1. Middle East Rail, Riyadh, 2014
Stephen Cantwell
Head of Rail
BRADKEN
RELIABILITY IN HEAVY HAUL

2. © 2014 BRADKEN®
Business Overview
Company History
Business Framework
Global Footprint
Customers
Business Scope
Manufacturing Capabilities
Lines of business
Reliability in Heavy Haul Rail
Presentation Overview
Analysis & Simulation
Testing & Validation
Continuous Improvement
Innovative Design
Manufacturing Processes
Maintenance & Support

3. © 2014 BRADKEN®
Bradken is a leading manufacturer an supplier of differentiated consumable and
capital products to the resources, freight rail and energy markets
Global sales of AUD$1.3B (Actual FY13)
Over 5,000 employees
140,000 cast tonnes per annum & 2500 rail cars
Divisions of the Company include Mining Products, Mineral Processing, Rail,
Industrial and Engineered Products.
Bradken operates 34 manufacturing, sales and service facilities throughout
Australia, New Zealand, the United States of America, Canada, China, Malaysia,
South Africa, Indonesia, South America and the United Kingdom
Business Overview

4. © 2014 BRADKEN®
History of Bradken
1922 Bradford Kendall incorporated
1949 Listed on Australian Stock Exchange
1982 Australian National Industries (ANI) acquires Bradken
1999 Smorgon Steel Group Limited (Smorgon) acquires ANI
2001 Smorgon sells Bradken Division to venture capitalists, Castle Harlan Australian Mezzanine Partners (CHAMP)
2004 Listed on Australian Stock Exchange
2005 Acquired Roche Castings Foundry, WA and opened manufacturing facility in Mackay, QLD both in AUS
2006 Acquired G.W. Brown Pty Ltd and Wundowie Foundry both in WA, AUS. Acquired Firth Rixson Castings in
Sheffield and Darlaston, UK. Bradken join Castle Harlan, Inc in acquiring 20% of AmeriCast Technologies,Inc.
USA
2007 Acquired Boogan Implement Company in QLD, AUS and TMS Engineering in TAS, AUS
Acquired Roll Neck Rings in Sheffield, UK Purchased 75% of Cast Metal Services Pty Ltd, QLD, AUS
Opened manufacturing facility in Xuzhou, China
2008 Acquired remainder of AmeriCast Technologies, Inc. USA
2009 Opened manufacturing facility in Mt Isa, QLD, AUS
2010 Purchased remainder of Cast Metal Services Pty Ltd, QLD, AUS
Acquired ALMAC Machine Works Inc, AB, CAN and Materix Engineering Pty Ltd, NSW, AUS
2011 Acquired Investment Casting Queensland Pty Ltd, QLD, AUS and Wear Protection Systems Pty Ltd, WA, AUS
Norcast Wear Solutions, Canada (Mont-Joli and Toronto) which included Swanmet, Malaysia (Merlimau and
Singapore) and Australian and Overseas Alloys Pty Ltd, Australia (Wollongong)
2013 New Global Corporate Centre opened in Australia (Newcastle). New greenfield foundry in
Xuzhou, China was opened.

5. © 2014 BRADKEN®
Bradken Business Framework

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Bradken Facility Overview

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Bradken Group Global Footprint
Foundry
Workshop
Metal Recycling
Sales Office
CMS Foundry Supplies
59manufacturing, sales
and service facilities
5,880employees

8. © 2014 BRADKEN®
Major Customers

9. © 2014 BRADKEN®
Mining
Design, manufacture and supply a
range of customised consumable
wear parts and capital equipment
for fixed & mobile plant and
equipment throughout the mining
industry
Sales by Industry Sectors FY 2013
Engineered Products
US based foundry and machining division
manufactures highly engineered, large, mission
critical steel castings for the construction, mining,
defence, rail and transit industries
Mineral Processing
Design, manufacture and supply of
high quality mill liners, crusher liners
and engineered parts, both
domestically and internationally.
Rail
Design, manufacture and supply freight
wagons, bogies, drawgear
;maintenance services; equipment
leasing; Spare parts

10. © 2014 BRADKEN®
Manufacturing Capabilities
Bradken is Australia’s largest combined foundry and heavy
engineering group and one of the leading ferrous-casting companies
in the world.
Bradken has a vast network of manufacturing facilities and sales and
service centers throughout Australia, New Zealand, China, Canada,
United States of America and the United Kingdom. This geographical
diversity underpins its position as a world class, cost effective, high
quality foundry and heavy engineering company.
Bradken’s manufacturing facilities employ the latest technologies in
product development, design, tooling manufacture, casting
processes, robotics, machining and assembly. Within Bradken there
is a broad wealth of technical expertise encompassing a wide range
of alloys and complex fabrication in addition to operational and field
experience.
This positions the company as one of the world’s most cost effective
and quality founders complemented by the extensive product range
and capacity offering customers high security of supply now and in
the long term.

11. © 2014 BRADKEN®
GET & Buckets Wear Plate and Block
Mining Products
Crawler Systems Mineral Processing

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Mill Head Segment
Crawler Side Frame
Machined Double
Helical Gear
Industrial
Multi-Axis Machining Centre

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Energy Industrial Products
Resources
Engineered Products

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Rail
Intermodal
40 Tonne Bogie
Coal Wagons
Iron Ore

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Analysis and Simulation
• Advanced analysis and simulation
technology in the design of wagons
• Assessment of operational risks, and
optimisation of designs to meet customer
specific requirements
• Fatigue assessment is conducted to
ensure reliable operation throughout
wagon life

16. © 2014 BRADKEN®
Testing & Validation
• Team of testing Engineers dedicated to
development of Wagons
• Testing translates into superior knowledge
of the operating conditions
• Wagons are validated prior to entering
operation
• Customers can have confidence that
Wagons are suited to their individual
requirements

17. © 2014 BRADKEN®
Testing & Validation
• Designs subjected to static and fatigue
testing prior to release into service
• Understand in-service performance to
feed into further product enhancements
• Application specific knowledge facilitates
work with customers to develop
maintenance schedules which optimise
reliability

18. © 2014 BRADKEN®
Continuous Improvement
• Close collaboration with customers and
suppliers to continuously improve
performance and reliability
• Ensure suppliers are of the highest
standard

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Drawgear Design
• Over 40 years proven history
• Proving ground has enabled Bradken to
develop a highly reliable drawgear system for
heavy haul applications
• Designs optimised using failure analysis,
FEA, fatigue simulation, and product testing to
destruction

20. © 2014 BRADKEN®
Bogie Design
• Worlds first 40 tonne axle load bogie
• Continued development of bogie to further
enhance reliability
• 40 tonne axle load bogie used by BHPB and
RioTinto for over 10 years in the Australia’s
Pilbara region
• The use of quality components ensures
reliability and reduced maintenance costs

21. © 2014 BRADKEN®
Manufacture Processes
• Castings and forgings used where best suited within
the range of drawgear systems
• Stringent quality requirements and destructive testing
to maintain tight control over fatigue performance
• Solidification Simulation, Xray, and Phased Array
Ultrasonics used extensively to ensure casting
consistency and integrity
• Manufacturing processes ensure drawgear operates
reliably in the toughest operating conditions

22. © 2014 BRADKEN®
• Bogie manufacturing facility has produced high
quality rail castings for over 50 years
• Castings required to meet detailed inspections
throughout the manufacturing process to ensure
industry requirements are exceeded
• Manufacturing processes ensure bogie’s
operate reliably in the toughest operating
conditions
Manufacture Processes

23. © 2014 BRADKEN®
Maintainability & Support
• Equipment designed to allow ease of
maintenance ensuring reliability in service
• Detailed maintenance manuals ensure
safe and efficient maintenance
• Continual technical support ensures
rolling stock performs to its full potential

24. Thank You