In modern aluminum wire and overhead conductor manufacturing, the continuous casting and rolling (CCR) process is recognized as the most efficient, reliable and cost-effective method for producing high-quality aluminum and aluminum alloy rods. The RLB Aluminum Alloy Rod Continuous Casting and Rolling Production Line combines melting preparation, online degassing & filtration, four-wheel continuous casting, straightening, optional medium-frequency induction heating, multi-stand continuous rolling, emulsion cooling and automatic coiling into one fully continuous, high-output system.
This turnkey line delivers premium rods of Ø9.5 mm, 12.5 mm and 15 mm in EC1350 (electrical conductor grade), Series 3#, 5# (5005/5154), 6# (6101/6201) and Series 8# (8176/8030) alloys. All products fully comply with ASTM B233, IEC, European and American standards. Typical electrical conductivity for EC1350 reaches 61.5–61.8 % IACS (resistivity as low as 0.027899 Ω·mm²/m in O temper). For 6101/6201 alloys used in AAAC conductors, tensile strength typically ranges from 150–220 MPa with conductivity of approximately 51–52 % IACS.
Engineered specifically for the demanding GCC climate and high-volume overhead line production, the RLB CCR line provides exceptional rod density, uniform grain structure, bright surface finish and minimal porosity. Available models offer capacities of 4.5–5 t/h (4.5T), up to 6–7.5 t/h (7.5T), with line speeds reaching 8 m/s and finished coil weights of 2–3 tons. Compared with traditional separate casting and rolling processes, users typically achieve 15–25 % higher output, significantly lower energy consumption and scrap rates below 1.5 %.
Detailed Technological Process – Complete Continuous Route
Raw material preparation (melting furnace supplied by customer or optional): A00 aluminum ingots, sow or high-quality scraps → Holding furnace with alloy addition and stirring → Online degassing & multi-stage filtration → Four-wheel continuous casting machine equipped with H-type crystallization wheel → Straightening machine → Front haulage device → Rolling shear → Medium-frequency induction heater (optional, for precise temperature control and online quenching) → Feeding device → Continuous rolling mill (configurable as 2-roller, 3-roller Y-type or combined 2+3 roller) → Cooling & emulsion lubrication system → Automatic coiling stand with arc guiding pipe and pre-deformation protection → Finished high-conductivity aluminum alloy rod coils (2–3 ton coils).
The H-type crystallization wheel (diameter range 1400–2300 mm, casting cross-sectional area 1600–3300 mm² depending on capacity) uses four-side cooling. This design ensures rapid yet uniform solidification, minimizes porosity, improves internal density and delivers a superior cast bar structure that translates directly into better final rod conductivity and mechanical performance.
Core Technical Advantages & Operational Excellence
- H-Type Four-Side Cooling Crystallization Wheel Produces dense, uniform ingots with excellent surface quality and minimal defects. Critical for achieving high electrical conductivity in EC1350 and consistent mechanical properties in high-strength alloys.
- Flexible Roller Configurations Optimized for Different Alloys
- 3-roller (Y-type): Best roundness and surface quality for standard EC1350
- 2-roller: High-speed production of simpler grades
- Combined 2+3 roller: Superior deformation control and mechanical properties for 6101, 6201, 8176 and similar high-strength alloys
- Advanced Medium-Frequency Induction Heater (Optional) Maintains precise rolling temperature, enables controlled online quenching and significantly reduces surface oxidation during processing of alloy grades.
- Intelligent PLC + HMI Full-Line Control Real-time monitoring of casting speed, rolling temperature, tension, emulsion flow and other critical parameters. Recipe storage allows rapid, repeatable changeover between multiple alloy grades without major mechanical reconfiguration.
- High-Capacity, Low-Scrap, Energy-Efficient Operation Models range from 4.5–5 t/h to 6–7.5 t/h. Typical scrap rate <1.5 % with proper degassing and filtration. Documented energy savings of 15–25 % versus conventional processes in GCC installations. Continuous 24/7 capability with automatic coiling.
- Complete Turnkey Integration & Compatibility Includes full lubrication, emulsion cooling & filtration systems, automatic coiling with arc guiding and pre-deformation protection. Fully compatible with existing melting furnaces through matching launders, flow control and synchronization packages.
These features deliver measurable gains in productivity, rod quality consistency and operating cost reduction while ensuring long-term reliability under Gulf climatic conditions.
Technical Specifications
| Model | Rod Diameter (mm) | Rolling Times | Capacity (t/h) | Roller Mode | Melting Furnace (t) | Holding Furnace (t) | Furnace Energy | Applicable Alloys |
|---|
| 4.5T | 9.5 / 12 / 15 | 15 | 4.5–5 | 3-roller | 6 | 10–15 | Natural gas / LPG | EC1350, 3#, 5#, 6#, 8# |
| 7.5T | 9.5 / 12 | 10 or 14 | 6–7.5 | 2-roller + 3-roller | 12 | 20–25 | Natural gas / LPG | EC1350, 3#, 5#, 6#, 8# |
Line speed up to 8 m/s. Coil weight 2–3 tons. Custom capacities and configurations available upon request.
Alloy Performance Data (Typical Values Meeting ASTM / IEC Standards)
EC1350 (Electrical Conductor Grade)
- Chemical composition (ASTM B233): Al ≥99.5 %, controlled limits on Si, Fe, Cu, Mn, etc.
- Conductivity: 61.3–61.8 % IACS (resistivity 0.027899–0.028126 Ω·mm²/m depending on temper)
- Tensile strength (typical ranges): O temper 59–97 MPa; H12/H22 83–117 MPa; H14/H24 103–138 MPa; H16/H26 117–152 MPa
6101 / 6201 (High-Strength Alloy Grades for AAAC)
- Chemical composition (typical EN 573-3 / ASTM ranges): Si 0.3–0.9 %, Mg 0.35–0.9 %, Fe <0.5 %, controlled minor elements
- Conductivity: approximately 51–52 % IACS
- Tensile strength (T4 temper typical): 150–220 MPa
- Excellent combination of strength, conductivity and corrosion resistance for overhead alloy conductors
Series 5# (5005/5154) and Series 8# (8176/8030) are also fully supported with appropriate process recipes.
Main Components & System Integration
- Melting and holding furnaces (customer-supplied or optional complete package)
- Online degassing and multi-stage filtration system
- Four-wheel continuous casting machine with H-type crystallization wheel
- Straightening machine and front haulage device
- Rolling shear
- Medium-frequency induction heater (optional)
- Continuous rolling mill (2-roller / 3-roller / 2+3 roller configurations)
- Lubrication and emulsion cooling / filtration system
- Automatic coiling stand with arc guiding pipe and pre-deformation protection
- Intelligent PLC + HMI electrical control system with recipe management
Purpose: One continuous, highly automated process from molten metal to finished high-conductivity rod coils, maximizing yield, minimizing intermediate handling and ensuring consistent quality.
Primary Applications
- Production of EC-grade aluminum rod for electrical conductors, building wire and power cables
- Aluminum alloy rod for overhead transmission and distribution lines (AAC, AAAC, ACSR, ACAR)
- High-tensile conductive rods for power cables and specialized industrial applications
- Aluminum alloy rod for automotive wiring and other industrial uses
- High-quality feedstock for subsequent wire drawing, stranding and conductor manufacturing
The RLB CCR line is particularly well-suited for producers supplying the rapidly expanding Saudi and GCC power grid infrastructure under Vision 2030.
Quality Assurance, Standards Compliance & Operational Reliability
Every production line undergoes full-load factory testing before shipment. Finished rods consistently meet or exceed the requirements of ASTM B233 for drawing stock, relevant IEC standards and customer-specific conductivity/tensile specifications. Online process control, precise temperature management and effective degassing/filtration ensure low hydrogen content, minimal oxide inclusions and excellent surface quality suitable for high-speed drawing.
Installation, Training & After-Sales Support in Saudi Arabia & GCC
We provide complete turnkey services: detailed layout engineering, installation supervision, commissioning, operator training (Arabic and English), process optimization and long-term technical support. 24/7 remote diagnostics combined with local spare-parts stock in the Eastern Province ensure minimal downtime. Performance-based maintenance contracts are available for long-term partnership.
Why Partner with Us for Your Aluminum Alloy Rod CCR Line?
- Reliable Quality: Full-load tested equipment delivering consistent rod density, conductivity and mechanical properties that meet ASTM/IEC requirements.
- Customized Technical Solutions: Tailored to your exact alloy portfolio, capacity targets, factory layout and local energy infrastructure in Saudi Arabia and the GCC.
- Long-term Cooperation: From project design and installation through operator training, spare parts and performance-based maintenance contracts.
- Technology-Driven Performance: Focus on measurable improvements in output, energy efficiency, scrap reduction and product quality.
- Vision 2030 Alignment: Supporting the development of local high-quality overhead conductor manufacturing capacity.
Ready to upgrade your aluminum rod production with a proven, high-efficiency Continuous Casting and Rolling Line?
Inquiry Now — Contact our technical team today. Within 48 hours you will receive a detailed configuration proposal, capacity and ROI calculation, preliminary layout drawings and relevant reference information from similar GCC projects.
Aluminum Alloy Rod Continuous Casting and Rolling Line
High-efficiency Aluminum Alloy Rod Continuous Casting and Rolling Line producing premium 9.5 mm, 12.5 mm and 15 mm rods in EC1350, 3#, 5# (5005/5154), 6# (6101/6201) and 8# (8176/8030) alloys. 4.5–7.5 t/h output with H-type crystallization wheel and flexible 2/3/2+3 roller configurations.
Product SKU:
CCR-AL-4.5T / CCR-AL-7.5T
Product Brand:
RLB Machinery
Product Currency:
USD
Product Price:
Contact for Quote
Product In-Stock:
InStock
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