EN 1.0038 Structural, Base Steel Flange

1,We Manufacturing processes are primarily classified into four types: 1:Forging, 2:Casting, 3:Cutting, 4:Rolling. 2,We can manufacture in accordance with these standards. Standards: GB Series (Chinese Standards), JB Series (Machinery Standards), HG Series (Chemical Industry Standards), ASME B16.5 (American Standards), BS4504 (British Standards), DIN (German Standards), and JIS (Japanese Standards). Internationally, there are two primary systems of pipe flange standards: the European system, represented by the German DIN standards (including those of the former Soviet Union), and the American system, represented by the US ANSI pipe flange standards. Other common standards include: the Chinese Ministry of Machinery Industry standards (JB series), the Ministry of Chemical Industry standards (HG series), the Chinese National Standard *GB/T 9112–9124-2010 Steel Pipe Flanges*, as well as US standards (ASME B16.5), British standards (BS4504), German standards (DIN), Japanese standards (JIS), and marine standards (CBM), among others. The nominal pressure ratings for the PN series are designated by "PN" and comprise the following nine levels: PN2.5, PN6, PN10, PN16, PN25, PN40, PN63, PN100, and PN160. The nominal pressure ratings for the Class series are designated by "Class" and comprise the following six levels: Class150, Class300, Class600, Class900, Class1500, and Class2500. Flange Classification 1. **According to Chemical Industry Standards:** Flanges are classified as follows: Plate Flat Welding Flange (PL), Necked Flat Welding Flange (SO), Necked Butt Welding Flange (WN), Integral Flange (IF), Socket Welding Flange (SW), Threaded Flange (Th), Butt Welding Ring Loose Flange (PJ/SE), Blind Flange (BL), Flat Welding Ring Loose Flange (PJ/PJ), and Lined Blind Flange (BL(s)). 2. **According to Petrochemical (SH) Industry Standards:** Flanges are classified as follows: Threaded Flange (PL), Butt Welding Flange (WN), Flat Welding Flange (SO), Socket Welding Flange (SW), Loose Flange (LJ), and Blind Flange (no specific designation). 3. **According to Machinery (JB) Industry Standards:** Flanges are classified as follows: Integral Flange, Butt Welding Flange, Plate Flat Welding Flange, Butt Welding Ring Plate Loose Flange, Flat Welding Ring Plate Loose Flange, Lap Joint Ring Plate Loose Flange, and Blind Flange. 4. **According to Connection Method/Type:** Flanges are classified as follows: Plate Flat Welding Flange, Necked Flat Welding Flange, Necked Butt Welding Flange, Socket Welding Flange, Threaded Flange, Blind Flange, Necked Butt Welding Ring Loose Flange, Flat Welding Ring Loose Flange, Ring-Type Joint (RTJ) Flange and Blind Flange, Large-Diameter Plate Flange, Large-Diameter High-Neck Flange, Figure-8 Blind Plate, Butt Welding Ring Loose Flange, etc. 5. **According to the Component Being Connected:** Flanges can be classified into Vessel Flanges and Pipe Flanges. 6. **According to Structural Type:** Flanges include Integral Flanges, Threaded Flanges, Flat Welding Flanges, Butt Welding Flanges, Lap Joint (Loose/Swivel) Flanges, and Blind Flanges. A flange—also referred to as a flange plate or rim—is a component used to connect shafts to one another, or, more commonly, to join the ends of pipes. Flanges are also utilized at the inlet and outlet ports of equipment to facilitate connections between two devices—for instance, the flange on a speed reducer. A "flange connection" or "flanged joint" refers to a detachable joint assembly comprising three interconnected elements—a flange, a gasket, and bolts—that together form a sealed structural unit. In the context of piping systems, a "pipe flange" specifically denotes a flange used for plumbing within the installation; when applied to equipment, it refers to the inlet or outlet flange of that specific device. Flanges feature a series of holes through which bolts are inserted to securely fasten the two flanges together, while a gasket placed between the flanges ensures a leak-proof seal. Flanges are broadly categorized into three types: threaded (screw-in) flanges, welded flanges, and clamp-type flanges. Flanges are invariably used in pairs; threaded flanges are suitable for low-pressure piping applications, whereas welded flanges are required for systems operating at pressures exceeding 4 kilograms per square centimeter. A sealing gasket is inserted between the two flange plates, which are then firmly secured using bolts. The thickness of a flange—as well as the specifications of the bolts used to fasten it—vary depending on the specific pressure rating required for the application. When connecting equipment such as water pumps or valves to piping systems, the corresponding connection points on these devices are often manufactured in the shape of a matching flange; this method of attachment is also referred to as a "flange connection." Generally, any connecting component that utilizes bolts to join and seal the perimeters of two flat surfaces—such as the joints in ventilation ducts—is termed a "flange"; such components may collectively be classified as "flange-type parts." However, since such a connection often constitutes merely a *portion* of a larger device—for instance, the interface between a flange and a water pump—it would be inappropriate to classify the entire water pump itself as a "flange-type part." Conversely, smaller components—such as valves—that feature such flanged interfaces may indeed be appropriately categorized as "flange-type parts." -:- For detailed product information, please contact sales. -: EN 1.0038 Structural, Hot Rolled, Base Steel Flange, t > 60 mm Product Information -:- For detailed product information, please contact sales. -: EN 1.0038 Structural, Hot Rolled, Base Steel Flange, t > 60 mm Synonyms -:- For detailed product information, please contact sales. -:

EN 1.0038 Structural, Hot Rolled, Base Steel, t > 60 mm Product Information -:- For detailed product information, please contact sales. -: # **Technical Datasheet: EN 1.0038 (S235J0) Structural Steel** **Condition: Hot Rolled, Base Material | Nominal Thickness: t > 60 mm** ## **1. PRODUCT OVERVIEW** **EN 1.0038 (S235J0)** in thicknesses **exceeding 60 mm** represents a **heavy-section, toughness-guaranteed structural steel** specifically engineered for demanding applications where **thick-plate fabrication** meets **moderate low-temperature service requirements**. This grade combines the fundamental strength characteristics of S235 steel with **mandatory impact toughness certification at 0°C**, making it suitable for critical structural components in heavy construction, industrial, and infrastructure projects where section thickness, weld integrity, and resistance to brittle fracture are paramount concerns. Supplied as heavy plate, block, or massive sections in the **normalized (N) or thermomechanically rolled (TM)** condition, this material undergoes specialized processing to ensure through-thickness property uniformity. The "J0" designation (0°C impact testing) provides assurance against brittle fracture in service temperatures down to approximately -10°C, a critical consideration for thick sections where triaxial stress states increase fracture risk. **Key Characteristics (t > 60 mm):** - **Through-Thickness Property Control:** Specialized processing minimizes centerline segregation and property degradation - **Certified Low-Temperature Toughness:** Guaranteed minimum 27J impact energy at 0°C, even in thick sections - **Enhanced Weldability Considerations:** Modified procedures required for thick-section welding - **Heavy Fabrication Suitability:** Designed for machining, cutting, and welding of massive components - **Structural Reliability:** Provides verified performance for safety-critical applications in moderate climates --- ## **2. CHEMICAL COMPOSITION (t > 60 mm)** **Compliance:** EN 10025-2:2019 - For product thickness > 60 mm up to 100 mm. *Note: Stricter controls apply compared to thinner sections.* | Element | Maximum (%) | Typical Range (%) | Metallurgical Significance for Thick Sections | |---------|------------|------------------|----------------------------------------------| | **Carbon (C)** | **0.17** | 0.10-0.15 | Deliberately controlled at lower range to maintain weldability and toughness | | **Manganese (Mn)** | **1.40** | 1.20-1.35 | Critical for through-thickness hardenability control; Mn:C ratio optimized | | **Phosphorus (P)** | **0.030** | ≤0.018 | Tighter control than thinner sections to prevent segregation-induced embrittlement | | **Sulfur (S)** | **0.030** | ≤0.012 | Strictly limited to minimize centerline segregation and improve Z-direction properties | | **Silicon (Si)** | **0.50** | 0.25-0.40 | Deoxidizer; slightly reduced maximum to improve toughness | | **Nitrogen (N)** | **0.012** | ≤0.008 | Tightly controlled to prevent aging effects in slow-cooled sections | | **Aluminum, total (Alt)** | — | **0.025-0.060** | Enhanced minimum for improved grain refinement through thickness | | **Microalloying Elements** | As agreed | Nb: 0.005-0.020
V: 0.005-0.010 | Optional for grain refinement in TMCP condition | | **Iron (Fe)** | Balance | Balance | Base metal | **Special Chemical Considerations for t > 60 mm:** - **Centerline Segregation Control:** Reduced maximum S and P to minimize segregation bands - **Carbon Equivalent (CEV):** 0.30-0.35% (lower than nominal for improved weldability) - **Cracking Parameter (Pcm):** 0.17-0.20% (optimized for thick-section welding) - **Deoxidation Practice:** Fully aluminum-killed with possible calcium treatment for sulfide shape control - **Optional Clean Steel Processes:** ESR (Electroslag Remelting) or VAR available for ultra-critical applications --- ## **3. PHYSICAL & MECHANICAL PROPERTIES** ### **A. Physical Properties (Typical, t > 60 mm):** - **Density:** 7.85 g/cm³ - **Modulus of Elasticity:** 210 GPa (may show slight anisotropy in thick plates) - **Shear Modulus:** 81 GPa - **Poisson's Ratio:** 0.30 - **Coefficient of Thermal Expansion:** 11.8 × 10⁻⁶/K (20-100°C) - **Thermal Conductivity:** 48 W/(m·K) at 20°C (lower than thin sections due to microstructure) - **Specific Heat Capacity:** 460 J/(kg·K) - **Electrical Resistivity:** 0.16 μΩ·m - **Acoustic Velocity:** 5900 m/s (longitudinal), 3250 m/s (shear) ### **B. Mandatory Mechanical Properties (EN 10025-2):** *For nominal thickness 60 mm < t ≤ 100 mm* | Property | Symbol | Minimum Value | Test Standard | Testing Location | |----------|--------|---------------|---------------|------------------| | **Yield Strength** | ReH | **215 MPa** | EN ISO 6892-1 | 1/4 thickness position | | **Tensile Strength** | Rm | **360-510 MPa** | EN ISO 6892-1 | 1/4 thickness position | | **Minimum Elongation** | A₅ | **22%** | EN ISO 6892-1 | 1/4 thickness position | | **Impact Energy (0°C)** | KV | **27 J** | EN ISO 148-1 | Surface and 1/4 thickness | ### **C. Through-Thickness Property Gradient (Typical):** | Property | Surface | 1/4 Thickness | Centerline | Notes | |----------|---------|---------------|------------|-------| | **Yield Strength** | 240-280 MPa | 220-260 MPa | 210-250 MPa | 5-10% reduction center vs surface | | **Tensile Strength** | 400-450 MPa | 380-430 MPa | 370-420 MPa | Consistent strength profile | | **Elongation** | 25-30% | 22-27% | 20-25% | Ductility reduction at centerline | | **Impact Energy (0°C)** | 50-80 J | 40-60 J | 30-50 J | Toughness gradient expected | | **Hardness (HB)** | 120-135 | 115-130 | 110-125 | Minimal hardness variation | ### **D. Special Properties for Thick Sections:** - **Z-Direction Properties:** Through-thickness reduction in area typically 15-25% - **Fracture Toughness:** K₁c values approximately 100-150 MPa√m at 0°C - **Fatigue Strength:** 140-160 MPa at 2×10⁶ cycles (as-rolled surface) - **Creep Resistance:** Not suitable for sustained temperatures >350°C --- ## **4. PROCESSING & FABRICATION (t > 60 mm)** ### **A. Cutting & Machining:** - **Thermal Cutting:** Oxy-fuel with 100-150°C preheat; plasma or laser for precision - **Mechanical Cutting:** Band saws with appropriate blade pitch and feed rates - **Machining Parameters:** - Turning: 80-120 m/min, feed 0.2-0.4 mm/rev - Milling: 60-100 m/min, feed 0.1-0.3 mm/tooth - Drilling: 20-40 m/min, peck drilling essential - **Edge Preparation:** Machining or grinding required for highly stressed edges ### **B. Welding Procedures (Critical for t > 60 mm):** **Mandatory Requirements:** - **Preheating:** 100-150°C minimum, based on CEV and thickness - **Interpass Temperature:** 150-250°C maximum - **Post-Weld Heat Treatment:** Often required for thickness >75 mm or highly restrained joints - **Heat Input Control:** 1.5-3.5 kJ/mm depending on joint design **Recommended Welding Consumables:** | Process | Electrode/Wire | Preheat Temp | PWHT Requirement | |---------|---------------|--------------|------------------| | **SMAW** | E 38 0 R C 12 (E7018) | 125°C min | For t > 75 mm | | **SAW** | S 38 2 + basic flux | 150°C min | Always recommended | | **FCAW** | T 38 2 P C 1 H5 | 125°C min | For highly restrained joints | | **Electroslag** | Special consumables | Not required | Always requires normalizing | **Weld Procedure Qualification:** Essential for thickness >60 mm; must include: - Through-thickness tensile tests - Charpy testing at multiple locations - Macroscopic examination for fusion and HAZ characteristics ### **C. Heat Treatment Considerations:** - **Normalizing:** Standard delivery condition; 890-920°C, air cool - **Stress Relieving:** 580-620°C, 2 hours per 25 mm thickness minimum - **Post-Weld Normalizing:** May be required for electroslag or high-heat input welds --- ## **5. TYPICAL APPLICATIONS** ### **A. Heavy Civil Engineering:** - **Bridge Components:** Main girders for medium-span bridges, pier caps, bearing blocks - **Dam Structures:** Gate components, trash rack supports, structural reinforcement - **Lock & Canal Systems:** Massive gate leaves, operating machinery supports - **Tunnel Linings:** Reinforcement ribs, segment connection plates ### **B. Power Generation:** - **Hydroelectric Plants:** Turbine casing supports, generator pedestals, penstock supports - **Thermal Plants:** Boiler supports, ductwork structural elements, stack foundations - **Nuclear Facilities:** Secondary containment structures, equipment supports (non-nuclear) - **Wind Energy:** Tower base sections, transition pieces, foundation components ### **C. Heavy Industrial:** - **Press Frames:** Massive forging press components, hydraulic press structures - **Mill Equipment:** Rolling mill housings, shears, heavy machinery bases - **Mining Equipment:** Shovel components, crusher frames, hoist supporting structures - **Shipbuilding:** Keel plates, bulkhead stiffeners, foundation seats for large vessels ### **D. Specialized Applications:** - **Offshore Structures:** Jacket nodes, pile sleeves, boat landings (moderate environments) - **Cryogenic Storage:** Secondary containment, support structures for LNG tanks - **Heavy Transportation:** Railway turntables, heavy lift device components - **Defense Applications:** Protective structure components, vehicle recovery equipment --- ## **6. INTERNATIONAL STANDARDS & EQUIVALENTS** ### **Primary Designations:** - **EN Standard:** EN 10025-2:2019 - **Material Number:** 1.0038 - **Steel Name:** S235J0 - **Product Form:** Heavy plate (EN 10029), forgings (EN 10222) ### **Global Equivalents for Heavy Sections:** | Country/Standard | Equivalent Grade | Thickness Range | Key Notes | |-----------------|------------------|-----------------|-----------| | **ISO** | ISO 630-2: E235B | Up to 100 mm | Similar properties with 0°C impact | | **USA (ASTM)** | ASTM A36 | Up to 200 mm | Higher carbon allowed; no mandatory impact | | **USA (ASTM)** | ASTM A573 Gr. 65 | 65-150 mm | Similar strength with improved toughness | | **Germany (DIN)** | DIN EN 10025-2: S235J0 | Up to 100 mm | Direct adoption | | **Japan (JIS)** | JIS G3106: SM400A | Up to 100 mm | Similar strength with 0°C impact | | **China (GB)** | GB/T 700: Q235C | Up to 100 mm | 235 MPa yield with 0°C impact | | **Korea (KS)** | KS D 3503: SS240 | Up to 100 mm | Similar grade with thickness limitations | ### **Thickness-Dependent Property Adjustments:** | Thickness Range | Yield Strength (min) | Impact Test Position | Special Requirements | |-----------------|----------------------|----------------------|----------------------| | **60 < t ≤ 80 mm** | 215 MPa | 1/4 thickness | Normalizing mandatory | | **80 < t ≤ 100 mm** | 215 MPa | 1/4 thickness | Ultrasonic testing recommended | | **t > 100 mm** | By agreement | Multiple locations | ESR/VAR steel may be specified | --- ## **7. QUALITY ASSURANCE & TESTING** ### **Mandatory Testing (t > 60 mm):** 1. **Tensile Tests:** Minimum two tests from 1/4 thickness position 2. **Impact Tests:** Three specimens from surface and 1/4 thickness at 0°C 3. **Macroexamination:** Etched cross-section for segregation assessment 4. **Ultrasonic Testing:** Per EN 10160 Class S2 or better (optional but recommended) ### **Additional Testing for Critical Applications:** - **Through-Thickness Tensile Tests:** For Z-direction loading applications - **Fracture Toughness Testing:** CTOD or K₁c values at service temperature - **Residual Stress Measurement:** For highly restrained components - **Chemical Analysis:** Multiple locations including centerline ### **Certification Requirements:** - **EN 10204 3.2 Certificate:** Independent inspection certificate - **Heat Treatment Records:** Complete normalizing cycle documentation - **NDT Reports:** Ultrasonic and possibly radiographic examination - **Traceability:** Unique identification of each heavy plate or forging --- ## **8. DESIGN & SPECIFICATION CONSIDERATIONS** ### **Design Advantages:** 1. **Verified Through-Thickness Properties:** Certified performance in massive sections 2. **Predictable Weld Behavior:** Well-established procedures for thick-section welding 3. **Economic Solution:** Cost-effective compared to alloy steels for many applications 4. **Proven Performance:** Extensive history in heavy construction applications ### **Critical Design Limitations:** 1. **Reduced Design Strength:** Lower yield strength than thinner sections (215 vs 235 MPa) 2. **Anisotropic Properties:** Directional differences in ductility and toughness 3. **Welding Challenges:** Complex procedures and potential for distortion 4. **Notch Sensitivity:** Increased in thick sections under triaxial stress states ### **Specification Best Practices:** ```plaintext EN 10025-2 S235J0+N Thickness: 80 mm Delivery Condition: Normalized (N) Supplementary Requirements: - Ultrasonic testing EN 10160 Class S2 - Through-thickness tensile testing - Charpy testing at 1/4 thickness and centerline - Heat treatment certificate with temperature chart ``` ### **Fabrication Sequence Recommendations:** 1. **Material Certification Review:** Verify all test reports before fabrication 2. **Welding Procedure Qualification:** Complete before production welding 3. **Preheat Verification:** Monitor continuously during welding 4. **NDT Planning:** Schedule UT/RT at appropriate stages 5. **Stress Relief Coordination:** Plan furnace availability for PWHT --- ## **9. TRANSPORTATION & HANDLING** ### **Special Handling Requirements:** - **Lifting:** Multiple lift points to prevent plate distortion - **Storage:** Horizontal on multiple supports to prevent sagging - **Temperature Control:** Protect from rapid temperature changes during transport - **Identification:** Permanent marking of heat numbers and test locations ### **Storage Conditions:** - **Maximum Stack Height:** Limited to prevent permanent deformation - **Support Spacing:** Based on plate thickness and stiffness calculations - **Environmental Protection:** Covered storage to prevent excessive rusting - **Access:** Maintain access for testing and inspection --- ## **10. TECHNICAL SUMMARY** **EN 1.0038 (S235J0)** in thicknesses **exceeding 60 mm** represents a **specialized structural steel solution** for applications where mass, weldability, and low-temperature toughness intersect. While maintaining the fundamental S235 strength classification, this heavy-section variant requires sophisticated processing controls and fabrication procedures to ensure reliable performance. **Key Application Decision Points:** - **Select this grade when:** Moderate low-temperature toughness is required in thick sections, welding procedures can be carefully controlled, and economic considerations favor carbon-manganese steels over alloy alternatives - **Consider alternatives when:** Higher strength-to-weight ratio is critical (consider S355), service temperatures regularly drop below -15°C (consider S355J2), or superior through-thickness properties are mandatory (consider improved Z-quality steels) **Industry Position:** S235J0 in heavy sections occupies a niche between general construction steels and specialized alloy steels. It represents approximately 15% of the heavy-plate market in Europe for applications requiring certified toughness without the cost premium of higher-strength or alloy grades. **Future Development Trends:** Increasing demand for thicker sections in renewable energy and infrastructure projects is driving development of improved processing techniques for this grade, including enhanced thermomechanical rolling and optimized microalloying to improve through-thickness properties while maintaining weldability. --- **Important Notice:** This technical information is based on standard specifications and typical industry practice. For specific projects, always: 1. Consult the latest edition of EN 10025-2 2. Review actual mill test certificates for the supplied material 3. Conduct project-specific welding procedure qualifications 4. Engage qualified welding and materials engineers for thick-section fabrication 5. Consider conducting additional testing based on specific application requirements Properties and requirements may vary between manufacturers and specific production heats. Always verify critical properties through independent testing for safety-critical applications. -:- For detailed product information, please contact sales. -: EN 1.0038 Structural, Hot Rolled, Base Steel, t > 60 mm Specification Dimensions Size： Diameter 20-1000 mm Length <5786 mm Size:We can customized as required Standard： Per your request or drawing We can customized as required Properties（Theoretical） Chemical Composition -:- For detailed product information, please contact sales. -: EN 1.0038 Structural, Hot Rolled, Base Steel, t > 60 mm Properties -:- For detailed product information, please contact sales. -:

Applications of EN 1.0038 Structural, Hot Rolled, Base Steel Flange, t > 60 mm -:- For detailed product information, please contact sales. -: Chemical Identifiers EN 1.0038 Structural, Hot Rolled, Base Steel Flange, t > 60 mm -:- For detailed product information, please contact sales. -:

Packing of EN 1.0038 Structural, Hot Rolled, Base Steel Flange, t > 60 mm -:- For detailed product information, please contact sales. -: Standard Packing: -:- For detailed product information, please contact sales. -: Typical bulk packaging includes palletized plastic 5 gallon/25 kg. pails, fiber and Steel Flange drums to 1 ton super sacks in full container (FCL) or truck load (T/L) quantities. Research and sample quantities and hygroscopic, oxidizing or other air sensitive materials may be packaged under argon or vacuum. Solutions are packaged in polypropylene, plastic or glass jars up to palletized 2257 gallon liquid totes Special package is available on request. E FORUs’ is carefully handled to minimize damage during storage and transportation and to preserve the quality of our products in their original condition