Past AIST Committee Activities
The RBRTC met in Columbia, S.C., during the AIST Rod and Bar Rolling Training Seminar on Monday, 25 February 2013, to finalize the 2013 North American Rod and Bar Roundup. Jerry Herrmann, RBRTC APB/roundup chair, presented the 21 parameters that were developed for publication of the roundup in the August 2013 issue of Iron & Steel Technology. The committee met after the plant tour of CMC South Carolina on Thursday afternoon, 28 February. The RBRTC officer elections for the 2013–2014 term are: Dan Davies, chair; Matt Blitch, vice chair; Tracy Schutz, papers chair; Jacob Selzer, members chair; Bob Greuter and Kevin Barbee, education co-chairs; Jerry Herrmann, roundup chair; and Gary Henderson, APB chair. The RBRTC’s fall 2013 meeting will include a tour of Cascade Steel in Portland, Ore., on 25–26 September 2013.
The Rod & Bar Rolling Technology Committee (RBRTC) met on 26–27 September in Cambridge, Ont., Canada. Silvio Lemos, vice president/general manager of Gerdau Cambridge, welcomed the committee and hosted a plant tour of the rolling mill at Gerdau Cambridge. Bob Greuter, RBRTC education chair, provided an update on the third annual Rod and Bar Rolling — A Practical Training Seminar, which is scheduled for 25–28 February 2013 in Columbia, S.C. CMC South Carolina will be the host plant. The meeting’s safety discussion covered mobile phone usage, wrenches versus impact/hydraulic tools for mill adjustments and automatic crane stops to prevent collisions. Eleven paper abstracts were selected for AISTech 2013. Jerry Herrmann, RBRTC APB chair, reviewed the Rod and Bar Rolling Roundup. Revisions were made to the Roundup categories for publication in fall 2013. Joe Kennedy, of Quad Engineering, provided a mill listing for possible plant additions to this Roundup. Presentations included, “Reheat Furnace Improvements,” by Ty Hall, and “Roll Cooling Strategies,” by Jerry Herrmann. These presentations are available in the Members Only section on AIST.org. The next RBRTC meeting will be held on Monday, 25 February in Columbia, S.C. Presentations will include, “Guarding Practices at Nucor Utah,” by Doug Fuhriman; “Roll Spring Repeatability at Nucor Berkeley,” by Jerry Herrmann; “Finishing Mill Electrical Upgrade at Nucor Seattle,” by Larry Dalke; and “Rolling With R Factors,” by Joe Kennedy.
The Rod & Bar Rolling Technology Committee (RBRTC) met on Tuesday, 8 May 2012 during AISTech. The RBRTC officers for 2012–2013 will be: Steve Boyles, chair; Dan Davies, vice chair; Matt Blitch, papers chair; Bob Greuter, education chair; and Jerry Herrmann and Gary Henderson, APB co-chairs. Greuter provided a review of this year’s Rod and Bar Rolling Training Seminar. The 2013 Rod and Bar Rolling Training Seminar will be held on 26–28 February 2013 in Columbia, S.C. CMC South Carolina will serve as the host plant. Herrmann asked the committee to help populate the Rod and Bar Rolling Roundup with additional plants.
The next RBRTC meeting will be held on 26–27 September 2012 near Toronto, Ont., Canada. Gerdau Cambridge will provide the plant tour. Presentations at that meeting will include: Reheat Furnace Improvements by Ty Hall (CMC Steel Texas), Roll Cooling Strategies by Jerry Herrmann (Nucor Steel–Berkeley), Rolling Mill Upgrades by Jeff Graeber (Dynamet), and Finishing Mill Electrical Upgrades by Larry Dalke (Nucor Steel Seattle Inc.).
The Rod & Bar Rolling Technology Committee (RBRTC) met in Scottsdale, Ariz., on Monday, 27 February 2012. There were 25 RBRTC members in attendance. The 2011 Steel Industry Fatalities report was reviewed, followed by a safety roundtable discussion. Jerry Herrmann, RBRTC roundup/APB chair, updated the committee on the North American Rod and Bar Rolling Roundup. A number of rolling mills are missing, and the committee was urged to contact colleagues who are not represented in this Industry Roundup. Dan Davies, RBRTC papers chair, presented the three paper sessions scheduled for AISTech 2012. Bob Greuter, RBRTC education chair, provided an overview of this year’s Rod and Bar Rolling Training Seminar, which had 99 attendees. The committee revised the AISTech 2013 Call for Papers statement for soliciting papers for next year. Ty Hall, RBRTC chair, encouraged everyone to attend AISTech 2012 in Atlanta, Ga. The next RBRTC meeting will be on Tuesday, 8 May.
The Rod & Bar Rolling Technology Committee (RBRTC) met in Seattle, Wash., on 14–15 September 2011. Review of the 2011 Steel Industry Fatalities started the meeting, which was followed by a safety roundtable discussion. Bob Greuter, education chair, reviewed the program outline for the 2012 Rod and Bar Rolling Training Seminar, scheduled for 26 February–1 March 2012 in Scottsdale, Ariz., for which the host plant will be CMC Steel Arizona. Larry Dalke, AIST Division V Director and Nucor Steel Seattle host, and Joe Kennedy, Quad Engineering, presented “New R-Factor System at Nucor Steel Seattle.” The meeting included “line of fire” presentations: Tracy Schutz, Nucor Steel Seattle; Ty Hall, CMC Texas and RBRTC chair; Steve Boyles, Cascade Steel and RBRTC vice chair; Chad McKeever, ArcelorMittal; and Dennis Pew, Nucor Steel–Berkeley. Adam Lorimer, Alphabet Energy, presented, “Thermoelectric Waste Heat Recovery for Reheat Furnaces,” which started the meeting on the second day. Dan Davies, papers chair, presented paper abstracts for AISTech 2012. Session chairs were selected and a RBRTC officer conference call will determine scheduled paper sessions for AISTech 2012. Sven-Erik Lundberg, Hatch Ltd., reviewed the table glossaries for Long Products and Flat Products for the next editions of the Making, Shaping and Treating of Steel. Dennis Pew and Jerry Herrmann, RBRTC roundup chairs, presented the North American Rod & Bar Rolling Roundup for committee review, and roundup format revisions were made. The AIST Process Benchmarker (APB) was introduced to the committee. This new benchmarking program will provide operating technology committees the opportunity to make comparisons between participating steel companies. Dennis Pew was nominated and elected as the RBRTC benchmarking chair. The next RBRTC meeting is scheduled for Monday, 27 February 2012 in Scottsdale, Ariz., before the 2012 training seminar. The meeting’s theme will be “Personnel Development for Rolling Mills,” with CMC Steel Texas, Nucor Steel–Berkeley, The Timken Co. and ArcelorMittal making presentations. A tour of Nucor Steel Seattle concluded this meeting.
The Rod & Bar Rolling Technology Committee (RBRTC) met on 4 May 2011 in Indianapolis, Ind. Current RBRTC membership is at 85 members with 24 members in attendance. The 2011 Steel Industry Fatalities Statistics were reviewed, followed by a roundtable safety discussion. The election for RBRTC officers was completed: Ty Hall, chair; Steve Boyles, vice chair; Dan Davies, papers chair; Matt Blitch, membership chair; Bob Greuter, education chair; Steve Pegg and Doug Fuhriman, safety co-chairs; and Jerry Herrmann and John Sadler, roundup co-chairs. The committee mission statement was reviewed and approved. Bob Greuter updated the committee on the successful 2011 Rod and Bar Rolling Training Seminar held in Charlotte, N.C., with Gerdau Charlotte as the plant host. The next Rod and Bar Rolling Training Seminar is scheduled for 27 February–1 March in Scottsdale, Ariz. CMC Arizona will be the host plant, with Alan Jackson as the keynote speaker. Those interested in participating in this training seminar should contact Bob Greuter before 1 August 2011. The next RBRTC meeting will be 14–15 September 2011 in Seattle, Wash., with Nucor Steel Seattle Inc. and Larry Dalke as host. Meeting topics will be “emergency line-of-fire response” presentations by Dalke of Nucor Steel Seattle Inc.; Ty Hall of CMC Texas; Steve Boyles of Cascade Steel; John Sadler of ArcelorMittal; and Dennis Pew and Matt Blitch of Nucor Steel – Berkeley. Contact Ty Hall to make a presentation during this meeting.
The Rod & Bar Rolling Technology Committee (RBRTC) met on 28 Feb in Charlotte, N.C. before the Rod and Bar Rolling Training Seminar. Current RBRTC membership stands at 91 members with 21 members in attendance. The committee reviewed the 2010 and 2011 Steel Industry Fatalities Statistics updated by Chad McClimans, Safety & Health Technology Committee education chair. A roundtable safety discussion followed. The committee then discussed plant cell phone policies, CPR and AED training, visitor safety contact programs, advocating safety audits and observations, outside contractor safety requirements, plant housekeeping, and employee family involvement with their safety programs. Jim Buhl, RBRTC vice chair, reviewed the paper sessions scheduled for AISTech 2011. The committee’s AISTech 2012 Call for Papers was revised so that rolling mill safety and innovations lead off the statement.
Bob Greuter, education chair, presented an overview of the initial Rod and Bar Rolling — A Practical Training Seminar, which followed this committee meeting. The seminar had 75 attendees. Gerdau Ameristeel Charlotte was the host plant, and Casimiro Liborio, vice president and general manager, was the keynote speaker. This two-and-a-half-day training seminar was a success for the rod and bar rolling mill community. Ty Hall, RBRTC chair, is working on a seminar site for February 2012. Jerry Herrmann, RBRTC Roundup co-chair, presented a Roundup format that the committee will aim to complete this year. The AIST Process Benchmarking program was presented, which will allow Technology Committees to benchmark certain Key Performance Indicators. Larry Dalke, past RBRTC chair and current AIST Division V director, recommended that the discussion topic for the next RBRTC meeting in the fall should be “line of fire” circimstances that have occurred in rolling mills. This emergency course of action/reaction needs to be communicated among plants. Nucor Steel Seattle, CMC Texas, ArcelorMittal, Nucor Steel–Berkeley and Cascade Steel are a few shops that will be asked to make presentations at the fall 2011 RBRTC meeting in Seattle, Wash., on 14–15 Sep, with a tour of Nucor Steel Seattle.
The Rod & Bar Rolling Technology Committee (RBRTC) met on 16–17 Nov 2010 in Charleston, S.C., with the Nucor Steel–Berkeley rolling mill as the host. Ty Hall, RBRTC chair, welcomed 33 committee members to this meeting. Current RBRTC membership stands at 88 members. The 2010 Steel Industry Fatalities Statistics were reviewed, with 19 fatalities recorded at the time. The 2009 fatality count was 17. A roundtable safety discussion followed, involving plant practices, cell phone usage and accident prevention programs. John Sadler discussed the fatality on 18 Oct at ArcelorMittal and presented a video on the company’s behavior-based safety program, which has been quite successful. Dennis Pew and Matt Blitch from Nucor Steel–Berkeley presented active safety programs, such as “PLAN” (People – Laws – Any hazard – Nucor team) and “STAR” (Safe Thinking and Recognition), that have contributed toward a goal of zero accidents. Nucor Berkeley has installed a Lock Out/Tag Out program that took significant work to complete. The RBRTC requested that this presentation be part of its initial training seminar in March.
AISTech 2011 will have three RBRTC sessions scheduled. The meeting at AISTech 2011 will be on Wednesday, 4 May at noon. Committee members were encouraged to submit terms for the AIST Steel Glossary to help grow this steel-related dictionary. Jerry Herrmann and John Sadler were nominated to be Roundup co-chairs for the RBRTC. Initially, 20 rod and bar mill statistics will be collected to identify North American producers. Steve Boyles, papers chair, mentioned a new style of hearing protection being used at Cascade Steel. You can find out more about these fitted ear plugs at www.protectear.com. Due to recent retirements, RBRTC officer elections for the 2011–2012 term were held. The following committee members were elected: Ty Hall as chair, Steve Boyles as vice chair, Dan Davies as papers chair, Matt Blitch as membership chair, Bob Greuter as education chair, Steve Pegg and Doug Fuhriman as safety co-chairs, and John Sadler and Jerry Herrmann as Roundup co-chairs. Bob Greuter organized the first Rod and Bar Rolling Training Seminar, scheduled for 28 Feb–3 Mar 2011 in Charlotte, N.C. Gerdau Ameristeel Charlotte will be the plant tour host, with Casimiro Liborio, vice president and general manager, as the keynote speaker. Mr. Greuter highlighted the seminar agenda, and presentation previews were given by Matt Allen, Joe Kennedy, Doug Fuhriman, Steve Pegg and Kevin Barbee. The next RBRTC meeting will be on Monday, 28 Feb prior to the training seminar.
The Rod & Bar Rolling Technology Committee (RBRTC) met during AISTech 2010 on Tuesday, May 4, with 21 people in attendance. Five attendees were potential new members for this committee. Larry Dalke reviewed the 2010 Steel Industry Fatalities Statistics, noting the eight recorded fatalities. Round table discussion followed, with everyone asked to discuss recent injuries and improvements in their safety programs. Current RBRTC membership stands at 97 members. The RBRTC officer elections for the 2010–2011 term resulted in Ty Hall being elected as chair, Jim Buhl as vice chair, Steve Broyles as papers chair, Dan Davies as membership chair, Doug Fuhriman and Steve Pegg as safety co-chairs, and Bob Greuter as education chair. Larry Dalke was elected as the AIST Division V board of directors representative for the 2010–2012 term. Bob Greuter, RBRTC education chair, presented a draft agenda for the initial Rod and Bar Rolling Training Seminar, scheduled for Feb. 28–March 3, 2011, in Charlotte, N.C. Gerdau Ameristeel Charlotte will be the host plant, with Casimiro Liborio, vice president and general manager, featured as the keynote speaker. Potential seminar presenters along with Bob Greuter are: Joe Kennedy, Matt Allen, Jim Buhl, Ty Hall, Doug Fuhriman, Steve Pegg, Dan Davies, Steve Broyles and Larry Dalke. The RBRTC Training Seminar Subcommittee will finalize program details during a meeting in early September. The next RBRTC meeting will be in Charleston, S.C., Nov. 17–18, 2010, with a tour of Nucor Steel–Berkeley’s rolling mill.
The Rod & Bar Rolling Technology Committee (RBRTC) met in Jacksonville, Fla., on Feb. 18–19 with a tour of the Gerdau Ameristeel Jacksonville Rolling Mill. There were 19 RBRTC members in attendance. Johnny Miller from Gerdau Ameristeel Jacksonville presented a safety and plant overview of the rolling mill, which was built in 1976. Safety discussions started with the Safety & Health Technology Committee Steel Industry Fatalities statistics, the importance of lockout/tagout, and how at older mills it is difficult and very costly to install quick disconnects. Steve Boyles mentioned a generation gap exists that creates a safety communication challenge for most plants. The RBRTC has committed to develop a Rod and Bar Rolling Training Seminar, scheduled for March 1–3, 2011, with Gerdau Ameristeel Charlotte as the host plant. Bob Greuter, RBRTC education chair, has encouraged committee member participation to provide the expertise in teaching rolling mill fundamentals. RBRTC officers Larry Dalke, Ty Hall, Jim Buhl and Doug Fuhriman will participate, along with members Joe Kennedy, Matt Allen, Steve Broyles, Dan Davies and Bill Smith. RBRTC officer rotation for the 2010–2011 term will be as follows: Ty Hall, chair; Jim Buhl, vice chair; Steve Boyles, papers chair; and Dan Davies, membership chair. Current RBRTC chair Larry Dalke will be the next Division V AIST Board of Directors representative for the 2010–2012 term. The RBRTC fall meeting will be held at Nucor Steel–Berkeley.
The Rod & Bar Rolling Technology Committee (RBRTC) met in Memphis, Tenn., on Oct. 1–2 with a tour of Nucor Steel Memphis’s rolling mill. Committee chair Larry Dalke welcomed the 26 RBRTC members attending. Steve Pegg and Doug Fuhriman, RBRTC safety co-chairs, gave an overview on rolling mill safety practices and procedures. Various safety audit programs were discussed, including E-Stop awareness, lift chain/cable inspections, contractor safety coverage, and supplier safety requirements. Dan Davies and Steve Boyles reported on the recent Steel Manufacturers Association meeting and the topics covered there. AIST’s Safety & Health Technology Committee’s 2009 steel industry fatalities statistics were the focus of an open discussion. Alan Jackson recommended that every plant visitor be asked to offer one safety audit suggestion for the shop they’re visiting. Larry Dalke mentioned the development of a rolling mill best practice, where issues like a roll change or cobble removal practice are detailed using the safest procedures. The RBRTC was reminded that each committee member can send an e-mail message using the AIST Extranet to communicate a safety incident or near-miss that recently occurred, in hopes of not repeating a similar safety hazard in another shop.
Bob Greuter, RBRTC education chair, presented a Rod & Bar Rolling Training Seminar agenda to the committee. The committee has scheduled this training seminar for March 1–3, 2011, in Charlotte, N.C. Gerdau Ameristeel Charlotte is a possible tour site. Presenters thus far include: Larry Dalke, Ty Hall, Jim Buhl, Bob Greuter, Steve Pegg, Doug Fuhriman, Joe Kennedy, Matt Allen and Dan Davies. If you have an interest in participating in this training seminar, contact Mr. Greuter. The committee will determine course length and topic material at its next meeting. Committee members are asked to mail sample product pieces to Mr. Greuter that will be used in the training seminar.
The AISI Steel Bar Product Guidelines was presented by Mel Head, AISI metallurgical consultant, who illustrated the revisions made to this manual since the 1996 edition. The new, revised copy can be purchased through AIST’s Steel Library. The next RBRTC meeting is scheduled for Feb. 18–19, 2010, in Jacksonville, Fla., with a tour of Gerdau Ameristeel Jacksonville’s rolling mill.
The Rod & Bar Rolling Technology Committee (RBRTC) met on Wednesday, May 6 at AISTech 2009. There were 23 committee members in attendance. Larry Dalke, chair, reviewed the RBRTC sessions at AISTech, which involved 15 papers. The AISTech 2010 Call for Papers asks for committee members to solicit papers for the 2010 conference in Pittsburgh, Pa. Contact Jim Buhl, papers chair, for details on submitting a paper. RBRTC officer elections were completed, with existing officers asked to complete a second one-year term for 2009–2010: Larry Dalke, chair; Ty Hall, vice chair; Jim Buhl, papers chair; and Bob Greuter, education chair. The RBRTC discussed creating Safety co-chairs, and this was approved. Steve Pegg and Doug Fuhriman were elected as Safety co-chairs. The RBRTC training seminar was discussed, and agenda items and a target audience were determined. Bob Greuter, education chair, will send a revised training seminar agenda with day-ending panel discussions to increase participation from attendees. Potential presenters will also be noted for review. The next RBRTC meeting is scheduled for Oct. 8–9, 2009, with a tour of Nucor Steel Memphis on Friday morning, Oct. 9. Committee presentations will be made on Thursday, Oct. 8, involving rolling mill safety concerns; shutdowns and start-ups; cost prevention while at reduced capacity; and quality concerns producing at slower rates. Contact Larry Dalke before Aug. 15, 2009, if you would like to make a 30-minute PowerPoint presentation on one of these topics. RBRTC members presented Mr. Dalke with a plaque in recognition of his dedication and participation within the rolling mill community.
The Rod and Bar Rolling Technology Committee (RBRTC) met in Duncansville, Texas, on April 1–2. The RBRTC meeting was held in conjunction with the Southwest Member Chapter’s spring meeting, which included a tour of Gerdau Ameristeel Midlothian. Committee chair Larry Dalke welcomed the 12 committee members in attendance. The RBRTC roster has 137 members that reflect inactive Long Products Committee members. The RBRTC will work on building a strong producer member base by reaching out to current rolling mill producers who are not yet involved with the committee. Safety round table discussions involved dehydration issues around the furnace area, combustion concerns with multiple start-ups and shutdowns, furnace relighting procedures, dust in the eye and its frequency, employee safety ownership, cross-departmental safety audits providing a fresh set of eyes to evaluate audit area, combining initial turn activity with safety, and exercising and increasing safety communications plant-wide. A serious injury was noted in which an employee was struck with a 1-ton bundle of bars below his knee. The possibility exists that he might lose his leg because a safe, clear distance was not maintained in this bar storage area. Nucor Steel Seattle and Nucor Steel–Nebraska discussed their Voluntary Protection Program (VPP), which has been recognized by OSHA. The RBRTC reviewed the 2008 Steel Industry Fatalities statistics provided by AIST’s Safety and Health Technology Committee. A proposal to improve committee safety awareness was presented. Taking an example from the Continuous Casting Technology Committee, two RBRTC members were elected to become safety co-chairs, who would solicit rolling mill safety papers for AISTech and encourage safety presentations for future committee meetings. Steve Pegg, Russula, and Doug Fuhriman, Nucor Steel–Utah, were asked to fulfill these committee assignments. The RBRTC was reminded to use the Members Only area of the AIST Web site to broadcast any injury that occurs in their plant that day in hopes of preventing a similar accident at another rolling mill.
The RBRTC’s sessions for AISTech 2009 were reviewed, with three scheduled sessions and 15 paper presentations. The RBRTC also updated its topic for the AISTech 2010 Call for Papers. Bob Greuter, education chair, discussed key elements for planning a Rod and Bar Rolling Training Seminar for the fall of 2010. Defining the audience will be critical, while addressing the following training subjects: safety concerns with rolling mills; introduction to rolling; hot rolled as-rolled attributes; steelmaking; metallurgy; rolling procedures; area-volume-mass flow; incoming material; reheat furnace operations; work rolls and speed; roll passes; drives; ancillary equipment; classification of defects; and yield factors. Larry Dalke and Ty Hall will collaborate and define what rolling mill training aspects will be addressed. Nucor Steel Seattle has volunteered to be host plant for the initial RBRTC training seminar.
Current RBRTC officers were nominated to extend their terms an additional year to help organize the training seminar. Larry Dalke, chair; Ty Hall, vice chair; Jim Buhl, papers chair; and Bob Greuter, education chair were nominated. These nominations were to be voted upon at AISTech 2009. Ty Hall and Jim Buhl made technical presentations at the Southwest Chapter spring meeting.
The Long Products Rolling Technology Committee (LPRTC) met in San Antonio, Texas, for a tour of CMC Texas. Under the direction of Larry Dalke (chair), Ty Hall (vice chair) and Jim Buhl (papers chair), the LPRTC decided to reinvent itself to give AIST members in the rolling mill community a substantive group to provide technical forums, training seminars, a more representative rolling mill committee membership, and improved networking. Active LPRTC members voted unanimously to change this committee’s name and mission statement. The Long Products Rolling Technology Committee will now use the name of Rod and Bar Rolling Technology Committee (RBRTC) to appeal to the rolling mill members. A subcommittee may be formed for rail and beam producers. Rolling mill training will serve as the first priority for this new committee. A Rod and Bar Specialty Training Conference will be scheduled for September 2010, with Nucor Steel Seattle serving as the host plant. The new RBRTC selected Bob Greuter, of Morgardshammar Inc., as its education chair, responsible for developing the training conference. Availability of AISI’s Rolling Mill Training Modules will help this committee formulate an effective training session. The RBRTC mission statement now reads, “To serve the Rod and Bar Rolling Technology Committee by providing forums to advance safety, quality, technology, and performance issues related to the long products industry. The RBRTC will accomplish this mission through the development of technical training seminars, promoting the AISTech conferences, and organizing committee meetings.” Ty Hall, CMC Texas rolling mill superintendent, presented a safety discussion entitled, “Safety Pays the CMC Way.” Safety improvements were noted, and a complete plant tour was provided for the committee. Housekeeping was rated as excellent by this committee. CMC Texas employs roughly 700 people who have adopted the safety philosophy of the “I’s of Safety,” where an employee is only as good as their next decision made. Bill Smith, of LAP Laser, made a presentation on current lasering practices in the steel industry. The next RBRTC meeting will be a joint venture with the AIST Southwest Member Chapter spring meeting in Dallas, Texas, on April 1–3, 2009.