Shipbuilding is a sector where steel must obey both strength and precision – simultaneously.

Rolling ultra-thick, high-strength plates with absolute accuracy is a critical step that ultimately defines structural integrity downstream. GEMAK Group of Companies strengthens this capability with a fully customized FACCIN 3-Roll Variable Axis plate rolling solution.

Engineered specifically for marine applications and designed to handle extreme thicknesses with tight tolerances, this solution ensures seamless integration with welding and assembly processes – further consolidating GEMAK’s position in the maritime industry.

Index of contents

Priorities and Solution: Turning Requirements into Capability

Gemak’s needs were clear:

  • Expanding capacity for rolling heavy plates used in large offshore and marine structures
  • Achieving superior pre-bending quality to minimize welding corrections and rework
  • Ensuring process stability and productivity across complex, one-off and small-batch shipyard projects

In short, this was not about adding capacity. It was about raising the bar.

Meeting these requirements meant going beyond a standard machine. Gemak was looking for a plate rolling solution capable of combining maximum power, flexibility, and precision – without compromise.

Following an extensive technical evaluation, the choice fell on the FACCIN Heavy Duty Variable Axis (HAV) plate rolling machine, installed at its Altınova Shipyard in Turkey. Gemak’s engineering-driven approach perfectly aligned with FACCIN’s philosophy – this shared mindset was the foundation of the partnership.
Engineered for extreme plate thicknesses and the most demanding forming applications, the HAV model delivers the level of performance required for advanced shipbuilding and offshore fabrication.

Key characteristics of the solution, specifically designed for shipbuilding, include:

  • Variable axis geometry with independent movement of the rolls, enabling excellent pre-bending performance even on very thick plates
  • Exceptional rigidity and rolling force, ensuring high accuracy in roundness tolerance across the full plate length
  • Advanced control systems allowing precise and repeatable forming, fully aligned with shipyard production workflows
  • Excellent performance in cone rolling, even under extreme operating conditions
  • State-of-the-art energy-efficient hydraulic system with load-sensing control, allowing maintenance operations to be carried out without stopping the system, ensuring continuous rolling over two or three shifts.

The machine configuration was fully customized to Gemak’s production requirements, ensuring seamless integration into the existing fabrication process.

Results and Benefits: Turning Capability into Competitive Edge

The investment in FACCIN HAV technology has already begun to deliver tangible, measurable advantages:

  • Increased forming capacity for thick and high-strength plates
  • Enhanced pre-bending quality, reducing welding stress and rework
  • Improved production efficiency, supporting demanding delivery schedules
  • Strengthened competitiveness in shipbuilding and offshore fabrication markets

The installation of the FACCIN Heavy Duty Variable Axis (HAV) plate rolling machine at Gemak’s Altınova Shipyard clearly illustrates how advanced bending technology can not only support—but anticipate—the evolving needs of modern shipbuilding and offshore construction.

By upgrading its plate rolling capabilities, Gemak further consolidates its position as a modern, forward-looking shipyard—fully equipped to execute complex heavy fabrication projects in line with the most demanding international standards.

 

In a sector where precision is non-negotiable and scale leaves no margin for error, this investment marks more than a technological upgrade—it defines a new benchmark for performance, reliability, and shipbuilding excellence.

Thanks to

Gemak Group of Companies

The Gemak Group of Companies is a leading player in shipbuilding, ship repair and conversion, offshore projects and heavy steel fabrication, serving global customers through its modern production facilities in Turkey.

With decades of expertise and a strong track record in delivering complex marine and industrial projects Gemak plays a strategic role in manufacturing large-scale steel structures, including hull sections, offshore structures and industrial structures.