Mechanical Fabrications

> Mechanical Fabrications is a key BCI forte. > Not only do we work with very competitive fa b ri to rs, b u t B C I s n a tu ra la d va n ta g e i ca ’ n e n g i e e ri g , g l b a lco m p o n e n ts n n o p ro cu re m e n t, m a ch i i g , q u a l ty a n d p ro j ct n n i e m a n a g e m e n t co m e s fu l y to g e th e r. l

BCI Mechanical Fabrications

The Mechanical Process
Detailing BCI takes design from concept stage to 3D models to shop drawings Services include: 2 Dimensional Drawings Isometric Drawings 3D Rendering 3D Assembly Modeling

S tru ctu ra l Fa b ri ti n s ca o

The Mechanical Process
Material Purchasing
Fabricates Highly

from any commercially available metals.

experienced in specifying international material equivalents which allows the use of local resources thereby lowering costs. monitors quality and can provide certification on all materials

Rigorously

The Mechanical Process
Sawing, Plate Cutting, and Drilling

Automated sawing Anglemaster

Oxyacetylene cutting Plasma cutting Laser cutting Water cutting

Autmated drilling CNC milling CNC beam drill line Dimensional reports are kept for all cut pieces.

The Mechanical Process
Fitting and Welding BCI uses AWS certified welders on all projects and has its own Certified Weld Inspector (CWI) on staff to ensure that best welding practices and all customer specifications are met. All major types of arc welding, as well as most forms of precision welding are available. For beam work, automated submerged arc welding is used. Dimensional records of all fit up sections are kept.

The Mechanical Process
Weld Inspection
BCI

Production Manager Scott Powrie, with 10 years of experience in fit up, welding and welding management, certifies all critical welds. He is a Certified Weld Inspector (CWI) can also arrange 3rd party inspection using all methods of Destructive and Non Destructive Testing (NDT) anywhere across Asia, North America and Latin America.
Ultrasonic Testing Radiographic Testing Magnetic

BCI

Particle Inspection Dye-Penetrant Inspection

The Mechanical Process
Grinding, Shot blasting, Galvanizing, Painting
Careful, supervised grinding ASTM hot-dip galvanizing for both large and small pieces

Sand-blasting, Steel shot blasting, Portable blasting boths

All international paints available

The Mechanical Process
Packaging, Loading and Shipping
Replacement bolts are colored for easy identification Lashings checked before, during and after loading to ensure proper tightness

Never any steel on steel after coatings applied

Bar coding available for easy field identification

The Mechanical Process
As you can see, Mechanical fabrications are similar to structural fabrications, and follow the same essential process of manufacture. However, mechanical fabs are more complicated and usually require:

•More design and engineering work • -Additional non-fabricated components: -Heat-treating -Heavy-duty machining -More in depth Non Destructive Testing.
BCI Mechanical Fabrications

The Mechanical Process
Engineering and design team

BCI engineers in Pittsburgh work closely with clients to design new systems, or to re-engineer systems to fit new applications. BCI engineers work closely with vendors to identify local material equivalents that match ASTM material standards.

BCI drafters and detailers are based in Vietnam and China, and work daily with our US engineers.

BCI Mechanical Fabrications

The Mechanical Process
Non-fabricated components

These are usually castings, forgings, gears, pulleys bearings/bushings, and hydraulics.

BCI can source these items from all over the world; though mostly we manufacture in China and Korea. Stand-alone components are a major part of BCI’s business. Please see BCI Castings & Forgings.ppt for more info.
BCI Mechanical Fabrications

The Mechanical Process
Heat-treating: stress-relieving and hardening

For castings and forgings BCI can handle many types of heattreating. Most of our Mechanical Fabs require the following:
Stress

Relieving
Reduces

internal stresses in welds. Occurs after fit-up and welding but before machining.

Surface

Hardening

Increases

surface hardness of wear parts with application of heat by flame (flame hardening) or, by induction coils (induction hardening). Usually on isolated parts of fabs, e.g. rails, wear plates, wheels, rollers, etc.


BCI Mechanical Fabrications

The Mechanical Process
Heavy-duty machining

Mechanical fabs usually require significant machining, and these machines need to be very large as well as precise.
Portable CMM

5-axis CNC mills Examples include….

Large vertical lathes

BCI Mechanical Fabrications

BCI field staff keep close watch over machining, keeping dimensional records which are constantly available on BCI’s online project tracking site.

The Mechanical Process
Non-Destructive Testing

Mechanical fabs frequently require certified 3rd parties to perform testing on safety-critical sections. While BCI is equipped to perform most tests, professional 3rd party agencies provide an extra level of guarantee. BCI works with many in the region.

UT X-Ray Radiographic MPI Dye-Pen

In some cases, destructive testing is required on first article samples….
BCI Mechanical Fabrications

Contact BCI Engineering today

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