(724) 266-0400 | sales@bci-engineering.com

SOLUTIONS FOR RENEWABLE ENERGY

Contract Manufacturing & Custom Fabrication

BCI has unmatched experience in contract metal fabrication, manufacturing products from individual components to complete assemblies. We partner with OEM companies helping them optimize their cost of manufacturing using our engineering and manufacturing services. BCI offers contract manufacturing support services, including integrated metal fabrication and manufacturing services for steel support. We own and operate fabrication plants in Kuala Lumpur, Malaysia, and San Luis Potosi, Mexico. We have joint venture operations in Suzhou and Ningbo, China.

BCI Engineering is a global supplier to heavy industries for structural and mechanical fabrication, including but not limited to roll forming, stamping/forging, casting, shaft & axle fabrication, and precision machining.

Our access to steel inventory and ability to manufacture large fabricated parts, machined parts, and subassemblies, has allowed us to offer OEMs integrated metal fabrication and manufacturing services for steel, as well as partner with customers in the oil & gas, construction, heavy automotive, and the mining and bulk material handling industries. In addition to being a major manufacturer of Mining and Mineral Handling capital equipment, we are also a supplier of OEM wears and spares.

Our capabilities include:

  • Roll forming
  • Heavy fabrication
  • Stamping/forging
  • Machining
  • Machined parts
  • Shaft & Axel (related to machined part)
  • Casting
  • Forging
  • Assembly & light assembly

Our Vision & Values

It is BCI's mission to empower our Customers to grow and flourish beyond every expectation. We create value through ingenuity, effort, and integrity and do so in a way that makes our partners better people and leaves the world a better place.

Customer Commitment

We provide optimum value to our clients worldwide and ensure that they are always kept up to date when it comes to industry trends and helpful information.

HEAT TREATING CAPABILITIES

STEEL & STAINLESS STEEL CAPABILITIES

  • We use black and green sand molding; aluminum molding; die casting, lost-wax/lost-foam methodsSizes from 0.1 kg to 8000 kg (3.5 oz to 9 tons)
  • All ASTM grades and alloys available
  • For higher quantity orders, BCI can directly cast ASTM grades; for lower quantity orders, conversion to Chinese GB or Japanese JIS standards is often necessary.

HEAT TREATING CAPABILITIES

Normalizing

Reduces internal stresses and improves crystalline structure by application of heat, maintaining temperature for appropriate duration, then slow cooling.

Water and Oil Quenching

Rapid cooling from an elevated temperature to increase hardness and strength. Often followed by tempering to restore some ductility (toughness).

Tempering

Reduces hardness and increases toughness by application of heat, maintaining for an appropriate duration, then controlled cooling.

Surface Hardening

Increases surface hardness of wear parts by engineered application of heat by flame (flame hardening) or induction coil (induction hardening).

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.Heat-treating: stress-relieving and hardening.

For castings and forgings, BCI can handle many types of heat-treating.

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 the 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.

CASTINGS AND FORGINGS

Types of Castings

Gravity Castings

(Sand mold, permanent aluminum mold)The process by which molten metal is poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solid casting is then ejected or broken out to complete the process. Small to large size.

Die Castings

The process of forcing molten metal under high pressure into mold cavities (which are machined into dies). Small to medium in size; capable of high detail.

Investment Castings

(Lost Wax/Loss Foam)The process of forming wax (or foam) into a shape, covering the shape with sand and then pouring molten metal into the cavity displacing the wax. Allows for high detail and dimensional accuracy. Generally small and medium size.

Testing

Testing

We can provide material certification for all castings: Chemical analysis and Mechanical tests, including Tensile strength/elongation and Hardness testing

We also provide Non-Destructive Testing upon request:

Dye penetration • MPI • UT • X-ray

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 worldwide.

CASTINGS AND FORGINGS

Types of Forgings

Impression Die Forgings

Pounds or presses metal between two dies that contain a precut profile of the desired part. From 0.1 to 27,000 kgs (a few ounces to 60,000 lbs)

Seamless Rolled Ring Forgings

Typically performed by punching a hole in a thick, round piece of metal (creating a donut shape), and then rolling and squeezing. Up to 9 meters (30 ft) diameter

Tuning and Finished Machining

Can rough machine shafts up to 24 meters (80 ft)
Can finish machine up to 14 meters (45 ft)
Can rough machine donuts up to 9 meters (30 ft)
Can finish machine up to 3.7 meters (12 ft) in diameter

Open Die Forgings

Pounds between flat dies with no precut profiles in the dies. Movement of the workpiece is the key to this method. Shapes up to 91,000 kgs (200,000 lbs.) and 24 meters (80 feet)

Cold Forgings

Typically for smaller parts. Including bending, cold drawing, cold heading, coining, extrusion, punching, etc

Surface Heat-Treating

Flame Hardening
A process whereby a forging is exposed to an open flame and then quenched (cooled in oil, water or air)

Induction Hardening
The localized surface heating of a forging by an electrically-heated induction coil

Testing

We provide material certification for all forgings in Chemical analysis and Mechanical tests including tensile strength/elongation and hardness testing

We also provide Non-Destructive Testing upon request:

Dye penetration • MPI • UT • X-ray

Structural and Mechanical Fabrications

Structural Fabrications

Sawing, Plate Cutting, and Drilling

Oxyacetylene cutting - Plasma cutting - Laser cutting
Water cutting - Automated sawing - Anglemaster
Automated drilling - CNC milling - CNC beam drill line

Weld Inspection

BCI can inspect or arrange for 3rd party inspection using all methods of Destructive and Non Destructive Testing (NDT) anywhere across Asia, North America, and Latin America. We provide Ultrasonic Testing - Radiographic Testing - Magnetic Particle Inspection - Dye-Penetrant Inspection

Fitting and Welding

BCI uses AWS certified welders on all projects 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.

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 booths - All international paints available

Structural and Mechanical Fabrications

Mechanical Fabrications

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

Mechanical Fabrications is a key BCI forte. Not only do we work with very competitive fabricators, but BCI’s natural advantage in engineering, global components procurement, machining, quality, and project management comes fully together.

GET IN TOUCH

LEARN MORE ABOUT HOW BCI CAN BENEFIT YOUR RENEWABLE ENERGY PROJECT

Contact us to discuss your project with our team of experts. We're here to help you find the right solutions.

Industries Served

We serve diverse markets and industries both nationally and globally in the light and heavy industrial sectors. BCI's ability to manufacture anything from single complex custom fabrications to multiple part projects has allowed us to successfully partner with customers in the following industries and vertical markets.

renewable energy

Renewable Energy

BCI Engineering provides total solutions for the renewable energies industry from parts fabrication to supply chain management. We specialize in the manufacturing of structural and mechanical components and parts for utility-scale solar racking and tracking systems.

bci-insulation

Insulation

BCI is a custom manufacturer of electrical insulator products and metal stampings. Products include mica parts, mica tape, steatite, cordierite, alumina, heating elements and metal stampings.  Visit www.bci-insulation.com  for more information.

Mining Fabrications

Mining Fabrications

BCI manufactures castings, forgings, structural and mechanical fabrications for the mining and bulk material handling industries. From 30kg to 30 tons in size, BCI has supplied projects all over the world, from Australia to India, from Canada to Mauritania.

Heavy Automotive Industry

Heavy Automotive

BCI manufactures large steel castings, with precision machining and assembly, along with heavy steel mechanical fabrications for heavy utility vehicles. Clients span Europe and North America.