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The key factors of an ERW line differ depending on tube application: metallurgical quality is essential for heat treated ERW OCTG grades, as are tight dimensional tolerances for precision tubes and high productivity for structural pipes. Different levels of automation, turn-key technological solutions, operating company assistance and project financing through an export credit agency or operating leasing company are possible means of increasing investment profitability.

Simplified, cost effective ERW mill configurations are also available for commodity tube producers.

Danieli can supply the complete package in the vertical integration of a steel complex including hot rolled coil mini-mills, slitting lines, multiple ERW lines to cover the requested product mix including a tailored tube-finishing floor.

Projections in the consumption of welded tubes show continued growth, especially in the area represented by ERW tubes. The reason is simple: tubular products cover a wide range of applications (structural, industrial, line pipe). It is a well-known and consolidated technology involving a small investment and few skilled operators, therefore appealing for newcomers that want to get in this market or consolidate producers with the aim to increase the market share or diversify the production range or quality. Input material is slit coils, which are easily sourced. Plant capacity can be gradually increased using a step-by-step approach installing additional ERW lines to cover wider size ranges in order to also enlarge the product mix flexibility and/or steel grades.

This market is segmented; different tubes applications require different tube finishing processes. Automotive DOM (draw over mandrel) or heat treated OCTGs are two high added-value products where ERW tubes are the starting material. To be profitable, an ERW plant needs to be efficient, with a high level of automation and capable of producing high-end products. In the most modern installation, particular attention is paid to the ergonomics of the solution for the operators and to the safety operations of the plant.