATIONS
VERTICAL STANDS
HORIZONTAL STANDS
TOT. 200 m3 170 m3
The foundations are the same, both for vertical and horizontal stands, it is a single concrete slab. The support
structure of the vertical stands, are made in steel carpentry instead of reinforced concrete, this means faster erection
of the rolling train.
Typical foundations for a BS 420 in horizontal

arrangement
FINISHING MILL - EXCAVATIONS FOR FOUNDATIONS AND CIVIL WORKS


FOUNDATIONS
TOT. 795 m3 534 m3
*the second number indicates the civil works regarding the support structure, it can be made in steel structure instead of concrete.
| 74
COMPARISON
PERT ROLLING MILL
PERT 2xTECHNOLOGY FINISHING BLOCK


FOUNDATIONS
VERTICAL STANDS
HORIZONTAL STANDS
TOT. 35 m3 45 m3
Typical foundations for PERT Finishing Block

(PWB35)
With the installation of PERT finishing block, the foundation are reduced in dimension and are more easy instead a
single six stands in horizontal and vertical configuration. This reduce also the installation timing. The PERT finishing
blocks are ready to roll due to the fact that are tested in PERT workshop before shipping.
TOTAL ROLLING TRAIN EXCAVATIONS FOR FOUNDATIONS AND CIVIL WORKS

FOUNDATIONS
ROUGHING MILL 366 m3 327 m3
INTERMEDIATE MILL 633 m3 480 m3
FINISHING MILL 795 m3 534 m3
TOT. 1794 m3 1341 m3
| 75 TECHNICAL BOOK
PERT FLUR® SYSTEM
PERT ROLLING MILL

FOUNDATIONS
ROUGHING MILL 145 m3 126 m3
INTERMEDIATE MILL 200 m3 170 m3
FINISHING MILL 35 m3 45 m3
TOT. 380 m3 341 m3
Summary Table

FOUNDATIONS
STANDARD ROLLING MILL 1794 m3 1341 m3
PERT ROLLING MILL 380 m3 341 m3
SAVINGS - 1414 m3 - 1000 m3
COMPARISON BETWEEN PERT ROLLING MILL AND STANDARD

ROLLING MILL -BUILDING DIMENSIONS
Annual production: 500’000 t/y

Hourly capacity: 80 t/h
Starting billet size: 130x130x12’000 mm
Plant on the ground level
18 stands
2-slitting for smaller rebar sizes

Length: 276 m Length: 192 m
Width: 25 m Width: 25 m
N° of Bays: 2 N° of Bays: 2
Height of the run ways of the cranes: 10 m Height of the run ways of the cranes: 7.5 m
Distance between columns: 12 m Distance between columns: 12 m
Covered surface: 13’800 m2 Covered surface: 9’600 m2
| 76
COMPARISON
COMPARISON TABLE BETWEEN PERT ROLLING MILL AND STANDARD

ROLLING MILL - BUILDING DIMENSIONS

COVERED SURFACE 13’800 m 3
9’600 m3
SINGLE COLUMN WEIGHT 6800 Kg 5500 Kg
TOT. COLUMNS WEIGHT 489’600 Kg 280’500 Kg
WEIGHT OF RUN WAYS FOR CRANES 452’640 Kg 314’880 Kg
TOT. WEIGHT OF TRUSS 487’320 Kg 340’600 Kg
WALL CLADDING SURFACE 24’300 m 3

16’500 m3
TOT. WEIGHT OF WALL CLADDINGS (1 mm) 306’180 Kg 206’250 Kg
OTHERS +5% +5%
TOTAL WEIGHT 1’822’527 Kg 1’199’341 Kg
WEIGHT PER m2 ≈ 132 Kg/m2 ≈ 125 Kg/m2
Summary Table
TOTAL WEIGHT
STANDARD ROLLING MILL 1’822’527 Kg
PERT ROLLING MILL 1’199’341 Kg
SAVINGS 623’186 Kg
Additional advantages introduced by the smaller dimensions of the buildings are:

XX Lower cost for buildings erection
XX Lower costs for buildings civil works
XX Lower cost for buildings exavations
XX Lower erection time, due to the smaller buildings dimensions and to the reduced amount of civil works and
excavations
The timing of erection of industrial buildings and related civil works, are crucial for the timely realization of the project.
The longest delays that occur very often in the construction of new steel plants, are almost always attributable to
these aspects.
Please note these evaluations as a result of an estimate, we tried to analyze two plants as similar as possible in terms
of productivity and general arrangement.
However, must be taken into account that the equipments proposed by PERT, are of new design
and they have a revolutionary concept and which cannot therefore be compared to other equipment
proposed by other competitors. This fact justifies such a big difference in the amount of excavation
and civil works for the rolling train.
| 77 TECHNICAL BOOK
PERT FLUR® SYSTEM
| 78
PERTECO
WATER TREATMENT
PLANT
| 79 TECHNICAL BOOK
PERTECO
INTRODUCTION
Water is necessary for cooling both the machinery and the steel during the functioning of a rolling mill.
With the proper cooling the machinery duration could increase significantly and this is particularly evident in rolls
duration. The fast cooling of the rebar with water is used to perform the thermal treatment on-line (quenching).
Through this treatment the mechanical characteristics of carbon steel are improved without adding expensive
additives to the steel to obtain the same result.
The Water Treatment Plant (WTP) is typically called “auxiliary plant”, but it is essential to assure the
stability and quality of production.
The WTP is carefully designed and built considering the characteristics of the rolling mill, the site of installation
(climatic conditions, available space and so on) and the special Customer requirements.
To supply the WTP for Rolling Mill PERT is supported by the sister company PERTECO that designs and supplies
water and fume treatment plants. The complete supply allows the realization of well integrated and rational whole
project, with optimized spaces and water distribution.
GENERAL DESCRIPTION OF THE WTP
About 90% of the amount of water required for cooling is used in cooling through direct circuits, in which the water
comes in contact with the material in production and with different parts of the machinery involved. The remaining
part is used in cooling with indirect circuits.
The philosophy that underlies the supply of a WTP is that of providing the required cooling in the plant with a
sufficient quantity and quality of water. The circulating water has to respect certain limits to prevent problems such
as encrustations, corrosion or wear. After the use as cooling fluid it is usually treated, when necessary, to remove the
solids (scale) and the oils and cooled before its reuse in the same circuit.
Fig 1. –Simplified Process Flow Diagram of

the WTP for rolling mill
| 80
WATER TREATMENT PLANT
To guaranty an adequate quality of water in the circuits, the drains from the evaporation towers used for cooling have
to be managed properly. Often, a proper treatment of the available water on site (raw water) before its use as make up
water in the plant is also necessary.
Fig 2. Cooling towers
For each plant an adequate treatment for raw water is selected. The treatment depends on the water source (network
water, natural well water, river water, etc.) and in most of the cases is aimed at reducing the salinity, the hardness and
pH correction. The purpose is to produce make up water with adequate quality respecting the required limits in the
cooling circuit (operating properly at the evaporation towers) and to reduce the water consumption. In most modern
applications the reverse osmosis is often applied.
Fig 3. Reverse osmosis (25 m3 /h)
Additionally, to obtain the desired quality and reduce the consumption of water, chemicals (anti scaling, anticorrosive
according to the needs) are added to the make up water.
The water consumption of the plant is given by the raw water flow. To comply with the above mentioned requirements,
the intake can be of about 3-5% of the total circulating flow, variable according to the configuration and operating
conditions of the WTP and the climatic conditions on site.
Particular treatments needed for the raw water or problems with scarcity of water are studied case by case.
| 81 TECHNICAL BOOK
PERTECO
With this purpose PERTECO can propose a WTP with low water consumption based on hybrid and dry coolers
substituting the traditional evaporative towers and on the recovery of the towers’ drains for their reuse in the WTP
(Drains Recovery WTP). With such solution water consumptions is reduced to less than 25% of that of a traditional
plant. It implies also a noticeable economic benefit due to the reduction of the consumption costs for chemical to be
added to make up water.
Fig 4. WTP for meltshop, CCM and RM with low

water consumption (under construction)
| 82
EQUIPMENT
The equipment are selected and designed based on the data of the cooling water flowrates and corresponding
temperature increase between the inlet and the outlet of the different Users.
Water coming from the Users in direct and indirect circuit are treated separately trough the sequence of equipment
below indicated. The reported information has to be considered as a general reference. Some variations could occur
in each plant.
| 83 TECHNICAL BOOK
PERTECO
The adopted solution by PERTECO generally foresees an adequate subdivision of the direct circuits in WTP, due to
the different requirement at the take over point, but also to the degree of pollution. For example the water used for
quenching has to be fed to the plant at a higher pressure with respect to the other circuits (12-13 barg compared to
3-4 barg) for its use in the coolers, but additionally the water coming from quenching is not polluted with oils and it
contains solids with dimensions and concentrations inferior to those coming from other sections of direct cooling. So
it has adequate characteristics to be fed directly to the sand filters without mixing with the other dirtier flows.
In the following some picture of installed equipment are shown.
From the left

Fig 5. Hydrocyclone
Fig 6. Settling basin
Fig 7. Oil skimmers
Fig 8. Sand filters battery (sludge
thickener on background)
| 84
REAL CASE
Now a practical case, that has recently confirmed the importance of the quality of water used in order to grant the
continuity in production, is presented.
From its start-up, the rolling plant has been cooled using raw water directly as make up water, with no treatment or
additivation, refused by the Customer to cut the costs.
In spite of the correct functioning of equipment for the solids separation (scale separator, clarifier, sand filters) and
cooling (cooling towers) equipment, after a few months serious damage was evidenced in different parts of the plant
that resulted in a prolonged stop in production for restoration.
To clarify the causes of the damage PERTECO performed the analysis of the raw water being used as make up
water in the plant.
Analyses carried out

The analyses were made to verify the quality of the water and its compliance with the values for a correct functioning
of the machinery composing the rolling line.
Based on the available data from the analysis, the indices to evaluate the aggressiveness (tendency to dissolve the
calcium carbonate encrustations) and the water’s corrosivity (attack to metallic materials) were calculated.
Aggressiveness indices: Langelier, Ryznar, EPA
Desired value Analysis value

(Temperature for LI
and RI = 25°C)
Langelier (LI) Encrusting if > 0 0,8
Desired -1 < LI < 1
Ryznar (RI) Encrusting if < 6 6,40
Desired 5,5 < RI < 6,5
EPA Encrusting if > 12 12,89
Desired 10 < EPA < 14
Observations:
The indices indicate that the water has equilibrium characteristics (encrusting-dissolvent).
It does not have encrusting characteristics. There are no protective encrusting films being formed against corrosion.
Corrosion Indices: Leroy, Larson
Desired value Analysis value

Leroy For corrosion to be unfavorable value should be 0,4
close to 1
Desired 0,7 < Leroy < 1,3
Larson For corrosion to be unfavorable value should be 4,7
< 0,4 – 0,6
(If > 1 it has a strong corrosive tendency)
Observations:
Both indices indicate a strong corrosive tendency.
| 85 TECHNICAL BOOK
PERTECO
CONCLUSIONS
The analysed water does not respect the prescribed limits for the cooling water and has a strong corrosive tendency.
The maximum limits are not respected, particularly for the quality of the direct circuits (total hardness, conductivity).
The sulphate and chloride concentration is at its limit.
As an aggravating factor there is an increase in concentration in the water flowing inside the circuits due to the
evaporation, which elevates the parameter’s values as the process goes on (the number of concentration cycles
increases).
As a consequence there has been evident damage in the machinery, for example in the fast finishing block, made with
suitable steel for the application as long as the water respects the prescribed characteristics and indications by the
supplier for the correct operation.
In the exemplified case, corrosion was observed in short times for both the carbon steels and the alloy steels that
wrongfully came into contact with water, even in non stressed and stationary parts (Fig. 10).
Fig. 9 – Corrosion of carbon steels and alloy steels in the fast finishing block
As a final support to the Customer, to remedy the situation in which the restart times had to be reduced to the
minimum, it was advised to adopt the use of a multifunctional chemical additive (anti scaling, anticorrosive and
dispersant), that protects the tubes and the machinery from the corrosion. Such additives are typically added in very
low quantities in the industrial cooling circuits, they do not alter the macroscopic composition of the water, but carry
out an efficient protective action on the plants.
The dosage can be done on the make up piping with concentrations ranging in the tens of ppm to obtain a
concentration of about 1,5 times superior in the circuit. This intervention should be combined to the correct use of the
evaporation towers.
In conclusion the proposed solution has limited impact in the plant. However, this will imply a higher consumption of
water with respect to a typical situation in which the water, duly treated, has the ideal characteristics to operate with 3
concentration cycles.
Furthermore, there will be a cost for chemical consumption in the order of 100.000 €/year, whose real value will be
evaluated based on the effective dosage in the plant.
The experience demonstrates the importance of the WTP for the production continuity.
| 86

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PERT

PERT FINISHING BLOCKS:

PERT ROLLING MILLS:

SECOND GENERATION OF PERT BS STANDS

Fig 1. 3D view of a roughing mill in

Fig 2. PERT BI-SUPPORT Stand

The finality of second generation BI-SUPPORT stands development project is:

To satisfy these purposes, PERT has proceeded as follows:

1. Improve final product quality

1a – Reduction of reactions on constraints, as shown in the following diagrams:

TRADITIONAL STANDS BI - SUPPORT STANDS = REACTION SURFACE

1c – Length of stress path

TRADITIONAL STANDS BI-SUPPORT STANDS

1d – Ring-holder shaft flexion

3. Reduce the investments for buildings, cranes and civil works

Fig 3. Difference of dimension between housing less stands and

The advantages, that such a contained overall make possible, are:

4. Reduce spare part costs

Adjusting screw for rolls

Fig 5. BS Stand Typical

GRAPHIC OF LOAD DISTRIBUTION

SUMMARIZED LOADS GRAPHIC

LOAD LOAD LOAD

MAX GAP MIDDLE GAP MIN GAP

5. Increase the safety of changing and maintenance operations

PERT BS HOUSINGLESS CANTILEVER

Absence of spindles Spindles as a spare part Absence of spindles

Absence of spindles Self-balancing spindle support Absence of spindles

Absence of chocks Chocks as a spare part Absence of chocks

Absence of chocks Hydraulic chock balancing system Absence of chocks

No piping on board Piping on board Piping on board

Shiftable stand Shiftable stand Fixed stand

- 85 % spare parts High number of spares High number of spares

PERT BS HOUSINGLESS CANTILEVER

Advantages on Capital Costs Advantages on Operative Costs

Less energy consumption

Smaller buildings Less spare parts

Less excavations for

Increased bearings working life:

Less lubrication oil

Rebar rolling mill

Mill capacity: 50 t/h

Total Electrical savings per year:

Assuming the cost of electrical energy of 0,08 €/kWh (European cost)

Table of savings regarding different rolling mill capacities:

Fig 1. Simple scheme of the

Fig 2. BS Stand – Gear

Fig 3. Braking load diagram

Referring to Figure 3, the total braking torque of cantilever stand is:

The total braking torque of BS stand is:

Friction Load on Reaction Braking torque Lubrication unit

Fig 4. Difference between

BS stand lubrication 220 CST 2.000 litres low No

ON BOARD REST BAR

A new typology of stand needs a new typology

The main advantages of PERT rest bar are:

The entire rest bar is movable, as shown in figure

The main advantages introduced by PERT

All the hydraulic and water piping

(cooling water collectors) can be 1 2

1 - Rest bars in working position

PERT LLR Rolls® for a

PERT LLR Rolls® consist of: