Montanstahl Group Overview
One Group. Five companies.
Multiple manufacturing technologies.
Montanstahl Group manufactures custom solid and hollow profiles in carbon steel, stainless steel, duplex stainless steel, nickel alloys, titanium and selected specialty metals. Across manufacturing locations in Switzerland, Italy, Germany and the United States, the Group combines hot extrusion, laser welding, hot rolling, cold drawing and cold rolling to match the manufacturing process to the profile requirement.
The Group brings together Montanstahl AG, Siderval S.p.A., Montanstahl GmbH, Stainless Structurals America and Extralloys LLC, combining decades of specialist experience within an international manufacturing network. Building on Montanstahl’s origins as a Swiss family-owned company founded in 1983, each business contributes complementary technical knowledge and production capabilities. Together, they serve a wide range of industries, including architecture and construction, mechanical engineering, energy, transportation and aerospace.
Group Map
Montanstahl Group capability envelope at a glance
Indicative Group-wide envelope. Final feasibility depends on the complete cross-section, material grade, dimensional ratios, tolerances, bar length, quantity and application.
Detailed Group profile capability matrix
The capability matrix below is the primary technical reference for engineers and buyers evaluating Montanstahl Group manufacturing options.
| Manufacturing technology | Companies | MOQ / volume | Max envelope | Thickness (mm) | Weight | Tolerance | Max bar length |
|---|---|---|---|---|---|---|---|
| Hot extrusion |
| Prototype to series | Ø432 mm; ID 20–200 mm | From 3 mm | 1.5 – 744 kg/m | From ±0.5 | 27,432 mm |
| Laser welding |
| 1 bar prototype to 100+ ton | 2,000 × 1,000 mm | 2 – 80 mm | 0.5 – 200 kg/m | ±0.5 mm; ±0.3 mm possible | 18,000 mm |
| Hot rolling |
| (stainless / carbon) Advised: 5 t / 15 t Feasible: 3 t / 5 t | Ø90 mm | From 2.5 mm | 0.5–10 kg/m; 10–12 kg/m subject to feasibility | ±0.5 mm; ±0.1 mm possible | 9,000 mm |
| Cold drawing |
| Project specific | Ø200 mm | From 2 mm | 0.5 – 70 kg/m | ±0.1 mm; ±0.05 mm possible | 12,000 mm |
| Cold rolling |
| carbon 500 kg; stainless 100 kg | Ø50 mm | From 0.5 mm | 0.1 – 6 kg/m | ±0.05 mm; ±0.02 mm possible | 7,000 mm |
Capabilities by manufacturing technology
Hot extrusion
complex solid and seamless hollow profiles
Hot extrusion is the Group’s primary route for complex solid sections and seamless hollow special profiles.
• Siderval S.p.A. in Italy covers complex extruded profiles up to Ø255 mm hollow, with 20–160 mm internal diameter, 1.5–110 kg/m, 4 mm minimum profile thickness, and lengths up to 16,800 mm.
• Montanstahl GmbH in Germany covers profiles up to Ø255 mm, hollow internal diameters from 20–200 mm, 1.5–120 kg/m, 3.5 mm minimum profile thickness and lengths up to 16,800 mm.
• Extralloys in Mississippi provides the Group’s largest extrusion envelope: up to Ø17 in (432 mm), with 0.79–15.75 in (20-400 mm) internal diameter, up to 500 lb/ft (744.1 kg/m), 0.125 in (3 mm) minimum profile thickness and 90 ft (27,432 mm) max bar length.
Laser welding and laser fusion
large sharp-corner profiles
Laser welding is suited to large custom structural sections, architectural profiles and hollow or solid sections where sharp corners, dimensional flexibility and low tooling investment are important. Minimum order quantities start as little as 1 bar up to 100+ ton per batch.
• Montanstahl in Switzerland can produce laser-welded or laser-fused profiles up to approximately 2,000 × 1,000 mm, 0.5–200 kg/m and 2–80 mm thickness.
• Stainless Structurals in Texas provides U.S.-manufactured laser-fused structural and custom profiles up to approximately 36 in high × 28 in wide (914 – 711 mm), weighing 0.336 – 201.6 lb/ft (0.5 – 300 kg/m).
Hot rolling
recurring high-volume solid sections
Hot rolling is suited to the production of small and medium-sized solid special profiles in carbon, alloy and stainless steel. The Group’s wire-rod-based rolling mills offer lower tooling costs and smaller production lots than conventional billet-based mills. Profiles are progressively formed at approximately 1,100°C and can also serve as pre-shapes for subsequent cold drawing. Montanstahl covers profiles fitting within a 90 mm circumscribed circle, weighing 0.5–10 kg/m, with a minimum material thickness of 2.5 mm and general dimensional tolerances of ±0.5 mm. Sections can be supplied in bars up to 9,000 mm or recoiled. Minimum production quantities start at 3,000 kg for stainless steel and 5,000 kg for carbon steel; recommended quantities for more competitive pricing are 5,000 kg and 15,000 kg respectively.
Cold drawing
tight tolerances on medium and larger solid profiles
Cold drawing is suited to medium and larger solid profiles requiring tight dimensional tolerances and a high-quality surface finish. Wire or pre-rolled sections are pulled through precision dies to achieve the required cross-section. Montanstahl specializes in stainless steel and supplies both custom profiles and standard sections, including flats, half rounds and key steel. Production capabilities cover profiles fitting within a 200 mm circumscribed circle, weighing 0.5–70 kg/m, with a minimum material thickness of 2 mm and general dimensional tolerances of ±0.1 mm. Bars can be supplied in lengths up to 12,000 mm. Production can start from just a few bars when no hot-rolled pre-shape is required; otherwise, minimum quantities follow those of the hot rolling process.
Cold rolling
small precision and exellent surface finish
Cold rolling is suited to small solid precision profiles requiring excellent surface quality, tight tolerances and small production lots. Round wire rod is progressively shaped through a continuous rolling process at ambient temperature. Cold working combined with selective annealing allows combinations of hardness, tensile strength, yield strength and ductility to be tailored to the application. Montanstahl covers profiles fitting within a 50 mm circumscribed circle, weighing 0.1–6 kg/m, with a minimum material thickness of 0.5 mm and general dimensional tolerances of ±0.05 mm. The material range includes high-alloy steels, stainless steels, nickel-based alloys and titanium. Profiles can be supplied as bars up to 7,000 mm or in coils, with production quantities starting at 100 kg for stainless steel and 500 kg for carbon steel.
Materials available across the Montanstahl Group
Depending on process and manufacturing location, the Group can manufacture special profiles in:
- Carbon and structural steels
- Fine-grained and high-alloy steels
- Austenitic and ferritic stainless steels
- Duplex stainless steels
- Nickel-based alloys
- Titanium
- Selected specialty metals including zirconium and niobium
What information should you send for a feasibility check?
To identify the right manufacturing technology and Group company, provide:
- 2D profile drawing and/or 3D CAD model
- Material grade and applicable standard
- Solid or hollow requirement, including internal diameter where relevant
- Dimensional tolerances and critical dimensions
- Surface finish requirements
- Required bar length
- Quantity per order and expected annual volume
- Mechanical properties, heat treatment or testing requirements
- Final application and industry
- Delivery location / target market
Which Montanstahl Group company should receive my inquiry?
You do not need to determine the final producing company yourself. Send the drawing, grade, tolerances, length and quantity. The Group can evaluate the requirement against the capability envelope and route the project to the most suitable manufacturing location.
Have a special profile to manufacture?
Send us your profile drawing, material grade, required tolerances, bar length and expected quantities. We will identify the most suitable manufacturing technology and Montanstahl Group production location.