TL;DR
A sticker breakout signal means the solidifying shell has attached to the mold copper. Reduce casting speed immediately when the sticker detection system activates. Never override this signal.
What you might see
- mold thermocouple temperature spike in a narrow pattern
- caster speed drop commanded by the sticker detection system
- friction force increase on the mold oscillation sensor
- abnormal copper mold surface condition at the meniscus
Likely causes
Shell sticking to the mold copper from insufficient mold powder lubrication
Mold powder melting rate too low for the casting speed, leaving bare meniscus zone
Mold taper incorrect for the steel grade causing excessive shell compression
Meniscus turbulence from high casting speed causing shell thinning
Required tools
- Access to caster DCS for thermocouple trend display
- Mold copper surface inspection tools
- Mold powder consumption log
Safety first
- Molten steel breakout from the strand guide is a life-safety emergency. Evacuate the area below the strand guide if a breakout is in progress.
- Extreme thermal radiation and molten steel splash hazard at the mold area. Aluminized PPE is mandatory.
- Never approach the strand guide with bare skin or non-heat-resistant clothing.
Procedure
- 1
Reduce casting speed immediately when the sticker detection system signals a thermocouple temperature pattern consistent with a sticker.
Warning: Never override a sticker detection alarm. Continuing at full speed after a sticker signal will result in a breakout. Molten steel breakout from the strand guide is a life-safety emergency. - 2
Allow the stuck strand to heal by running at the reduced speed for the specified recovery period.[1]
- 3
Monitor the thermocouple pattern. If the temperature pattern normalizes, the sticker has healed and speed can be gradually increased.[1]
- 4
If the sticker does not heal, stop the caster and allow the strand to solidify before any further action.
- 5
After the event, inspect the mold copper for scoring or sticking marks. A rough mold surface accelerates sticker events.
- 6
Review the mold powder consumption rate for that grade. Low consumption means inadequate lubrication.
Sources
SMS Concast SMS Concast CONROLL Continuous Caster general technical documentation, SMS Concast
General continuous casting sticker breakout detection and recovery procedures (general)
More guides for SMS Concast SMS Concast CONROLL
How to diagnose secondary cooling spray faults on a SMS Concast CONROLL caster
A blocked or low-flow spray nozzle in secondary cooling causes a local hot zone in the strand that can lead to internal cracks. Verify flow in each cooling zone and replace blocked nozzles before the next cast.
How to detect strand guide roll bearing failure on a SMS Concast CONROLL caster
A seized strand guide roll marks the billet surface and concentrates strand guide load on adjacent rolls. Replace failed rolls during the next planned stop and verify all rolls rotate freely after installation.
Stop fixing the same fault twice.
Dovient turns guides like this into your team's shared playbook, with AI that catches recurring issues before they break the line.