Production Capabilities

Centrifugal and static casting methods provide robust and reliable solutions for producing iron or steel rolls, rings, and sleeves across diverse mill types.

BRC ensures consistent material properties, customised to meet the demands of industrial applications. By fine-tuning casting parameters through process controls, we minimise imperfections, delivering components optimised for performance in challenging operational environments.

Forging is essential to produce material grades of rolls and related products with superior performance under extreme operating conditions.

BRC oversees a comprehensive forging process, starting with highly clean steel prepared through smelting and refining techniques. Then the liquid steel is Ladle Refined and Vacuum Degassed to control oxygen, nitrogen, and hydrogen content, ensuring quality. Once refined, the steel is cast into ingots, which are either directly forged or reprocessed through Electro Slag Refining (ESR) for enhanced purity. This meticulous process results in forged blanks with minimal non-metallic inclusions and customised mechanical properties.

We implement rigorous testing protocols, including ultrasonic testing, X-ray diffraction metallography, and destructive sample analysis to ensure product integrity. These measures ensure defect-free products that deliver consistent performance and exceptional durability in demanding mill environments.

Sintering is used to combine metallic and non-metallic powders to produce high-performance composite materials. This method is especially effective for producing cemented carbide products, known for their exceptional hardness and durability.

BRC employs state-of-the-art pressing and sintering techniques. These processes are carefully controlled to produce materials optimised for rolling applications and specific mill conditions.

Heat treatment is essential for enhancing the properties of steel components, making them suitable for demanding applications in various mill environments. This process improves hardness, strength, and wear resistance, ensuring products withstand extreme operational conditions.

BRC utilises multi-stage thermal processing and specialised quenching techniques. This approach fine-tunes the outcome to meet the performance criteria of each mill application.

Machining is a crucial process for achieving precise dimensions and tolerances in steel products. This capability is vital for components that require intricate shapes, excellent surface finishes and precise tolerances.

BRC applies advanced CNC turning, milling, and grinding. Rigorous quality control ensures components are precise and integrate efficiently into mill operations.

BRC offers assembling capabilities to ensure that our steel rolls and components meet the unique requirements of your mill. Our expertise includes:

• Shrink Fitting: A reliable method for joining components using interference fitting. This reliable method allows the re-use of shafts and arbors once the mounted sleeve reaches the end of its useful life. BRC utilises both heating and cryogenic methods to achieve the clearance for fitting as best suited to the individual designs.
• Composite Roll Systems: Available with mechanical or hydraulic clamping, offering flexible solutions for various mill environments.
• Other assembly methods are available on request.

Our assembly techniques are supported by quality assurance protocols, ensuring every component performs optimally under operational stresses.