A preventive maintenance schedule for steel, foundry, forging and metal plants is the plan of checks, services and inspections that keeps the plant’s equipment running between breakdowns. Furnaces, cranes, rolling mills, hydraulics and cooling water, all working in heat and load. Cranes and lifting equipment also carry statutory examination dates.
Below are the equipment types we list for this industry, each with its own preventive maintenance schedule and checklist, and the common utilities every plant has. The tasks and intervals follow common industry practice; the maker’s manual and site safety procedures come first.
Equipment in a steel, foundry, forging and metal plants preventive maintenance schedule
Furnaces, foundry & surface treatment
Cranes, lifting & material handling
Conveying, bulk handling & dust control
Machine tools, metalworking & assembly
Mining, cement, metals & minerals
Water & effluent treatment
Oil, gas, power plant & environment
Boilers, steam & thermal systems
Instruments, automation & laboratory
Valves, piping & hydraulics
Pumps
Fire protection & safety
Heat exchangers, vessels & storage
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Shell-and-tube heat exchanger preventive maintenance schedule | 5 | 35 h |
| Plate heat exchanger preventive maintenance schedule | 5 | 35 h |
| Air-cooled heat exchanger preventive maintenance schedule | 6 | 53 h |
| Cryogenic tank and vaporiser preventive maintenance schedule | 6 | 59 h |
Compressors & compressed air
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Centrifugal compressor preventive maintenance schedule | 7 | 130 h |
| Compressed air dryer (desiccant) preventive maintenance schedule | 6 | 38 h |
| Nitrogen generator preventive maintenance schedule | 6 | 38 h |
Electrical distribution & power quality
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Flooded lead-acid preventive maintenance schedule | 6 | 49 h |
| Outdoor switchyard: breakers preventive maintenance schedule | 6 | 54 h |
| Protection relays, metering preventive maintenance schedule | 5 | 22 h |
Power generation & backup
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Gas engine generator set preventive maintenance schedule | 6 | 157 h |
| Gas turbine / turbo generator preventive maintenance schedule | 7 | 230 h |
| Large generator preventive maintenance schedule | 6 | 122 h |
Fans, blowers, vacuum & ventilation
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Roots blower preventive maintenance schedule | 6 | 51 h |
| Local exhaust ventilation preventive maintenance schedule | 6 | 61 h |
Process & chemical equipment
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Filter press / filtration unit preventive maintenance schedule | 6 | 100 h |
| Ball mill / hammer mill / pulveriser preventive maintenance schedule | 6 | 107 h |
HVAC & refrigeration
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Humidification plant, air washer preventive maintenance schedule | 6 | 102 h |
| Vapour absorption chiller preventive maintenance schedule | 7 | 145 h |
Motors, drives & power transmission
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| High-tension motor preventive maintenance schedule | 7 | 80 h |
Packaging, filling & inspection
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Shrink wrap tunnel, stretch wrapper preventive maintenance schedule | 7 | 135 h |
Other equipment
| Equipment | Tasks | Hours per year, one unit |
|---|---|---|
| Machine guarding, interlocks preventive maintenance schedule | 5 | 18 h |
Common plant equipment in steel, foundry, forging and metal plants
Pumps, compressors, motors, boilers, chillers, air handling units, transformers, generators and conveyors appear in almost every industry. Their schedules:
- Centrifugal pump preventive maintenance schedule
- Air compressor preventive maintenance schedule
- Electric motor preventive maintenance schedule
- Boiler preventive maintenance schedule
- Chiller preventive maintenance schedule
- Cooling tower preventive maintenance schedule
- Air handling unit preventive maintenance schedule
- Power / distribution transformer preventive maintenance schedule
- Diesel generator set preventive maintenance schedule
- Belt conveyor preventive maintenance schedule
- Overhead crane preventive maintenance schedule
- Fire pump set preventive maintenance schedule
The full list is on the page of equipment preventive maintenance schedules.
How big is the preventive maintenance schedule for steel, foundry, forging and metal plants?
For one unit of each of the 112 industry-specific equipment types in our library, the schedule has 700 recurring tasks and about 10,094 hours of work a year. Adding one unit of each of the 62 common equipment types makes it 1067 tasks and about 12,862 hours. A real plant has several units of most of them, which is why the monthly workload needs balancing.
Build your steel, foundry, forging and metal plants preventive maintenance schedule
Pick your equipment in the free generator and download a 12-month schedule as an Excel file, with tasks, intervals and monthly workload hours. For the method, read the guide to the preventive maintenance schedule, and the preventive maintenance checklist.
To run it in software, see maintenance software for steel and metals, or the preventive maintenance software module.
Build my steel, foundry, forging and metal plants preventive maintenance schedule (free Excel)
Frequently asked questions
What should a preventive maintenance schedule for steel, foundry, forging and metal plants include?
The equipment that decides output and safety, the tasks and intervals for each, the time each task takes and who does it, and a record of completion. For this industry the biggest groups of equipment are furnaces, foundry & surface treatment, cranes, lifting & material handling, conveying, bulk handling & dust control, machine tools, metalworking & assembly. Add the statutory examinations that apply to your plant.
How many types of equipment does the steel, foundry, forging and metal plants schedule cover?
Our library lists 112 industry-specific equipment types for steel, foundry, forging and metal plants and 62 common plant equipment types, each with its own tasks, intervals and times.
Is there a free preventive maintenance schedule generator for steel, foundry, forging and metal plants?
Yes. The free preventive maintenance schedule generator opens with this industry selected, lets you choose your equipment and quantities, and gives a 12-month schedule as an Excel file.