Continuous Caster Roll Manufacturing & Reconditioning

Primetals Technologies specializes in manufacturing and reconditioning rolls and components for continuous casting machines. Using advanced metallurgical engineering, performance evaluations, failure analysis, computerized roll tracking, and proprietary weld overlays customized for each roller position, we deliver superior roll performance and exceptional value — backed by expert workmanship and rigorous quality assurance.

Our proprietary continuous caster roll overlay technology and service expertise empower customers with optimized roll designs and enhanced base materials—engineered to withstand the harshest mill environments. By analyzing roll erosion, corrosion, wear, and thermal fatigue, we define the variations and chemistry of overlay materials and apply advanced surface engineering and process controls tailored to each application.

The primary benefit of a roll overlay is to reduce operational wear while significantly extending roll life and reliability. This directly supports the roll’s core function: maintaining the shape and integrity of the cast product.

Benefits of Caster Roll Manufacturing and Reconditioning

• Typically outperforms OEM-supplied rolls 2-1 and up to 3-1

• Salvages the roll base material, which can yield a 25-50% cost savings compared to new roll options by applying patented welding wires

• Allows for optimization of the roll base material composition and the ability to apply proprietary surface overlays designed to combat the operational conditions in each area of the mill

• Decreases the long-term spend due to improved lifetime and opportunity for skim machining campaigns

• Increases mean time between repair (MTBR) driven by greater reliability

• Increases product yield by decreasing the possibility of product defects and production interruptions

Additional Roll Manufacturing and Reconditioning Services

• Retrofit of existing rollers to the latest technology, including EcoStar peripherally-cooled rolls

• Design, FEA analysis, and CAD/CAM machining

• Automated robotic welding for process optimization and consistent quality
• Journal and bore reconditioning
• Welding processes—SAW, FCAW, GMAW, GTAW, SMAW
• Non-destructive testing/failure analysis

• Roll fleet tracking and preventative/predictive maintenance scheduling via the Maintenance Asset Technology (MAT) platform