BCI Engineering

Structural and Mechanical Fabrications:

An Overview of Capabilities

Last Updated: February 28, 2010

Contents

! Introduction to BCI Engineering

! Structural Fabrications
! Mechanical Fabrications
! Online Project Tracking
! Case Study
Structural Fabrications

! BCI Engineering is highly competitive in structural

fabrication.
! Steel pipe, beam, and plate weldments to AISC
standards using AWS certified welders.
! Manufacture stand-alone facilities and structures
housing mechanical work.
The Structural 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

Structural Fabrications
The Structural Process

Material Purchasing

! Fabricates from any commercially available

metals.
! Highly experienced in specifying international
material equivalents which allows the use of
local resources thereby lowering costs.
! Rigorously monitors quality and can provide
certification on all materials.
The Structural Process

Sawing, Plate Cutting, and Drilling

- Automated sawing - Oxyacetylene cutting - Autmated drilling

- Anglemaster - Plasma cutting - CNC milling
- Laser cutting - CNC beam drill line
- Water cutting

Dimensional reports are kept

for all cut pieces.
The Structural 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 Structural 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)
! BCI 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 Particle Inspection
" Dye-Penetrant Inspection
The Structural Process
Grinding, Shot Blasting, Galvanizing, Painting

Careful, supervised ASTM hot-dip

grinding galvanizing for both
large and small
pieces

All international
paints available

Sand-blasting,
Steel shot blasting,
Portable blasting boths
The Structural Process
Packing, Loading and Shipping

Replacement bolts
are colored for easy
identification

Bar coding
available for
easy field
Lashings checked before, identification
during and after loading to
ensure proper tightness
Never any steel
on steel after coatings
applied
The Structural Process

Field Installation Support

! BCI can organize support teams for field installations;

they can be “dropped” into any region of the world.
! BCI full-time foreman, Sam Loh, not only supervises
shop teams, but organizes mobile teams for field work
support.
Mechanical Fabrications

! 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.
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

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.
Mechanical Fabrications

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.
Mechanical Fabrications

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 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.
Mechanical Fabrications

Heavy Duty Machinery

! Mechanical fabs usually require significant machining, and these

machines need to be very large as well as precise. Examples Include:
" 5-axs CNC mills
" Large vertical lathes
" Portable CMM
! BCI field staff keep close watch over machining, keeping dimensional
records which are constantly available on BCI’s online project tracking
site.

5-axis CNC mills Portable CMM Large vertical lathes

Mechanical Fabrications

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.

In some cases, destructive testing is

required on first article samples….
Please Contact Us

Jerry Carroll, Director of Sales

" Phone: (724)-689-8532

" Fax: (724)-240-1500
" E-mail: jerry@bci-engineering.com