Our structured process ensures each induction-hardened roll meets your mill's exact specifications for surface integrity and load tolerance.
We review your mill configuration, reduction schedule, and material grade. Our engineers analyze wear patterns and load data to recommend the optimal roll composition and hardness profile.
Based on the consultation, we select the alloy grade and design the roll geometry — including crown, taper, and neck dimensions. A detailed drawing is shared for your approval before production begins.
The roll body is forged from high-alloy steel and undergoes controlled heat treatment to achieve uniform core toughness. Induction hardening is then applied to the surface, reaching 90–95 Shore C hardness with a hardened depth of 8–12 mm.
Each roll is ground to a tolerance of ±0.005 mm on diameter and surface finish. We perform ultrasonic and magnetic particle inspection to verify internal soundness and surface integrity. Dimensional reports are issued with every roll.
For backup roll assemblies, we mount the chocks, bearings, and seals. The complete assembly is tested for runout, balance, and bearing clearance. A final functional check simulates operating conditions before packaging.
Rolls are protected with anti-corrosion coating, wrapped in heavy-duty polyethylene, and secured in custom crates. We coordinate shipping to your plant, including customs documentation and delivery tracking.
Definitions and scope of supply
Our induction-hardened work rolls are specified to a surface hardness of 90–95 Shore C, measured at mid-barrel. The hardened depth is a minimum of 8% of the roll body diameter, with a gradual transition to a tough, ductile core. These values apply to rolls manufactured for cold-reduction of carbon and alloy steels up to 0.5% carbon equivalent.
Yes, each backup roll assembly includes precision-machined chocks, hydrostatic or hydrodynamic bearings as specified, and a self-aligning bearing housing. The assembly is fully tested for runout and concentricity before dispatch. Bearing type and lubrication interface are confirmed at order placement.
Calendar rollers for aluminum and copper finishing are ground to a diameter tolerance of ±0.005 mm and a surface finish of Ra ≤ 0.2 µm. Crown profile accuracy is held within ±0.002 mm across the face length. Dynamic balancing is performed to ISO 1940 G2.5 grade at maximum operating speed.
Every roll shipped includes a material test certificate (EN 10204 3.1) covering chemical composition, mechanical properties, and hardness traverse. Additional ultrasonic and magnetic particle inspection reports are available on request. Certificates are issued by our in-house metallurgical lab, which is accredited to ISO 17025.
Standard lead time for a custom backup roll assembly is 16–20 weeks from approval of final drawings. This includes forging, heat treatment, rough machining, final grinding, and assembly. Expedited schedules are possible for compatible designs; contact our project team for current capacity.
Warranty covers manufacturing defects in material and workmanship for 12 months from commissioning or 18 months from shipment, whichever occurs first. Surface spalling caused by mill operating conditions outside our recommended parameters is not covered. A full inspection protocol is provided with each roll to document pre-shipment condition.
Our sintering machinery and induction-hardened rolls are built to maintain structural surface integrity under continuous wear and friction. Each capability is engineered to reduce downtime and improve strip quality in cold-reduction plants.
Explore our solutionsSurface hardness of 90–95 Shore C with a tough, ductile core. Precision-ground to within 0.005 mm for consistent strip quality over extended campaigns.
Reduces spalling and abrasion in tandem millsHydrostatic bearing technology minimizes friction and heat generation under extreme loads. Forged high-alloy steel body with uniform hardness distribution.
30% increase in bearing life compared to conventional assembliesCentrifugally cast shell with hardened chrome layer for aluminum and copper sheet finishing. Optimized crown profile reduces edge drop and waviness.
Operates at speeds up to 1200 m/minMetallurgical analysis and heat-treatment protocols tailored to your mill’s load profile. We optimize roll microstructure for wear resistance and shock absorption.
Custom hardness gradients for specific reduction ratiosIn-house grinding with tolerances down to 0.002 mm. Dynamic balancing ensures vibration-free operation at high rotational speeds.
Extends roll life and protects mill bearingsOn-site inspection, re-grinding, and re-hardening services to restore rolls to original specifications. Scheduled maintenance programs reduce unplanned downtime.
Service intervals aligned with your production calendar