The companies of Altra Industrial Motion offer many critical drivetrain products utilized in metal mill applications including mill spindles, gearing and geared motors, couplings, U-joints, torque-limiting devices and backstopping clutches

1. Applications & Innovations
Metal Producer
Market

2. We’re committed to the
Metal Producer Market
The companies of Altra Industrial Motion offer many critical
drivetrain products utilized in metal mill applications including
mill spindles, gearing and geared motors, couplings, U-joints,
torque-limiting devices and backstopping clutches.
Altra Brands Deliver Value Throughout the Drivetrain
Altra Industrial Motion is positioned to provide OEMs with
exceptional drivetrain value by ensuring component compatibility
and optimized performance combined with time-saving,
single-source convenience.
Extensive Technical Experience in Metal Mill
Applications
Major OEMs routinely rely on the vast metal mill application
knowledge of Altra’s engineering teams that collaborate to
thoroughly analyze specific customer applications and then apply
the latest technologies in design, materials and manufacturing.

3. Application ProfileApplication Profile

4. • A leading Midwest seamless tube piercing steel mill was experiencing
repetitive OEM universal joint knuckle failures on their mandrel and
piercing mills.
• Ameridrives developed a new, custom-engineered knuckle solution that
provided years of service compared to the premature failures of the
original OEM universal joints.
• Special Americardan U3575, U3675 and U3750 universal joints
were supplied.
• Ameridrives was also able to retrofit the existing yokes with new cross
and bearing kits after verifying the strength of the existing material,
saving the mill money.
• In the six years since Ameridrives and their distribution partner began
the repair program, the steel mill has seen universal joint knuckle
savings of approximately $6.7M. With most of the retrofits now
completed, the mill expects an annual savings of over $2.7M.
Custom-Engineered Ameridrives
Power Transmission Universal Joints Save
Millions on Seamless Tube Piercing Mills
www.AmeridrivesPowerTransmission.comP-7827-APT.pdf

5. Application Profile
Seamless Tube Piercing
Steel Mill
Problem:
A leading Midwest seamless tube piercing steel mill was
experiencing repetitive OEM universal joint knuckle failures on
their mandrel and piercing mills. The U-Joint knuckles would
catastrophically fail without warning, turning rollers and other
component fragments into projectiles which created a major
safety concern while shutting down production.
Solution:
Ameridrives Power Transmission developed a new, custom-
engineered knuckle solution that provided years of service.
APT was also able to retrofit the existing yokes with new cross
and bearing kits after verifying the strength of the existing
material, saving the mill money.
• Special U3575, U3675 and U3750 universal joints supplied
Custom Americardan Universal Joints

6. Application Profile
Steel Mill Slab Caster
Problem:
The original U-joints installed featured split-flanged yokes. Tight
space constraints did not allow full access to the roller end of the
U-joints. This resulted in mounting bolts that could not be
tightened to the torque specifications. Over time, the loose bolt
connections between the spool and split-flange yoke allowed the
key to shift, causing the keyway and holes to become elongated
in the mated flanges.
Solution:
• Integral tapered key pad developed for roller ends of U-joints
• U-joints compensate for approximately 10-degree angular
misalignment and shock loads of up to 800,000 in. lb. torque
• Tapered key allows for easier, more reliable connection of
U-joints to segment roll spools
• Mill rotation speed: 8 RPM (5ft./min.)
• 11 pairs of U-joints were modified
Modified Americardan 3285 Universal Joints

7. Rolling Mill Roughing
Stand Drives
Problem:
A large Midwestern steel mill was experiencing excessive
downtime due to frequent spindle repair and replacement on
their hot strip mill roughing stand drives.
Solution:
Ameridrives Couplings provided five (over/under) pairs of
Model SM38 spindles.
• Spindles are 38" dia. by 13 ft. long
• Spindle roll-end adaptor features a flattened bore for large
80,000,000 in. lb torque capacity.
• Ameridrives Advanced Gear Design with fully-crowned
teeth
increases torque capacity by 300%
• Mill rotation speed: 65 RPM (870 ft./min.)
Application Profile
SM38 Mill Spindles

8. Screwdown Mill Stands
Problem:
A large steel mill in Pennsylvania was experiencing continuous
problems with the gear drives in their screwdown mill stands.
The existing manufacturer’s gear material was breaking down
which caused fatiguing, cracks and broken teeth due to inherent
designed duty-cycle stresses.
Solution:
The Delroyd team reverse-engineered the screwdown gearbox
to develop a more robust solution. The bronze gear material was
changed to manganese for enhanced yield and overall strength.
• A larger radius and shot peen process was added to the root of
the worm thread hence reducing the root stresses
• Through hardened, ground and polished alloy steel worm
• The new Delroyd gearbox design extended the gearing life
from 3 years to more than 6 years
Application Profile
Worm Gear Drives

9. Screwdown Mill Stands
Problem:
Screwdown mill stand gear drives at a major steel mill in Ohio
were failing prematurely causing extensive downtime. The worm
gear teeth were wearing and breaking down at an accelerated
rate due to improper meshing at the contact zone. The problem
created excessive pressure at the gear’s pitch line/contact zone.
Solution:
A spare worm and gear sample was sent to the Delroyd facility
so that a new gearing solution could be reverse-engineered to
ensure that all gear sets installed on the hot mill stands would
have a matching thread/tooth design.
• The new Delroyd gearing solution extended the gearing life
from 6 months to more than 6 years
• Aluminum bronze gear material used for enhanced durability
• Carburize hardened, ground and polished alloy steel worm
Application Profile
Worm Gear Sets

10. Steel Mill Runout Table
Problem:
High quality couplings were needed to connect motor shafts
to individually driven rollers on a new hot strip runout table
installed at a steel mill plant expansion near Budapest,
Hungary. The 505-foot long table is equipped with 337 six-
foot wide, 12-inch diameter, stainless steel rollers
Solution:
TB Wood’s DuraFlex couplings were selected over
competitive models due to their ease of assembly and simple
radial-mounting installation.
• Each roller driven by 10HP motor operating at 900RPM
• Highest operating temp
• High parallel and angular misalignment ratings
• Patented design of the urethane bond to the steel shoe
Application Profile
DuraFlex®
Couplings

11. Application Profile
Steel Slab Mill
Problem:
A steel slab mill utilized three cooling water pumps connected
to a common manifold. Each vertically-mounted pump was
driven by a 1,750 HP electric motor operating at 890 RPM. The
mill was experiencing short operating life from the overrunning
clutches mounted on the top end of all three electric motors.
The clutches prevent each pump from backflowing when its
motor needed to be shut down for servicing.
Solution:
To meet the application requirements Formsprag Clutch
supplied 10” diameter FSO-800 overrunning clutches with a
13,000 lb.ft. (17,680 Nm) torque capacity. The replacement
clutches were shipped with special high-temperature grease
and installed with increased clearance around the torque arm to
accommodate thermal growth that can cause binding. FSO
clutches feature a high torque density and require no
adjustments or controls.
FSO Overrunning Clutches

12. Application Profile
Steel Mill Conveyor
Problem:
A major steel producer needed a backstopping clutch for use
on an inclined conveyor that feeds coal into a coke oven at
one of their Midwestern mills.
Solution:
A Formsprag HSB clutch was selected to meet the
requirements of this application. HSB Series clutches are
intended for use as backstops on the high speed shaft or
intermediate shaft of a reducer, and as holdbacks on the
head shaft of conveyors.
• Units are comprised of an FSO clutch combined with
an oil reservoir
• Model HSB 700 clutch features a torque capacity of
5,000 lb.ft. (6800 Nm),
• Formsprag exclusive PCE®
sprag design
• Reservoir features a flush oil sight gauge
Model HSB Backstopping Clutch

13. Steel Mill Cooling Fan Drive
Problem:
A leading industrial fan OEM needed a clutch solution for a large
cooling fan installed at a steel mill. The heavy-duty fan required a
low-speed turning gear drive that keeps the fan impellers rotating
slowly when the main drive is shut down. Without the slow
rotation in the high-temp mill environment, the impeller would
heat or cool unevenly and distort the fan blades and/or shaft.
Solution:
A Marland CECON 12M overrunning clutch with a 12,000 lb.ft.
torque rating and a max speed of 2,500 RPM was supplied to
meet the requirements. The clutch is positioned between the low-
speed drive and the fan. When the fan’s main drive is shut down,
the CECON engages the smaller, turning gear drive. The low-
speed drive is also used to start the fan from rest before the
larger high-speed motor is turned on. The CECON automatically
disengages the low-speed drive when the main high-speed
motor is powered up, preventing damage to the low-speed drive.
Application Profile
CECON Clutch

14. Steel Strip Mill
Problem:
A major steel manufacturer needed a clutch solution for one of
its large strip mills in the US. The mill utilizes two drives, one
electric motor powers the mill when operating at normal
production speeds, a low-speed motor drives the mill when
inching or creeping speeds are required for inspections or
servicing. Positioned between the two drive motors, the clutch
provides a smooth transfer of power from one motor to the other
without stopping the mill. The low speed drive is limited to one
direction of rotation and cannot be reversible.
Solution:
A Marland CECON 2M clutch with a 2,000 lb.ft. torque rating
and a max speed of 4,200 RPM was selected to provide
automatic, instantaneous change-over from one drive to the
other without complex controls. CECON clutches are completely
enclosed and designed for high-speed, continuous-duty
applications in unprotected, adverse environments.
Application Profile
CECON Clutch

15. Steel Mill Charging Crane
Problem:
Charging crane hoist drive gear boxes were failing prematurely at
a large steel mill in Northeastern U.S. The failures were causing
unfavorable outages and expensive periods of downtime.
Solution:
Due to their desire and reputation to solve problems, Delroyd
was called in to help analyze the situation and develop a
solution. Delroyd engineers developed new worm gear sets
utilizing
aluminum bronze gears and redesigned the bearing mountings
to enhance strength and durability.
• Carburize hardened, ground and polished alloy steel worm
• Fabricated steel housing design for superior rigidity
• Extra-heavy side plates connect the worm and gear shaft
bearing supports, assuring proper meshing of the gear
• Redesigned lubrication system
• Delroyd design changes resulted in extending the gearbox life
by over five years.
Application Profile
Hoist Worm Gear Drives

16. Application Profile
Blast Furnace Slag Granulator
Problem:
A global designer and manufacturer of slag granulator systems
needed heavy-duty drivetrain assemblies for a new steel mill
installation. Molten slag is a by-product generated by the mill’s
blast furnace during the steelmaking process. The slag
granulator utilizes several identical drivetrain assemblies to move
the slag slowly on a conveyor while it is subjected to water jets
which disperse/convert the slag into small granules.
Solution:
Nuttall engineers worked closely with the OEM to design the
overall drivetrain assembly configuration. The complete
drivetrains, including Nuttall reducers as well as customer-
supplied couplings, torque limiters and motors, were assembled
and mounted to custom fabricated pedestal bases by Nuttall
technicians.
• Primary parallel-shaft enclosed reducers
• Moduline R-Type concentric in-line, shaft-mounted creep drives
Drivetrain Assemblies

17. European Steel Rod Mill
Problem:
A steel mill in the Midwestern U.S. needed replacement gear
couplings for its rod mill. The mill was built in Europe and
utilizes more than 50 couplings that have non-standard bolt
circle diameters (BCDs). The mill operators were having
difficulty sourcing replacement and spare couplings in the U.S.
since the European gear couplings do not meet AGMA standard
exposed or shrouded bolting patterns. Ordering spares from the
European OEM was costly and required long lead times.
Solution:
In response to the problem, Ameridrives designed a version of
its popular Amerigear coupling with a modified flange that can
be drilled to match multiple European manufacturer’s BCDs.
Since the new couplings utilize a standard (in stock) Amerigear
sleeve and barrel size, Ameridrives can hold the same short
lead times as its standard AGMA couplings with only a modest
upcharge.
Application Profile
Modified Amerigear Couplings

18. Steel Mill Roughing Stand
Problem:
A major steel manufacturer needed a large replacement gear
coupling as part of an upgrade for a roughing stand drive at one
of its U.S. mills. Positioned on the low-speed, high-torque shaft
between the gearbox and pinion drive, the gear coupling rotates
at approx. 10 RPM. The goal was to ensure that the new
coupling was capable of transmitting the new, higher torques.
Solution:
The mill contacted several coupling manufacturers, including
the original coupling OEM. Ameridrives was the only coupling
manufacturer that was willing and able to provide a reliable
replacement coupling in the large size needed. The original
drawing for the 20-year-old existing coupling was utilized to
ensure that the new coupling was a drop-in replacement.
• Size 230, 80 in. diameter gear coupling
• Torque rating of 60,000,000 in.lbs.
Application Profile
High Torque Gear Coupling

19. Application Profile
Rail Rolling Mill
Problem:
Russia’s second largest rail rolling mill, located in
Novokuznetsk, needed drives for a mill that produces railway
tracks for high speed trains.
Solution:
To meet the challenging application, Bauer BF Series
shaft-mounted geared motors were shipped to the mill. The
geared motors will be used to drive conveyors that transport
the formed steel to a straightening machine and then onto a
cooling bed.
• BF Series models feature high-tensile cast housings
• Torque rating to 18500 Nm
• Completely enclosed, sealed against dust and moisture
• IP65 Enclosure (Standard), IP66 (Optional)
BF Series Geared Motors

20. Application Profile
Steel Mill Assembly Line
Problem:
The Essar Group, headquartered in India, is active in many
industries including energy, communications, transportation,
and building construction. Essar Steel is a fully integrated steel
manufacturer with plants located around the world. They
required robust geared motors for a new, five-meter long,
assembly line at their Hazira, India mill.
Solution:
With the help of Bauer partner, International Combustion (IC),
located in India, Essar selected Bauer BG and BF Series
geared motor to meet the demands of this tough application.
• BG and BF Series geared motors are ideal for use in high
temperature environments
• Special roller table design
• Motors feature ring-ribbed housings
• Torques up to 18500 Nm
BG and BF Series Geared Motors

21. Steel Mill
Problem:
In an attempt to save a small amount in maintenance
costs, a metal processing mill in Malaysia chose to install
a non-genuine replacement copper wear plate in a Wichita
Kopper Kool clutch. After a short period in service, the
production line had to be shut down since the braking system
developed a serious coolant leak and started overheating.
Further investigation showed that the unauthorized copper
plate had become distorted and suffered from serious wear
that led to the leaks.
Solution:
The mill’s maintenance manager eventually replaced the
bad wear plate with a genuine Wichita replacement plate.
All replacement Wichita Clutch brand copper wear plates are
precisely matched with mating Wichita clutch and brake
components for optimum performance and ease of
installation.
Application Profile
Genuine Wichita Replacement Wear Plate

22. Steel Bar Mill Cranes
Problem:
A leading steel producer needed a robust replacement braking
solution for the overhead cranes at its bar mill in the U.S. The
mill was experiencing repeated problems with the existing drum
brakes and thrusters installed on multiple cranes throughout the
mill. Each crane utilizes two to four thrusters. The thruster seals
were leaking because they couldn’t withstand the harsh mill
environment. The brakes often failed, causing an excessive
amount of unplanned production stoppages.
Solution:
Stromag supplied Series SDB/SAB drum brakes with electro-
hydraulic thrusters sized for drum diameters between 13" and
30". All units featured Stromag’s exclusive “Steel Makers
Option” which is designed to withstand high temperature and
dusty mill environments. SDB units meet DIN 15435 & DIN
15430 Norms.
SAB units meet AISE N.11 - 63.120.
Application Profile
Series SDB/SAB Drum Brakes with Thrusters

23. Steel Mill Cranes
Problem:
China Steel, one of the largest steel making plants in
Taiwan relies on brakes to provide safe crane control
within their vast mill line.
Solution:
Twiflex installed over 150 EMX type calipers as they can
be used to cover a wide range of power ratings and
provide standardization and cost savings.
• EXM calipers are fail safe with electro-mechanical
release
• Rated between 110 to 200 kW
• Operate on a 910 mm diameter disc
Application Profile
EMX Caliper

24. Bridge Cranes
Problem:
Over 140 bridge cranes are required to operate in adverse
conditions with dust and heat being the main problem.
There is little time for routine maintenance and much
communication and planning are needed for rare
maintenance to be effective.
Solution:
The hoist brakes on the cranes were changed to an
electrically operated Twiflex EMX brake, which is similar to
an automobile disc brake. These brakes are self adjusting
and produce less heat during stopping.
• 1.5 times the stopping power of an equivalent drum brake
• Easy installation with few modifications required
• No air gaps or basic lubrication
• Application times range from 0.15 to 0.4 seconds
• Release times range from 0.1 to 0.2 seconds
Application Profile
EMX Disc Brake

25. Cross Transfer Conveyor
Problem:
The continuous casting floor area of a Scunthorpe UK plant
is situated some 10 meters below ground level. This means
that the cast blooms need to be raised before being
distributed to the stock pile or hot mills and require an
effective braking system.
Solution:
Twiflex EMX type calipers were chosen in preference to three
other suppliers because of their compact design, technical
features and proven record of reliability.
• Safe locking and holding control of six blooms, each
weighing over 10 tons
• More reliable than brake motors
• EMX caliper acting on a 610 mm disc
Application Profile
Twiflex EMX Type Caliper

26. Ladle Hood Winches
Problem:
A modern steel plant in the UK invests in being an
environmentally friendly producer, an example being the
de-sulphurizing unit at their Port Talbot works. A system is
required for controlling the winch mechanism needed to raise
and lower a ladle hood winch in the BOS plant.
Solution:
A single, spring applied MXSH type disc brake, released by
hydraulic pressure is employed between a motor rated for
55 kW at 1500 RPM and a 112:1 ratio gearbox connected to
a winch drum.
• Spring applied, hydraulically released type VCS 60 calipers
provide the emergency brake installed on the winch barrel
• Lock and hold the drum when the driving motor is
de-energized
Application Profile
Spring Applied Type VCS 60 Calipers

27. Barrel Reclaimer Drives
Problem:
A steel plant in the UK is one of the most modern steel
making facilities in the world and produces high-quality metal.
Therefore the plant requires very accurate blending of its raw
materials. Barrel reclaimer drives collect the material and
blend them by rotation, then discharge them onto a belt.
When stopping the belt’s two motors, it is important to
ensure the barrel reclaiming buckets are clear of the
reclaimed bed area.
Solution:
Twiflex EMX calipers are installed between the motors and
gearboxes and are applied to give a controlled and
accurate stop.
• Spring applied, electrically released brakes
• Hold the machine in place when stationary
• Fail-safe
Application Profile
EMX Caliper

28. Rail Wagons
Problem:
Large pusher machines are used to discharge red hot
coke into rail wagons where it is water cooled before being
transferred to the stockpiles. 20 ton locomotives pulling these
wagons are controlled electrically through the drive motor,
and the vehicle brakes originally fitted were unreliable in this
tough environment.
Solution:
Four Twiflex T40 hydraulic brake calipers are applied to
safely stop the wagon in the event of an emergency or
power failure.
• Chosen for toughness and reliability in hostile operating
conditions
• Long life in harsh environments
Application Profile
Twiflex T40 Hydraulic Brake Caliper