Tata Steel has awarded a major contract to Welsh engineering specialists, Systems Group, for the first phase of the refurbishment of its two continuous casters in Port Talbot, South Wales.
Systems Group, based in Maesteg, will carry out critical structural work and pipework replacement on Port Talbot’s two continuous casters – an essential part of the steelmaking process, turning liquid steel from the Electric Arc Furnace into solid steel slabs.
The scheme is a key part of Tata Steel UK’s £1.25 billion transition to greener steelmaking.
The life-extension of the continuous casters will support the journey to sustainable low CO₂ steelmaking as the business prepares for the commissioning of a new state-of-the-art electric arc furnace (EAF) by the end of 2027. Once operational, the EAF is expected to reduce Port Talbot’s carbon emissions by approximately 90%, equivalent to 5 million tonnes of CO₂ per year.
Ian Ellis, Engineering Project Manager at Tata Steel and lead on the caster life-extension, said:
“This is a hugely important project for Port Talbot and for Tata Steel’s future in the UK. The casters are where liquid steel – produced at more than 1,600 degrees Celsius – is solidified into slabs, ready for further processing.
“This work will ensure our existing casters are in the very best condition to handle steel from our new electric arc furnace in the volumes and qualities demanded by our customers.
Importantly, we can retain refurbish and replace these critical facilities rather than having to build from new, saving considerable cost and time.
“We’re delighted to be working with Systems Group – a trusted local partner – on this first phase of work.”
Ryan O’Neill, Managing Director at Systems Group, said:
"We are delighted to have been awarded this important contract by Tata Steel. As a local company, we are proud to play a role in helping secure the future of steelmaking in South Wales.
This project not only supports the region’s economy but also helps deliver cutting-edge, low-carbon steel production.”
The caster project will include replacement of over 1.5 miles of key pipework and two giant water tanks. In future phases there will be further replacements of equipment, structures and pipework as well as the installation of advanced technologies such as variable-speed-drives and next-generation process control systems.
Following the appointment of Systems Group, Tata Steel expects to award further contracts in the coming months for additional electrical mechanical and process control system upgrades.
About Tata Steel UK
- The Tata Steel Group has been named one of the most ethical companies in the world, and is among the top producing global steel companies with an annual crude steel capacity of 34 million tonnes.
Tata Steel in the UK has the ambition to produce net-zero steel by 2045 at the latest, and to have reduced 30% of its CO2 emissions by 2030. - In October 2024, Tata Steel ceased ironmaking at its Port Talbot site and temporarily paused steelmaking pending the construction of a 3.2Mtpa Electric Arc Furnace, due to be commissioned late in 2027 / early 2028. For that period, the business will import slab and hot rolled coil to support manufacturing and distribution operations at sites across Wales, England and Northern Ireland as well as Norway, Sweden, France, Germany and UAE. It also benefits from a network of sales offices around the world.
- Throughout 2024 Tata Steel UK has been undergoing a restructuring that will reduce the size of its workforce to around 5000 direct employees, supplying high-quality steel products to demanding markets, including construction and infrastructure, automotive, packaging and engineering.
- Tata Steel Group is one of the world's most geographically-diversified steel producers, with operations and a commercial presence across the world.
- The group recorded a consolidated turnover of around US$26 billion in the financial year ending March 31, 2025.
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