Menu

Castings

Our Cast Roll technologies offer Maximum Performance, Reliability, Flexibility, and Savings. We use our competence and technology to provide the ultimate cast roll solutions for your rolling needs.

Jump to a mill solution

About PCC’s Work

As an ISO 9001: 2008 certified company, we are serious about making certain that every cast roll leaves our facility meets or exceeds customer specifications. PCC’s casting technology is the foundation for the high-quality cast rolls used to meet the most demanding rolling mill applications. PCC offers a full range of static and spun cast rolls in compliment to PCC’s cemented carbide rolls. This guides us as we work towards a future where the best rolling solution is affordable and sustainable for all.

PCC Solutions

Every rolling mill is unique, which means that each one requires a tailor-made solution. PCC offers the most comprehensive range of products on the market and our experienced personnel is there to assist you in selecting the optimum roll application and provide service support over the entire operating life of your rolls. With a world-class product portfolio and global services, we are your leading partner for all rolling solutions.

Request a quote

Mill types

Bar

Rebar: 3-High, 2-High and Continous

Roughing Stand

  • ASB
  • NCIP

Intermediate Stand

  • NCIA
  • NEX™ HSS
  • Endura™
  • PCR30

Finishers Stand

  • NCIA
  • NCIC
  • NEX™ HSS (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Finishing Block

  • PCR30 – PCR20 (Big Rod)
  • PCR18 – PCR10 (Small Rod)

Rebar: Cantilever

Roughing Stand

  • ASB
  • NCIP

Intermediate Stand

  • NCIA
  • NEX™ HSS

Finishers Stand

  • NCIA
  • NCIC
  • NEX™ HSS (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Rebar: Kocks / 3-Roll Set

Intermediate Stand

  • NCIP
  • Endura™

Finishers Stand

  • NCIA
  • NCIC
  • Endura™ (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Finishing Block

  • PCR30 – PCR20 (Big Rod)
  • PCR18 – PCR10 (Small Rod)

Wire Rods

Angles: 3-High, 2-High and Continous

Roughing Stand

  • ASB
  • AGS
  • NCIP

Intermediate Stand

  • NCIP
  • NCIA

Finishers Stand

  • NCIA
  • NCIC
  • NEX™ HSS (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Angles: Cantilever

Intermediate Stand

  • NCIP
  • NCIA

Finishers Stand

  • NCIA
  • NCIC
  • NEX™ HSS (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Rounds: 3-High, 2-High and Continous

Roughing Stand

  • ASB
  • NCIP

Intermediate Stand

  • NCIA
  • NEX™ HSS
  • Endura™
  • PCR30

Finishers Stand

  • NCIA
  • NCIC
  • NEX™ HSS (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Finishing Block

  • PCR30 – PCR20
  • PCR18 – PCR10

Rounds: Cantilever

Roughing Stand

  • ASB
  • NCIP

Intermediate Stand

  • NCIA
  • NEX™ HSS

Finishers Stand

  • NCIA
  • NCIC
  • NEX™ HSS (Dog-bone / Slitting)
  • PCR30 (Notch — Ribbing)

Rounds: Kocks / 3-Roll Set

Intermediate Stand

  • NCIP
  • Endura™

Finishers Stand

  • NCIA
  • NCIC
  • Endura™
  • PCR30 (Notch — Ribbing)

Seamless

Piercing Mandrel

  • H11
  • H13

Piercer Plugs

  • NCCR

Piercer Rolls

  • #50 ESR
  • ACS

PQF / MPM / Sizing Rolls

  • NCIA

Kocks / 3-Roll Set

  • NCIP
  • NCIA
  • NCIC

Light Sections

3-High, 2-High and Continuous

Roughing Stand

  • ACS
  • ASB
  • NCIP
  • NCNC

Intermediate Stand

  • ASB
  • AGS
  • NCIP

Finishing Stand

  • ASB
  • AGS
  • NCIA

Medium Sections

3-High, 2-High and Continous

Roughing Stand

  • ASB
  • AGS
  • NCIP
  • NCNC

Intermediate Stand

  • ASB
  • AGS
  • NCIP

Finishing Stand

  • ASB
  • AGS
  • NCIP

Heavy Sections

Blooms: 2-High or 3-High

Roughing Stand

  • ACS
  • AGS

Slabs: 2-High or 3-High

Roughing Stand

  • ACS
  • AGS

Billets: 2-High or 3-High

Roughing Stand

  • ACS
  • NCIP
  • NCNC

Beams: Universal

Roughing Stand

  • ACS
  • ASB
  • NCIP
  • NCNC

Finishing Stand

  • ASB
  • NCIP
  • NCIA

Edger/Vertical Stand

  • ASB
  • NCIP

PCC Materials

With strong know-how in rolling technology and engineering materials, PCC offers a complete range of products to satisfy various rolling needs. Our experienced personnel will assist you to determine the best material for maximum performance.

Request a quote

ENDURA™

ENDURA™ is the cost-breaking innovation in the production of Long Products Rolls. This breakthrough metallurgy process has superb wear resistance and toughness because of extra higher alloy content and uniform fine microstructure produced under PCC's proprietary Computerised Processing Control (CPC). Our CPC production system will ensure the highest precision and repeatability in the production environment ensuring every ENDURA™ roll leaves our facility meets customer's requirements. ENDURA™ is a perfect material used to complement cemented carbide rolls to achieve maximum performance in a rolling mill. ENDURA™ can also be an alternative solution when nodular cast rolls are inferior to be used economically and cemented carbide cannot be used due to mill condition deficiency. This achievement has placed ENDURA™ as one of highest performing grade and the obvious choice for maximum performance.  

 

Key Characteristics

  • Upto 5 - 8 times performance over conventional NCI grades.
  • Retain hardness throughout the requirement.
  • Equally distributed minute fine carbides, improvements to toughness, wear-resistance, and minimize cracks.
  • Excellent surface and profile retention improve the surface quality of finished products (ideal for SBQ production).
  • No adjustments required.
  • Easy machinability.

 
Hardness
75 - 88 HSC
COMPOSITION
PCC PROPRIETARY
CHARACTERISTICS
CPC production, precision hardness control, without porosity, superior wear resistance, extremely high alloy content, uniform fine microstructure, good machinability
APPLICATIONS
Section, bar and wire rod intermediate and finishing, wire rod block and KOCKS mill rolling.

NEX™

NEX™ rolls are composed of high alloy and high carbon centrifugally cast double poured outer shell with a nodular cast iron core. NEX™ provides excellent hardness, wear resistance, and high-temperature properties. The is particularly suitable for mills requiring the highest standards of surface finish and dimensional control where the exceptional wear resistance reduces the need for frequent roll changes, so enhancing mill productivity. The fine microstructure and high hardenability of this material mean that there is no fall-off in hardness to discard so ensuring consistently excellent performance throughout the life of the roll.  
Hardness
70 - 85 HSC
Composition
C 1 - 3.5, Si 1.2 - 2.2, Ni 1.0 - 5.0, Cr 2.2 - 6.5, Mo 0.2 - 8.5, W 0.2 - 18, V 1.1 - 6.0
CHARACTERISTICS
Highly alloyed, evenly distributed fine hard carbides, high hardness, provides excellent wear resistance.
APPLICATIONS
Section, bar intermediate and finishing, wire rod roughing and intermediate rolling.
CASTING METHOD
Centrifugally Cast

NCIP

Has a working layer which contains nodular graphite within a pearlitic matrix. The material used primarily for hot rolling in long product and section mills. They are most suited to the early roughing stands, where firecrack resistance, shock resistance, and moderate abrasion resistance is required.
Hardness
40 - 65 HSC
Composition
C 3 - 3.6, Si 1.2 - 2.3, Ni 1.3 - 2.5, Cr 0.2 - 0.5, Mo 0.2 - 0.5
Characteristics
High strength and thermal resistance
Applications
Blooming, section, wire rod and bar roughing stands rolling.
Casting Method
Static Cast | Centrifugally Cast

NCIA

Used when increased abrasive/mechanical wear is needed, i.e. late intermediate and finishing stands in wire/rod, section re-bar, and pipe mills. The rolls can be cast statically or horizontally spun cast (CC NCIA) depending on diameter, pass depth, and hardness. The centrifugally cast rolls have a tough, strong pearlitic nodular iron core. The NCIA roll material is more highly alloyed than the softer NCIP material. As a result, the roll matrix is rendered acicular, and is martensitic, in the harder grades. The material has a bainitic matrix and softer grades usually display a mixed matrix of bainite/martensite. The higher chromium content increases the primary carbide volume fraction resulting in increased wear resistance.
Hardness
65 - 78 HSC
Composition
C 3 - 3.6, Si 1.3 - 2.5, Ni 1.2 - 3.8, Cr 0.3 - 0.5, Mo 0.2 - 0.5
CHARACTERISTICS
Higher hardness and improve wear resistance.
APPLICATIONS
Section, bar intermediate and finishing, wire rod roughing and intermediate rolling.
casting method
Static | Centrifugally Cast

NCIC

With a working surface of a three phase microstructure containing free carbon as flake graphite, eutectic carbide, set in a bainitic/martensitic matrix, depending on chemistry and hardness. Graphite content increased with depth and carbide content decreases, which explains the hardness fall off. NCIC rolls exhibit excellent wear and bruise resistance which is why they are found in hot narrow strip mills, mills rolling high volumes of flats and light section mills. Their resistance to fire cracking and breakage is good, especially in the softer grades.
Hardness
60 - 78 HSC
COMPOSITION
C 3 - 3.6, Si 0.6 - 1.5, Ni 1.8 - 3.0, Cr 0.5 - 1.2, Mo 0.2 - 1.0
CHARACTERISTICS
Excellent wear and bruise resistance. Good breakage resistance in softer grade.
APPLICATIONS
light section mills rolling, hot narrow strip mills rolling.
CASTING METHOD
Static Cast | Centrifugally Cast

NCNC

Rolls for roughing applications require a combination of properties, some of which unfortunately negate each other effect. These properties include wear, firecrack, and impact resistance, hot hardness and strength. The excessive network of carbide will improve wear and impact resistance, but dramatically reduces fracture toughness which under roughing conditions, initiates firecrack formation and propagation. To offset the excessive carbide and still retain some wear resistance, the matrix can be alloyed with Nickel and Molybdenum to produce a bainitic/martensitic form which will be considerably harder and more wear resistance than the conventional pearlitic matrix. The Molybdenum also helps to improve the hot hardness.
Hardness
40 - 60 HSC
COMPOSITION
C 3 - 3.6, Si 1.5 - 2.5, Ni 1.8 - 5.0, Cr 0.2 - 0.2, Mo 0.4 - 1.2
CHARACTERISTICS
Excellent wear and firecrack resistance. Alleviate slippage on entry pass.
APPLICATIONS
Roughing stands of all sections in particular deep grooves for finishing profiles.
CASTING METHOD
Static Cast

ACS

Chosen for their strength and toughness and are used primarily for breakdown, blooming, roughing and heavy section mills. The main element of carbon varies with application and hardness required, though other elements such as chromium, silicon, manganese, moly, and nickel may be present. At 0.50-0.80% carbon, only small amounts of carbide are present and the hardness is low at about 35-42 Shore C. The microstructure consists of an entirely pearlitic matrix with little carbide in the low carbon grades, to a mixed bainitic/pearlitic matrix containing small amounts of carbide in the harder grades.
Hardness
35 - 42 HSC
COMPOSITION
C 0.5 - 0.8, Si 0.2 - 0.7, Ni ≥0.2, Cr 0.8 - 1.6, Mo 0.6 - 1.1
CHARACTERISTICS
High toughness, good bending strength.
APPLICATIONS
Blooming mills, two high stands requiring high bending forces.
CASTING METHOD
Static Cast

ASB

Contain between 1.20 - 2.00% carbon. As the carbon content increases, so too does the carbide content. At about 2.00% carbon the carbide network becomes continuous and a roll hardness of about 60 Shore C is achieved. ASB materials are available with a series of carbon contents. When the wear resistance is a primary requirement, a higher carbon level is used. When strength is the most important factor, a lower carbon content is necessary. High temperature heat treatment can offer either a spherodised or normalized pearlitic structure, with a semi continuous carbide network. The soft annealed or spherodised treated roll have better strength properties and better resistance to fire cracking but may sacrifice a couple of points of hardness.
Hardness
43 - 60 HSC
COMPOSITION
C 1.2 - 2.0, Si 0.3 - 0.8, Ni 0.2 - 2.5, Cr 0.8 - 3.5, Mo 0.2 - 0.8
CHARACTERISTICS
High tensile strength, good wear resistance.
APPLICATIONS
roughing stands heavy or medium section, profile, blooming, slabbing, breakdown, rail, beam, universal mill rolling.
CASTING METHOD
Static Cast | Centrifugally Cast

AGS

Very similar to ASB as is the hardness and microstructure. However, the microstructure contains free graphite which enhances the material's thermal properties. It has better firecrack resistance than ASB due to a superior coefficient of thermal conductivity. The material is most suited to deep section rolling in intermediate and finishing stands and is ideal for small beam rolling and especially rail rolling on continuous mills. The free graphite imparts a "non-stick" property to the rolls which give a good release to the bar.
Hardness
35 - 65 HSC
COMPOSITION
C 1.3 - 1.9, Si 1.2 - 1.6, Ni 0.2 - 2.2, Cr 0.4 - 2, Mo 0.2 - 0.8
CHARACTERISTICS
Free graphite, good thermal properties and firecrack resistance.
APPLICATIONS
Blooming and Roughing stands mill rolling.
CASTING METHOD
Static Cast | Centrifugally Cast