Tube and Pipe

Abbey and OTO mill solutions

The guarantee of functionality, safety and productivity

for the production of ERW tubes.

• Dedicated to the production of any type of ERW tubes: carbon steel and stainless steel from 4.75 mm
to 914,4 mm OD and wall thickness from 0,4 to 28 mm
• State-of-the-art technologies
• Innovative design and continuous Research and Development
• High quality standards and advanced manufacturing techniques
• Professional systems integration, installation, start up and training
• Fast, reliable and skilled service
Fully automated entry lines composed by Turnstiles, Loading carriages,
Automatic cranes, Decoilers, Pinch Rolls and Levellers, Shear End
welders/Strip joiners, Strip accumulators

DECOILER
Machines dedicated to high speed coil unwinding,
maintaining a costant strip tension
A wide selction of decoilers to satisfy all production requests
and covering the largest market range.
Double mandrel, single mandrel, double cone mandrels
and double step mandrels uncoilers with manual or fully
automatic coil preparation.

Production coverage:
— Strip width from 30 to 2400 mm and strip thickness from
0,4 to 28 mm. Max coil weight 45 t.

Sturdy equipments that has been conceived to endure

the loading and high speed layoff operations of heavy
coils, with a focus on operators safety

SHEAR END WELDERS / STRIP JOINERS

Designed to provide the most reliable, the fastest, and
the most automated joining of steel coils
Built with ample engineering safety factors and precision-
machined components, our strip joiners are conceived to
provide precise weld operations.
They offer the possibility to perform
trimming and joining of the trailing of the strip either
automatically, semi automatically or manually.

Production coverage:
— Strip width from 30 to 2400 mm and strip thikness from
0,4 to 28 mm

Designed to simplify weld inspection and

to withstand many years of use in the most demanding
applications with minimal maintenance

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STRIP ACCUMULATOR
Horizontal and vertical accumulators with improved
features
Fives’ strip accumulators have been designed to offer high
speed capability and high accumulation capacity, without
compromising on a careful strip handling required by
modern quality materials.
Our equipment allows the operations of end shearing and
— Excellent accumulation capacity / dimensions ratio
— Foundation work not necessarily required
— Ease and rapidity of installation
— Minimum strip damage due to distortion or scoring
— Few manual adjustment operations and low
maintenance required
welding to be carried out while the mill continues to run at
constant speed with no stoppages or decelerations.
Fives has great experience with space-saving vertical
accumulators and also offers a complete range of horizontal
accumulators to satisfy different needs in terms of
accumulation capacity.
— Maximum noise control during all operating phases
— Safety of use
— Great possibility of customization in terms of manual
or fully automatic adjustments
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Widest range in the world of High Productivity Tube Mills
for carbon steel and stainless steel
OTO TUBE MILL 322 FOR AUTOMOTIVE
High precision tube mill, for high steel grades up to 1200 N/mm
OTO Tube Mill 322 is a high Precision ERW tube mill for the
production of tubes for Automotive Industry
— Outside diameter tight tolerances thanks to special
backlash-free clamping systems
— Forming and welding of high strength and micro alloyed
materials thanks to compactness and rigidity and
accurate design of stands distances
OTO TUBE MILL 897 FOR DRAWN ON MANDREL PROCESSES
Heavy duty tube mill, high yield material
Thanks to the experience obtained during the last decade on
tube mills mostly utilized in the automotive and in the D.O.M.
industry, Fives OTO designed and manufactured this heavy
duty mill, specifically named OTO Tube Mill 897.
Main features
— High D/T ratio
— Possibility of processing high yield materials and at
the same time the production of shapes for the heavy
4
— Free of burr tube cutting system and Tube length
tight tolerances for sellable cut thanks to our
patented electronic control system
— Short changeover times thanks to patented quick
change over systems
— High quality welding process thanks to squeezing
pressure load cells and temperature control
structural industry
— High accurate control of the pull through force that each
pair of rolls applies to the strip
— Easy control of the production of a wide range of
tubes, thanks to a dedicated and reliable software
— Quick and repetitive change of rolls when passing
from a production to another one, thanks to OTO
Q.T.C. system
OTO TUBE MILL 6096 ETC FOR STAINLESS STEEL
Large outside diameter tube mill, extremely high diameter/thickness ratio
Fully automated tube mill for the production of high D/T — Strip accumulation tower
ratio laser welded stainless steel process pipes for fluids and — Edge trimmer
food industry. — Mill section
— Raw material: Austenitic stainless steel — 4 blade orbital cutoff
— Maximum tube diameter: 609 mm — Run-out conveyor
— Welding process: Laser
— The most innovative tube mill for SS tubes
Tube mill configuration: — Breakdown section with universal tooling
— Loading Car — Weld-box with bronze ‘caterpillar’ type edge trimmer
— Single decoiler — ETC: Easy Tool Change system for Fin-pass and Sizing
— Strip-joiner — Orbital cutoff working with HSS and TCT blades

ABBEY TUBE MILL

Abbey 3K3H TBS & 24K TBS large mill design
Fives supplies complete lines to make
heavy wall products for specialty
cylinder tubes to large ERW pipe
for the oil, gas and construction
industries.
Abbey patented TBS, the latest
forming technology for medium
and large mills, is the heart of the
forming section that features extreme
size capability of tube and pipe mills.
— 24K Forming Section
— O.D. range up to 914 mm (36’’
Diameter)

— Minimized tooling cost

— Reduced size changeover
times
— Extreme D/T’s to be
manufactured efficiently
— Setups can be “remembered”
and “recalled” and
automatically adjusted

5
MILL SECTION
Fives ERW Mills Round Tube Capability Table
OD wall thickness
mm in 0,5 0,7 0,8 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 8 9
4,0 1/6 5,7
4,8 1/5 6,8 6,0
6,4 1/4 12,7 9,1 7,9 6,4
8,0 1/3 16,0 11,4 10,0 8,0
9,0 1/3 18,0 12,86 11,3 9,0 6,0
10,0 2/5 20,0 14,29 12,5 10,0 6,7 5,0
12,0 1/2 24,0 17,14 15,0 12,0 8,0 6,0 4,8
15,8 5/8 31,6 22,57 19,8 15,8 10,5 7,9 6,3 5,3
19,0 3/4 38,0 27,14 23,8 19,0 12,7 9,5 7,6 6,3 5,4
21,3 5/6 42,6 30,43 26,6 21,3 14,2 10,7 8,5 7,1 6,1 5,3
25,4 1 50,8 36,29 31,8 25,4 16,9 12,7 10,2 8,5 7,3 6,4 5,6
28,0 1 1/9 40,00 35,0 28,0 18,7 14,0 11,2 9,3 8,0 7,0 6,2 5,6 5,1
30,0 1 1/6 42,86 37,5 30,0 20,0 15,0 12,0 10,0 8,6 7,5 6,7 6,0 5,5 5,0
33,7 1 1/3 48,14 42,1 33,7 22,5 16,9 13,5 11,2 9,6 8,4 7,5 6,7 6,1 5,6 5,2
38,1 1 1/2 54,43 47,6 38,1 25,4 19,1 15,2 12,7 10,9 9,5 8,5 7,6 6,9 6,4 5,9 5,4
42,4 1 2/3 53,0 42,4 28,3 21,2 17,0 14,1 12,1 10,6 9,4 8,5 7,7 7,1 6,5 6,1
48,3 2 60,4 48,3 32,2 24,2 19,3 16,1 13,8 12,1 10,7 9,7 8,8 8,1 7,4 6,9 6,0
50,8 2 63,5 50,8 33,9 25,4 20,3 16,9 14,5 12,7 11,3 10,2 9,2 8,5 7,8 7,3 6,4
57,0 2 1/4 71,3 57,0 38,0 28,5 22,8 19,0 16,3 14,3 12,7 11,4 10,4 9,5 8,8 8,1 7,1 6,3
60,3 2 3/8 75,4 60,3 40,2 30,2 24,1 20,1 17,2 15,1 13,4 12,1 11,0 10,1 9,3 8,6 7,5 6,7
63,5 2 1/2 63,5 42,3 31,8 25,4 21,2 18,1 15,9 14,1 12,7 11,5 10,6 9,8 9,1 7,9 7,1
70,0 2 3/4 70,0 46,7 35,0 28,0 23,3 20,0 17,5 15,6 14,0 12,7 11,7 10,8 10,0 8,8 7,8
76,1 3 76,1 50,7 38,1 30,4 25,4 21,7 19,0 16,9 15,2 13,8 12,7 11,7 10,9 9,5 8,5
88,9 3 1/2 88,9 59,3 44,5 35,6 29,6 25,4 22,2 19,8 17,8 16,2 14,8 13,7 12,7 11,1 9,9
101,0 4 101,0 67,3 50,5 40,4 33,7 28,9 25,3 22,4 20,2 18,4 16,8 15,5 14,4 12,6 11,2
108,0 4 1/4 72,0 54,0 43,2 36,0 30,9 27,0 24,0 21,6 19,6 18,0 16,6 15,4 13,5 12,0
114,3 4 1/2 76,2 57,2 45,7 38,1 32,7 28,6 25,4 22,9 20,8 19,1 17,6 16,3 14,3 12,7
121 4 3/4 60,5 48,4 40,3 34,6 30,3 26,9 24,2 22,0 20,2 18,6 17,3 15,1 13,4
127 5 63,5 50,8 42,3 36,3 31,8 28,2 25,4 23,1 21,2 19,5 18,1 15,9 14,1
139,7 5 1/2 69,9 55,9 46,6 39,9 34,9 31,0 27,9 25,4 23,3 21,5 20,0 17,5 15,5
146 5 3/4 73,0 58,4 48,7 41,7 36,5 32,4 29,2 26,5 24,3 22,5 20,9 18,3 16,2
152,4 6 76,2 61,0 50,8 43,5 38,1 33,9 30,5 27,7 25,4 23,4 21,8 19,1 16,9
168,3 6 5/8 84,2 67,3 56,1 48,1 42,1 37,4 33,7 30,6 28,1 25,9 24,0 21,0 18,7
177,8 7 88,9 71,1 59,3 50,8 44,5 39,5 35,6 32,3 29,6 27,4 25,4 22,2 19,8
193,7 7 5/8 96,9 77,5 64,6 55,3 48,4 43,0 38,7 35,2 32,3 29,8 27,7 24,2 21,5
203,2 8 81,3 67,7 58,1 50,8 45,2 40,6 36,9 33,9 31,3 29,0 25,4 22,6
219,1 8 5/8 87,6 73,0 62,6 54,8 48,7 43,8 39,8 36,5 33,7 31,3 27,4 24,3
244,5 9 5/8 97,8 81,5 69,9 61,1 54,3 48,9 44,5 40,8 37,6 34,9 30,6 27,2
254,0 10 101,6 84,7 72,6 63,5 56,4 50,8 46,2 42,3 39,1 36,3 31,8 28,2
273 10 3/4 109,2 91,0 78,0 68,3 60,7 54,6 49,6 45,5 42,0 39,0 34,1 30,3
304,8 12 101,6 87,1 76,2 67,7 61,0 55,4 50,8 46,9 43,5 38,1 33,9
323,9 12 3/4 92,5 81,0 72,0 64,8 58,9 54,0 49,8 46,3 40,5 36,0
355,6 14 101,6 88,9 79,0 71,1 64,7 59,3 54,7 50,8 44,5 39,5
406,4 16 101,6 90,3 81,3 73,9 67,7 62,5 58,1 50,8 45,2
426 16 7/9 106,5 94,7 85,2 77,5 71,0 65,5 60,9 53,3 47,3
473 18 5/8 105,1 94,6 86,0 78,8 72,8 67,6 59,1 52,6
508 20 101,6 92,4 84,7 78,2 72,6 63,5 56,4
609,6 24 101,6 93,8 87,1 76,2 67,7
660,4 26 101,6 94,3 82,6 73,4
711,2 28 88,9 79,0
762 30 84,7
812,8 32
863,6 34
914,4 36
Difficult because of the D/T ratio
Mill size to be selected according to material properties
Out of range
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 OD
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 mm
4,0
4,8
6,4
8,0
9,0
10,0
12,0
15,8
19,0
21,3
25,4
28,0
30,0
33,7
38,1
42,4
48,3
50,8
57,0
6,0 60,3
6,4 63,5
7,0 70,0
7,6 6,9 76,1
8,9 8,1 88,9
10,1 9,2 8,4 101,0
10,8 9,8 9,0 108,0
11,4 10,4 9,5 8,8 114,3
12,1 11,0 10,1 9,3 121,0
12,7 11,5 10,6 9,8 9,1 127,0
14,0 12,7 11,6 10,7 10,0 9,3 139,7
14,6 13,3 12,2 11,2 10,4 9,7 146,0
15,2 13,9 12,7 11,7 10,9 10,2 9,5 152,4
16,8 15,3 14,0 12,9 12,0 11,2 10,5 168,3
17,8 16,2 14,8 13,7 12,7 11,9 11,1 10,5 177,8
19,4 17,6 16,1 14,9 13,8 12,9 12,1 11,4 193,7
20,3 18,5 16,9 15,6 14,5 13,5 12,7 12,0 11,3 203,2
21,9 19,9 18,3 16,9 15,7 14,6 13,7 12,9 12,2 11,5 219,1
24,5 22,2 20,4 18,8 17,5 16,3 15,3 14,4 13,6 12,9 12,2 244,5
25,4 23,1 21,2 19,5 18,1 16,9 15,9 14,9 14,1 13,4 12,7 12,1 254,0
27,3 24,8 22,8 21,0 19,5 18,2 17,1 16,1 15,2 14,4 13,7 13,0 12,4 273,0
30,5 27,7 25,4 23,4 21,8 20,3 19,1 17,9 16,9 16,0 15,2 14,5 13,9 304,8
32,4 29,4 27,0 24,9 23,1 21,6 20,2 19,1 18,0 17,0 16,2 15,4 14,7 323,9
35,6 32,3 29,6 27,4 25,4 23,7 22,2 20,9 19,8 18,7 17,8 16,9 16,2 15,5 355,6
40,6 36,9 33,9 31,3 29,0 27,1 25,4 23,9 22,6 21,4 20,3 19,4 18,5 17,7 16,9 16,3 406,4
42,6 38,7 35,5 32,8 30,4 28,4 26,6 25,1 23,7 22,4 21,3 20,3 19,4 18,5 17,8 17,0 16,4 15,8 426,0
47,3 43,0 39,4 36,4 33,8 31,5 29,6 27,8 26,3 24,9 23,7 22,5 21,5 20,6 19,7 18,9 18,2 17,5 473,0
50,8 46,2 42,3 39,1 36,3 33,9 31,8 29,9 28,2 26,7 25,4 24,2 23,1 22,1 21,2 20,3 19,5 18,8 18,1 508,0
61,0 55,4 50,8 46,9 43,5 40,6 38,1 35,9 33,9 32,1 30,5 29,0 27,7 26,5 25,4 24,4 23,4 22,6 21,8 609,6
66,0 60,0 55,0 50,8 47,2 44,0 41,3 38,8 36,7 34,8 33,0 31,4 30,0 28,7 27,5 26,4 25,4 24,5 23,6 660,4
71,1 64,7 59,3 54,7 50,8 47,4 44,5 41,8 39,5 37,4 35,6 33,9 32,3 30,9 29,6 28,4 27,4 26,3 25,4 711,2
76,2 69,3 63,5 58,6 54,4 50,8 47,6 44,8 42,3 40,1 38,1 36,3 34,6 33,1 31,8 30,5 29,3 28,2 27,2 762,0
81,3 73,9 67,7 62,5 58,1 54,2 50,8 47,8 45,2 42,8 40,6 38,7 36,9 35,3 33,9 32,5 31,3 30,1 29,0 812,8
86,4 78,5 72,0 66,4 61,7 57,6 54,0 50,8 48,0 45,5 43,2 41,1 39,3 37,5 36,0 34,5 33,2 32,0 30,8 863,6
83,1 76,2 70,3 65,3 61,0 57,2 53,8 50,8 48,1 45,7 43,5 41,6 39,8 38,1 36,6 35,2 33,9 32,7 914,4

Mills for max tube OD 660.4 mm (26inches) and above are suitable for plate processing too
If required, if product falls in the “out of range” area of the table but is adjacent to the feasible products, please contact Fives OTO for technical evaluation.
7
QUICK TOOL CHANGE
OTO RTC: Rapid Tool Change system
Operating principle
— Two interchangeable sets of rafts (one on the mill base and the other off-line) for mill changeovers
— A Third Stand mounted on the mill base and permanently connected to the gearboxes

— Roll height adjustment to bring the rolls to the new

working position thanks to high precision hydraulic
motors.
— The automatic set-up saves time because precision
off-line roll height adjustment is not necessary,
tooling set-up being performed automatically from
the main control desk.
— The complete raft changeover of the forming, fin-
pass, sizing and straightening sections is carried
out in approximately 20-30 minutes, even on heavy
mills.
— Compactness and ease of handling of the rafts,
which are not equipped with universal joints (in this
system the universal joints are permanently on the
mill, connected to the third stand).

OTO QTC: Quick Tool Change system

OTO Quick Tool Change system QTC,
which enables a drastic reduction in
downtime during mill changeover
operations, is based on the principle of
two interchangeable sets of rafts (one on
the mill base and the other off-line) for
mill changeovers.

With this solution the operator

simply installs and sets up the
rolls off-line so they are ready for
the new tube size to be produced
at the time of the next mill
changeover.

OTO ETC: Easy Tool Change system

Operating principle:
— Mill configuration specifically
designed to execute very quick
change on large tube dimensions
machines.
— A set of driven shafts and side roll
supports assemblies fitted with rolls
on line and one or more additional
set out of line already equipped with
different rolls for the production of
new dimensions.

With this system the operators will have the possibility to maintain different productions “just in time” in one only shift.

8
MILL CCT QUICK CHANGE SYSTEM (For Small & Medium Mills)
CCT: Abbey Continuous Cart Transfer
The Abbey Patented Quick-change system is one of the most
productive systems for quick change. This advanced system
reduces change time drastically and yet is simple to use and
maintain. It is the most cost-effective system for this type of
mill in order to get to an advanced level of quick-change.
Cassette Quick Change system (For Large Mills)
The Cassette System is the ultimate system for large mills
to speed tooling changeover of four-roll passes. It uses
removable cassettes that hold all rolls and insert and remove
them as an assembly into the driven passes.
This system is normally used with two sets of cassettes. One
remains in the mill passes during operation. The other set
remains off line for preparation for the next tube size to be
run.
Our mills can be supplied with the CCT System in stages:
— Quick Change Ready (for future quick change)
— Additional Sub Plated Sections (for lift-off quick change)
— Addition of Third Stands (with driven push/pull used for
lift-off sub-bases)
— Full On-Line CCT Quick Change System (with driven carts)
— Off-Line Quick Change Devices
— Cassette System with CCT carts usually take less than 30
minutes to change over.
— Eliminate the use of mill cranes for the on-line staging
and interchanging of the cassettes
— Mill driven spindles remain in place in the stand as the
cassette housing allows easy access to the rolls off line
— All adjustments are powered and automatic sequencing is
used to load and unload the cassettes
— The cassette roll changeover system can be used on the
fin, weld, pullout and sizing passes
9
OTO HSU MILLS
A technology dedicated to the universal forming of Hollow Sections
OTO HSU Mills technology, based on high quality standards, This special forming system guarantees very interesting
guarantees the possibility to produce hollow sections within a material savings and it provides the use of the same set of
certain range of dimensions and thickness without changing rolls to cover the complete range of products of the machine,
rolls, saving set up time, reducing maintenance and facilitating drastically reducing the tooling costs that in a conventional
the use of the machine. tube mill represent one of the heaviest components of the total
With OTO Universal forming system, square and rectangular investment.
sections are directly welded without going through the welding The use of the same rolls for every dimension allows a
process of round tubes and subsequent shaping into four rolls very fast changeover time and facilitates a real just in time
sizing stands or turkshead sections. production.
The process is completely automated and it is easily controlled
by the operator.

— No rolls change required

— Saving time and space
— Reduced changeover time
— Costs reduction for rolls investment
— Rolls management optimization
— Material saving
— Just in time production
— High automation through the use of the “Mill
Manager” software
— Minimal intervention of the operator required for
tuning
— Easy maintenance thanks to easy access and good
visibility

10
Operators friendly CUT-OFF with 90% of energy savings.
New generation motion control card to enable faster and more precise
control of cut-off trolley and scrap reduction.

FLYING CUT-OFF
The most complete range of flying cutoffs.
— Cutting speed adjustment to allow the use of all
— Heavy-duty friction saw cutoffs
cold saw blades currently available (HSS, coated
— Cold saw cutoffs
screwed tips, TCT) Minimum cut tolerances, with
— Double shear cutoffs with mechanical clutch or hydraulic
a guaranteed bar length tolerance of ± 1.0 mm at
actuators
maximum operating speed
— Orbital cutoffs
— Maximum quality levels: perfect clean in-line cut
— Carbide tool rotary cutoffs
without distortion or burr
— Laser and Plasma cutoffs
— Ease of use thanks to Cutoff Manager system
— Bandsaw cutoffs
enabling to set and to record all key cutting and
— Cutoffs specially designed for inside scarfed tubes and for
statistical parameters
special profiles.
— High precision and reliability
— Minimal and easier equipment maintenance and
longer blade life
— Proprietary control board card (Eltav 6) to optimize
the cutting sequences and allowing a large variety
of optimization features

ORBITAL CUT-OFF
Orbital milling cut-offs TOAC series are designed — The machine is equipped with platforms and railings to
specifically for tube lines that require cuts without burr on guarantee access to all parts of the machine pursuant to
a wide production range. current safety standards.
The use of 4 cutting heads means that you can considerably — The machine is equipped with automatic greasing and
reduce cutting times and consequently increase the line’s lubrication systems for the main moving components. There
speed. The machine is however designed to be able to work are also inspection hatches on the cut-off to access rotating
with just two cutting heads as well. Small diameter blades are parts normally protected against chips and emulsion water.
used: this means greater rigidity, lower level of vibrations and
consequently improved finishing and longer life of the blades.
— Universal clamping system.
— Outstanding carriage stroke: long stroke means high
mill speeds for long cutting times. The tube is supported
correctly throughout the whole stroke by mobile supports.
— Cutoff manager and oscilloscope: the machine is
complete with software (cutting parameter management)
and acquisition system of the main parameters (speed
and current of motors) to be able to constantly monitor
operational efficiency.
— Thanks to the remarkable strength of the machine and to
the clearance recovery systems installed, the tube cut end is
excellent.

11
 Copyright © 2016 - Fives - All rights reserved.

CONTACT US:
Fives OTO S.p.a.
Fives Bronx, Inc. Via Domenico Marchesi, 4
8817 Pleasantwood Ave. N.W. Zona Industriale Rondello
North Canton, OH 44720 – USA Boretto (RE), 42022 – ITALY
Tel: +1 330 244 1960 Tel: +39 0522 481211
Fax: +1 330 224 1961 Fax: +39 0522 964188
Email: fivesbronx-sales@fivesgroup.com Email: fotospa.info@fivesgroup.com www.fivesgroup.com