At Blackrow Group, we are proud to announce the successful installation of advanced machines and comprehensive piping systems for our valued clients. Our expertise in this field has allowed us to seamlessly integrate our own technology and efficient infrastructure into their operations.
The construction of a Billet Caster Evacuation Area is a complex project that involves the design, engineering, and installation of specialised machinery for producing high-quality steel billets.
This case study presents an overview of the construction process, highlighting the approach, resources supplied, challenges faced and lessons learned during the project.
The new Billet Caster Evacuation Area will manufacture lengths of semi-finished steel – known as billets – with enhanced internal and surface qualities, enabling them to become more competitive and expand their offering to customers.
The £54 million project is the largest single investment Jingye has made since purchasing British Steel in 2020.
Blackrow Group provided 85 personnel for the successful execution of the Billet Caster Evacuation Area and by bringing their expertise, skills, and coordination it ensured the project progressed efficiently and safely.
This included the following disciplines – Site Manager, Piping Engineers, Welding inspector, Quality Controllers, Site Admin, Supervisors, Welders, Pipefitters, Mechanical fitters, Electricians, Platers, Commissioning Engineers, Surveyor, AP Lift Supervisor, Riggers, Plant Operators, Material Controller, Semi-skilled, Labourers, Painters and a dedicated Health & Safety Advisor.
Discharge Roller Table
Also known as a run-out table or roller conveyor, an essential component in the continuous casting process for steel billets. Its primary function is to transport and guide the freshly cast billets from the caster to the subsequent stages of the steel manufacturing process.
111.320,000 KG
The client benefited from Blackrow’s extensive heavy fabrication, laser cutting and precision machining capabilities, which enabled a swift resolution for any design flaws
Lateral Transfer Car Assembly
Also known as a billet transfer car or a billet transporter, its main function is to transport steel billets from the Discharge Roller Table to the Walking Beam Cooling Bed
78.702,000 KG
Blackrow supplied an AP lift supervisor to oversee the intricate and precise installation
of the 20 Ton Lateral Transfer Car.
Walking Beam Cooling Bed
A steel billet walking beam cooling bed is a crucial component in the steel manufacturing process. As the billets are transported along the cooling bed, they are exposed to ambient air, which facilitates the cooling process. The cooling bed allows for controlled and gradual cooling of the billets, which helps to reduce internal stresses and prevent thermal cracking.
278.000,000 KG
A collaborative effort was made by a team of Blackrow employees, comprising of a structural engineer, surveyor, supervisors, platers, welders, riggers, and mechanical fitters to successfully install the walking beam cooling bed.
Pawl Collecting Table
The Pawl Collecting table plays a crucial role in the steel manufacturing process by providing a controlled environment for cooling, aligning, and preparing billets for subsequent operations. It helps improve the efficiency, quality, and handling of steel billets within the production line.
37.050,000 KG
Our engineers worked in conjunction with the surveyor to ensure the design measurements and tolerances were achieved. The billets may undergo some deformation during the rolling or casting process, and the collecting table helps straighten them and ensure uniform dimensions.
Water Treatment Plant & Cooling Towers
The WTP and cooling towers play a vital role in maintaining the optimal operating temperatures for the billet caster operations and processes, ensuring their reliability, efficiency, and longevity.
Lifting and installing the cooling towers with a 55-ton mobile crane is an intricate and carefully orchestrated process. Precise positioning and alignment among the riggers, lift supervisor, and crane operator are essential for this task.
Piping Systems
Various piping systems play crucial roles in ensuring the efficient and safe operation of the casting process.
Blackrow Group completed more than 4,000 welds to ensure that the hydraulic, cooling water, grease and skid lines met the necessary standards and specifications. Our team, consisting of highly skilled piping engineers and dedicated quality personnel, consistently delivered completion packs of outstanding excellence, adhering to a rigorous standard.
The construction of a Billet Caster Evacuation Area requires precise engineering and integration of various mechanical, electrical, and hydraulic systems. Coordinating the design and installation of these complex systems posed technical challenges throughout the project.
Efficiently coordinating multiple contractors requiring simultaneous access to cranes and scaffolding represents a critical challenge in construction project management. The complexity of scheduling, resource allocation, and ensuring safety and productivity across various work fronts demands meticulous planning and effective communication. Addressing these challenges necessitates a well-structured coordination strategy, proactive risk management, and open lines of communication among all parties involved.
Providing the appropriate management team was crucial in this scenario due to the significant number of Blackrow personnel present at the site. Ensuring the program was well-balanced and consistently aligned with the working team’s objectives was of paramount importance.
Thorough planning, including detailed design, accurate cost estimation, and realistic scheduling, proved instrumental in overcoming construction challenges and maintaining project timelines.
Implementing a comprehensive monitoring and quality assurance program enabled the early detection of issues and facilitated timely corrective actions, ensuring adherence to quality standards.
The overall project was a complex endeavour, demanding careful planning, technical expertise, and effective project management. By adopting a systematic approach, addressing challenges head-on, and applying lessons learned, the successful completion of the project can lead to improved production capabilities and increased competitiveness for the client in the steel manufacturing industry.
Supporting the UK steel industry is not just about business; it’s about preserving a key part of our national identity and industrial heritage.