Continuous Casting Engineering
ATS helps steel plants upgrade critical caster components and process control systems to achieve higher efficiency and improved product quality.
Modernizing Existing Casters for Higher Productivity and Quality
Our Services
We support steel plants with targeted caster modernization: mechanical upgrades, process optimization and engineering improvements tailored to each plant's production requirements. From strand and machine geometry to secondary cooling, mold and segments, and automation—we help you achieve higher efficiency and improved product quality.
Strand & Machine Geometry Optimization
Improving the strand path and roll configuration to enhance casting stability and reduce breakout risk.
Secondary Cooling System Upgrade
Optimizing spray distribution and cooling control to improve solidification and surface quality.
Mold & Segment Improvements
Upgrading mold design and segment systems to increase caster performance and reliability.
Automation & Process Optimization
Implementing advanced control solutions to stabilize casting operations and increase productivity.
Modernisation Scope
Strand Layout Optimization
Improving machine geometry and roll configuration to enhance casting stability.
Secondary Cooling Upgrade
Redesigning spray systems to optimize solidification and surface quality.
Mold System Improvements
Upgrading mold design and cooling performance.
Segment & Roll Technology
Enhancing strand support and reducing bulging risks.
Process Control Improvements
Optimizing casting parameters and operational stability.
Why Modernise Your Continuous Caster
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Increase casting capacity
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Improve steel cleanliness
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Reduce breakout risk
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Extend equipment lifetime
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Improve surface quality
Our Engineering Approach
Process analysis of existing caster
We start by reviewing your current caster layout, operating data and maintenance records. This includes strand geometry, cooling zones, mold and segment condition, and process parameters. The analysis highlights where performance falls short of your targets and where upgrades will deliver the best return.
Identification of bottlenecks
Using the process analysis, we pinpoint bottlenecks that limit capacity, quality or availability—whether in the mold, secondary cooling, strand support, automation or logistics. Priorities are agreed with your team so the modernisation scope stays focused and cost-effective.
Engineering redesign of critical systems
For each chosen scope item we deliver detailed engineering: layout and geometry, cooling and spray design, mold and segment upgrades, or control strategy. Designs are tailored to your product mix, steel grades and production targets, and are ready for procurement and execution.
Implementation & commissioning support
We support installation, cold and hot commissioning, and tuning so the upgraded caster reaches target performance. This includes coordination with suppliers and contractors, commissioning procedures, operator training and handover documentation so your team can run and maintain the system confidently.
Project Experience
Continuous Casting Revamp Project
Extension of mold length and redesign of mold body to increase production capacity and improve product quality.
Modernizing Existing Casters for Higher Productivity and Quality
Discuss your caster modernisation project with our engineering team.