Zdas EAF forming machine

ZDAS SteelProductíon
Annual capacity of the Steel P1ant is 60 thousand tons oł steel. The steel made is either poured into ingotmoulds ingots or into moulds castings . A wide range of steels is produced, from structural, low- and medium-alloy steels including tool steels, to high-alloy Cr, Ni, Mn , austenit c and spec al steels ıntended 
for aerospace and power engineering.
Manufacturing facílítíes:
Steel making takes place in three electric arc furnaces EAF , one ladle furnace LF and a deep-
deoxidation vacuum degassing facility also offering the possibility of vacuum decarburization of high-
a11oy chrome liquíd alloys VD/VOD .
Capacíty of production uníts
No. 2 EAF 16 to 22 tons LF 14 to 22 tons
No. 3 EAF 4 to 8 tons VD 14 to 22 tons
No. 4 EAF 12 to 19 tons VOD 14 to 19 tons
Materíals produced:
CaгЬoп steels
Low-alloy and medium-alloy steels
High-alloy steels
Nodular cast iron
According to the customeŕ s requirement, if the condition of moltén metal heat aćcumuİation is śatisfied.
Production of high-grade steels processed using vacuum 1ad1e réfining technology VD/VOD/V1C . These
VD - vacuum degassing
VOD - vecuum oxygen decarburization
V1C - vacuum ingot casting
The EAF, LF VD/VOD integrated workstation offers high variab ılity óf the molten-metal-making process,
molten metal processing and pouring. Guaranteed are:
Manufacturing proćess is chosen according to customer requirements, mainly with regard to the range o g f as content H2, N2, 02 ,
chemical composition. ultrasonic testing. micro- and macro-cleanliness, gas content etc., comprises both micro-cleanliness to D1N 50602
primary and secondary metallurgy steps, enables to achieve, on a standard bas ıs, high qualitative para- ultrasonic testing to SEP 1921
meters, flexïbility and respond to customer wish within a гeasoпaЬle time. austenitic grain size
Productíon of Castíngs Productíon of ingots
The manufacturing program is currently aimed at MAGMA-aíded castings Manufacturíng program:
being demanding for theír shapes and materials; weight of these castings is The range of íngots produced in the ingot Shop comprises about 40 types of
ranging from 200 kg to 40,000 kg of rough castíng weight, the maximum íngots with weight ranging from 500 kg to 12 tons. The ingots are intended for
dimensions being 8500 x 4800 x 3000 mm. open die forging octagonal polygonal ingots of 8K series and rolling
pentadecagonal polygonal, round and slab,type ingots . Production of new
Sand míxtures used: types of ingots can also be agreed according to customeŕ s requirement.
1. Organic-resin-bonded chromite mixture
2. Water-glass-bonded slate-clay mixture Manufacturíng process:
3. Water-glass-bonded silíca míxture ingots are bottom poured into ingot moulds on plate lined with high-clayey
4. Bonding bentonite míxture refractory casting materíal. When pouring ingots, the steel surface ís pгo-
tected with casting powder. ingot top is treated using isolating or exothermic
Heat treatment mixtures/powders. During steel casting, argon protection of the flowing metal
is carried out in modernized natural-gas-fíred furnaces wíth automatic ís used. Based on customer requirement/our recommendation, ingots can be
temperature control, temperature difference throughout the furnace delívered as annealed soft annealed, stress relief annealed .
space does not exceed 5 deg. C. The castings can be delivered in
 condition, water, oil, air quenched and tempered. Delívery condítíon:
- non-split ingots with their tops
Fettlíng and surface finísh, - certificate of chemícal composition
being included in the manufacturing process, is performed through - absence of radioadtivity certificate
ordinary cleaning operations such as hydro blastíng and steel shot - annealing certificate - oп request
blasting, compressed-air grit blasting. Rough grindíng is carried out at the - also íngots in hot condition can be delivered to customers
robotized workstation ANDROMAT and using portable grinding machínes.
Delívery condítíon of castings:
- fettled rough castings
- machine-fettled rough castings
- rough machined castings having machíning allowance of agreed size
Processes

processed scrap
open Die Forgíngs Patterns
The Forge Shop has been manufacturing open die forgings since The Pattern Shop produces pattern equipment both for hand and
1966 in a comprehensive range of shapes, with weights ranging machine mouldìng, piece and series production as well. Work-
from 20 kg to 9000 kg. manshíp classes depend on customer s requirement, the material
beíng polystyrene, wood, plastics, metal and combinations of the
Steels used, made solely at ŽĎAS Steel Plant:
named materìals.
Structural standard-grade steels intended for various application
Structural carbon steels for quenching and tempering, Complete technological equipment ís available, providing high
case-hardeníng etc. quality of all the manufacturing operatíons, from materíal prepa-
Structural alloy-steels of various types - Mn, Si, Cг, Ni, Mo, V, A1, W. ration includíng íts drying through finishíng of the pattem equip-
A11oy, high Cr, Ní, Mn content steels ment by paintíng. Available is a well-equipped workstation inten-
Too1 carbon and alloy steels for forming tools ded for receipt of production documentation and 3D patterns in
Steels for special application majoríty of engineering standards, 1ges, VDA, STAP, ProE,
Autocad, CAT1A and CAD/CAM system workstation intended for
Manufacturíng facílítíes: documentation processing and CNC-machine cutting.
3 open die forging presses of in-house design, CKV 630,
CKV 1250 and CKV 1800, Maximum size of non-split pattern equipment is 10000 x 5000
with rail-bound manipulators x 4000 mm. Rotary patterns up to a diameter of 5250 mm, milled
heating furnaces car-hearth + chamber type patterns up to a radius of 15500 mm and 40 deg., working on
heat treatment furnaces car-hearth + soaking type CNC machine having the work-table size 6000 x 2000 mm.
quenching tanks water + oil .
material-divíding saws, up to a diameter of 1000 mm
sampling saws
Delívery condítíon, accordíng to customer s requírement: 
forged and heat treated rough machined finish machined

The Metallurgy Plant has ultrasonic, magnetic and liquíd-penetrant testing facílíties to ČSN, D1N, EN and ASTM
standards available. The testing personnel is qualífíed íncompliance with the EN 473 and SNT-TC-1 A standards.
Final inspection documentation and certifícate of conformity are íssued ín accordance with EN 10 204 and customer s technical requirements.
The Labs are íncorporated ín a system being accredited to IS0 9001:2000 and they, on a regular basis, take part in ínterlaboratory tests ín order to provide high quality of the results.
Aírcraft lndustry
Power Engineeríng

Forgings for transport aeropianes undercarriages Forgíngs of bosses for nuc/ear power engineeríng Forgings for nucIear power stations technologies
Roughing of chain wheel castíng for head Exactíng casting for power engineering Castíng ol part of gas turbine casíng frames guying
Castings of gas turbine casíngs Semiproducts for nuclear accelerator casing Gas turbine casing
Roughed forgings of bosses for wind power Spherical valve Forgings of connectíng rods ol ship motors
plants
Castings of ship rudders Castings of bosses for ship rudders Forgings of rudder shatts
of Tooiing

Automobíle lndustry
Successful reference deliveries of the tooling for the leading European
automobíle manufacturers verified the abilities of technicians and workers
of the ŽĎAS Toolíng plant and made possible to enter even this highly
specialised fíeld of production. in addition to the tooling for smaller types
of stampings, complete equipment of forming lines for the most intricate
parts of car bodies are, above all, concerned.
Transfer Forming
The ŽĎAS compaпy belongs to the leading European suppliers of forming
machines. Among others, the deliveries of automatic machines for transfer
forming for production of parts for automobile, consumer and
electrotechnical índustries are concerned. Shape intricacy of stampings
and high number of productíon operations demand the utilisation of all
creative potential also during making of respective tools.
Consumer lndustry
Recently, more than 30 of parts in this field is made by forming.
However, according to the world-wíde prognosis, the increase of thís
portion is expected. Thus a suffícient space is being made available for
the development of pressing shops and also for their partners such as
manufacturers of forming machines. You can find ŽĎAS references every-
where from the satellite antenna corpuses, parts of electrical appliances
up to various components for building industry.
specíal Toolíng and Jígs
Tooling plant obtaíned wíde experíence including in production of tools for
solid and special forming technologies. Prototype tools, measuring and
checkíng jigs are also included in the production assortment. Accuracy of
jigs is ensured by means of 3D measuring workplace checking.
Tooling for automobile industry
ŠKODA Auto, Mladá Boleslav, Czech Republic
Mü11er Weingarten Werkzeuge GmbH, Germany
Polynorm GRAU GmbH, Germany
SCHULER Cartec GmbH, Germany
Transfer tooling for automobile índustry
Automobiltechnik Praha, Czech Republic
KARSIT Praha, Czech Republic
lnjection moulds
HASELBECK GmbH, Germany
Tooling for consumer índustry
SIEMENS Elektromotory o. Mohelnice,
Czech Republic Productíon Facílítíes
MORA Moravía Hlubočky, Czech Republic
surfacing equípment
Horizontal boríng and mílling machines
altogether 10 machines, 5 of them CNC system MEF1
Boring machine 2 machìnes - Heidenhein system
Milling machine 4 machìnes
Жuwτ Surface grínding machine 5 machìnes
Rotary machíníng equípment
P1aín grindíng machíne altogether 2 machines
Lathe 5 machines
Free-area machiníng equípment
Machining centres 4 centres
Measuring centre 1 centre
Profile milling machine 1 machine, MEF1 control system - CNC
Electrical erosion machíne altogether 2 machines
Electrical díscharge machíne 1 machine
Too1 testíng equípment - presses
Mechanical presses altogether 3 presses
Hydraulic presses altogether 5 presses
Production
Weldíng

Welding workplace equípped with CLOOS robots and positioning
device for pieces to 3,700 mm x 7,000 mm, height 3,000 mm.
CLOOS M1G/MAG 403, 503, 553, 603 welding machines
for pieces of varíous shapes and dimensions.
Lathes altogether 55 machines Stress relievíng by annealíng or víbrating.
Machining of pieces of diameter to 2,100 mm, length to 10,000 mm. Bronze weld deposíts T1G, MAG
Stainless steel weld deposits sumberged-arc welding
Boring and turníng mí11s altogether 10 machínes
Welding of gears wíth diameter to 2,000 mm when preheated
Pieces of diameter from 200 mm to 4,000 mm, heíght to 2,500 mm.
in the rotary-hearth furnace.
Honíng machínes altogether 2 machínes Butt weldíng
Pieces of diameter from 20 mm to 1,000 mm, length to 6,000 mm. Ro11 bending
P1aín grinding machínes altogether 8 machínes Pícklíng
Parts of diameter from 5 mm to 1,000 mm, length to 10,000 mm. Pickling in Ferropur NaH + NaOH , plates from width of 5 mm,
tubes from DN 25, maximum length 6,000 mm.
Vertical grinding machine 1 machine Pickling ín HC1, sheets up to width of 5 mm, tubes up to DN 25,
Pieces of diameter to 2,600 mm, maximum ground diameter maximum length 6,000 mm.
2,500 mm, maximum workpíece height 1,700 mm, maximum Stainless steel dip picklíng
ground height 1,400 mm, max. ground hole length 800 mm. Staínless steel spray pickling
Dímensions of tanks 1,000 x 2,200 x 6,000 mm, maximum weight Surface gríndíng machínes altogether 5 machines
of batch 4,000 kg.
Surface 22,00 mm x 8,000 mm, height to 2,250 mm.
1onic Nítrídíng
Gun-boring machines aitogether 2 machines
Vessel: piece díameter 650 mm
Pieces of diameter from 31 mm to 1,000 mm, length to 10,000 mm.
pіece length 7,400 mm
Horizontal boring and millíng machínes altogether 60 machines batch weight 8,000 kg
Machining of pieces of height to 4,150 mm and length to 15,000 mm Vessel: piece díameter 1,100 mm
on tables, to 4,000 mm x 4,000 mm on turning tables. pіece length
- hung-up 4,300 mm
Knee-type míllíng machínes altogether 12 machines - standing 5,000 mm
Machining of pieces to 300 mm x 1,400 mm, heíght to 300 mm. batch weight
- hung-up 8,000 kg
Planer type míliíng machines altogether 10 machines - standing 12,000 kg
Machining of pieces to 1,600 mm x 8,000 mm x 1,500 mm. Vessel: piece díameter 1,100 mm
piece length 2,000 mm
Planers altogether 1 machine batch weíght 5,000 kg
Machining of pieces to 1,000 mm x 6,000 mm x 1,000 mm.
1n cooperation wíth other dívísíons, we provide services
shaping machines altogether 4 machines as follows:
A11ow the machining along círcumference up to height of 1,700
Materíai Cuttíng mm and in the hole up to 850 mm. Diameter of table is 1,400 mm
max. Water beam cutting - up to width of 50 mm.
F1ame cutting up to width of 220 mm.
Drilling machines altogether 14 machines Cutting.
Diameter of drilling up to 100 mm, maximum height of piece 1,600 mm.
Anneaiíng
Gearíng altogether 24 machines Annealing chambers with dimensions: 4,000 x 3,500 x 8,200 mm,
Spur gearing, m , wheel diameter 10-4,000 mm, 3,000 x 3,800 x 9,200 mm,
width 1-600 mm. weight 32;000 kg
Beve1 cyclopaloid gearing, m 7-20, diameter 100-850 mm.
Hardening, Quenching and Tempering, Beve1 straight, helical gearing, m 2-14, diameter 40-800 mm.
Chemical/Heat Treatment Worm wheels, m 1,5-20, diameter 40-1,500 mm.
Pieces with diameter to 750 mm, length 1,800 mm, weight 2,500 kg Coupling hub barrel-shaped gearing , m ,
diameter 40-1,200 mm. Heat Treatment of Slender Píeces
Rack, m 1-12, by milling m 12-45, length 20-4,000 mm, Pít furnace, oi1, water. For pieces of diameter to 800 mm,
width 1-650 mm. length 7,000 mm, weight 10,000 kg.
Grinding of spur gears, m 2-30, diameter 40-2,000 mm,
width 1-650 mm. Compressed Air Blastíng
Gear shafts, m 1,5-25, length of piece 200-7,500 mm, Pieces of maximum dimensions of 8,000 x 4,500 x 3,500 mm,
length of gearing 1-4,000 mm, diameter of gearing 50-800 mm. weíght up to 32,000 kg.
Endless screws, m 1,5-20, díameter 20-300 mm. .
lnternal gearing - straight, m 1-12, díameter 30-1,500 mm,
width 1-400 mm. QUІрMьс.,,
lnspection ι V,
Precision with HOEFLER equípment up to the maximum díameter
of 2,600 mm, including the print out of results report.

Assembly
The External Assembly P1ant is a separate branch of ZDAs, a. s. performing and providing disassembly, repair, erection, adjustment and commissioning of the equipment. Our people are provided with up-to-date erection tools and instruments.
The division guarantees high productivity and quality of erection work, short erection times and a ow price. The professional and language knowledge of our personnel guarantees good results even abroad. Heavy machinery can be disassembled and displaced even in straitened circumstances.
Personnel of the External Assembly has successfully carried out erections of large investment units such as the medium and light rolling mill at Poldi Kladno, medium section rolling mi11 at NH Ostrava Kunčice as well as supervisions of erections of the medium section mills ìn Iran, Turkey, Romania and the billet mills in Pakistan and former Yugoslavia. For foreign
customers, we have carried out erections or supervisions of erections of machines and equipment.
Hydraulíc Cylinders
Delivered hydrauiic cylinders have standard but, above ail, special desígns with límít dimensions. Hydraulic cylinders are made of high-grade forged materials with a differenı surface quality of the cyiinder and piston rod, depending on the application.
The possible surface treatments are íonic nitriding, hard chromium or plasma spraying. Other offered services are:
major overhauls and spare parts deliveries for hydraulic cylinders, documentation working out, consultative and advísory services.
The quality of ZDAS cyiinders has been proved in heavy duty service at the coal area on the North of Bohemia and at the Gabcikovo water dam on the Danube, where thesehydrauiic cyiínders have already been ensuring the lock operation for a long tíme.
Hydraulíc Power Packs
l he ŽĎAS company produces hydraulic power packs,especially those intended for special applications and higher outputs up to approx. 300 to 2000 kW, with pressures up to 35 MPa, in special cases even higher pressures.
The design and manufacture of these packs utilíses long experíence with the manufacture of the mill hydraulic drives, presses, forging presses as well as special-purpose machines and equipment, such as tensioning equipment
with a 63 MPa hydraulic power pack for tensioning the ropes of the 1000 MW reactor safety jacket at the Temelin power plant.
Control Manífolds
Hydraulic manifolds as well as hydraulic power packs and cyiínders, are made of high-grade materíals and provided with hydraulic elements, sealing and fíttíngs from prestigious world manufactures.
They are offered with or without the protective casing, wíth inner diameter of channels from 6 Js up to 100 Js. Manifolds for hydraulic elements testing are composed according to the type of eiements to be tested, as requested by
customer. Reconstructions and repairs of hydraulíc systems are also implemented.
The present incorporated compaпy ŽĎAS has been established after the transformation of thestate enterprise ŽĎAS in accordance with the
approved privatization projecl pursuant to paragraph 172 of Law No. 513/1991 of Digest of the Commercial Code, based on uniphase establishment by the founder - State Property Fund of th
Czech Republic - under the founder s deed of 28 ^ Apri1, 1992.
 September 2002 the incorporated companyŽĎAS was entered by a strategic partner and the Slovak company Železiarne Podbrezová,
became the majority shareholder the aim of which is the stabilization and further development of the company.
History of the joint stock company Železiarne Podbrezová dates back to the year 1840. Nowadays, this company belongs to the top producers of
seamless tubes, their technology and management. Great advantage of the company is the closed cycle of production and further processing of steel pipes. The company Železiarпe Podbrezová exports its products directly or through the mediation of the subsidiary trading corporations into fifty countries of the world.

RODBREZıO VА
Activíties of Železiafne Podbrezová are not limited only to production and sale of steel pipes. Podbrezová has a significant influence on development of the entire region of the Hron river upstream.
A championship golf course with 18 holes as  as downhill skiing pistes are available for the sport lovers in the recreation centre Tále. The Tále centre and its surroundings provide outstanding opportunities for rest and recreation  the year round.