CSCase study · Forging
Forged work rolls for a rebar mill
Client[Client name] rebar mill
LocationKatowice, PL
CategoryForging
Duration9 weeks
CompletedFebruary 2026
01The brief
Work rolls delivered without stopping the mill
The rebar mill needed twelve new work rolls for its finishing stand, but could not afford a stoppage to change them all at once.
We forged the rolls from 42CrMo4 ingots poured in our own melt shop, quenched and tempered them to the hardness band on the stand drawing and turned and ground them to size. Delivery was split into two batches so the mill could swap stands between campaigns.
02What we did
From our own ingot to a ground roll
- Poured the 42CrMo4 ingots in-house, so the heat number runs from ladle to roll
- Forged every roll on the 2,500 t press with the reduction ratio on record
- Quenched and tempered to the specified hardness band, proven on each roll
- Turned, ground and ultrasonically tested before dispatch
9wksFrom order to the second batch
12rollsForged, hardened and ground
0hrsOf unplanned mill downtime
“Two batches, two stand changes, no lost shifts. The hardness readings matched our own on every roll.”
KNK. NowakRoll shop manager, rebar mill
