Brooks Forgings Ltd

BROOKS FORGINGS GROWS SHACKLE FORMING CAPACITY

Brooks Forgings Ltd — 16/07/2019

Brooks Forgings Ltd is a leading UK manufacturer of forged, machined and fabricated components.

Our diverse range of over 20 manufacturing processes enables us to offer a bespoke and tailored solution to customers requiring nonstandard components.

The recent closure of a local shackle manufacturer has given us the opportunity to increase our capacity even further by acquiring their range of specialised tooling and machinery.

We are able to produce shackles with a body diameter of up to 100mm, in a range of ferrous and non-ferrous materials by using a combination of upset forging, drop forging, hot bending and machining processes.

Our standard range includes dee, bow and overhead powerline shackles and the more specialised designs such as the heavy-duty 25 & 50 ton NATO recovery shackles.

If you have a standard or fully bespoke requirement for shackles, or any other components, please do not hesitate to contact us on 01384 563356 or visit our website www.brooksforgings.co.uk for more information

Marposs Merlin Computer - Latest Addition To Brooks Forgings QC Department

Brooks Forgings Ltd — 14/07/2015

Brooks Forgings is always looking for new developments in technology that can help achieve and surpass the strict quality standards required for metal components supplied into many industries across the globe.

The latest addition to our Quality Control department is a Marposs Merlin Gage Computer. Primarily designed for the shop floor environment, the Merlin is used for measuring applications and gathering statistical information.

The Merlin allows effective collection of data from up to 32 traditional or wireless measuring devices. This includes statistical process control that allows multiple measurements, data segregation and product batch tracking, all displayed in real time with on screen numeric and graphical layouts. Electronic bore and snap gauges are currently used in our machining processes, allowing immediate and accurate inspection of machined internal and external diameters.

Prior to any measuring procedure, batch codes are allocated to maintain full batch traceability and a calibration routine is performed using fully traceable calibrated setting masters, ensuring accurate data is recorded.

For ease of use by the operator, measurement values are recorded and displayed in a colour coded format, both graphically and numerically on the Merlins LCD screen. This allows the operator to adjust settings in the manufacturing process to prevent the manufacture of non-conforming parts and aid continual improvement of the overall process.

Extensive Manufacturing Processes Help Secure New Orders and Ensure On-time Delivery

Brooks Forgings Ltd — 02/12/2016

Brooks Forgings Ltd was recently approached to produce special lifting assemblies that are used to safely lift and relocate heavy industrial stillages.

Our client, originally importing components from abroad, was let down on delivery.

Brooks Forgings was happy to step in and provide an on time solution that was achieved due to the extensive on-site manufacturing capabilities available.

The overall assembly comprises of a link and eye bolt, produced from high tensile material. The M20 eye bolt was designed to function with a working load limit of 2 tonne and fully drop forged, machined and threaded in-house. The link, manufactured from 20mm diameter material, was hot bent and flash butt welded, also on-site, allowing for heat treatment.

Once assembled, each component was tensile tested on-site to provide the necessary certification required by our customer.

The order was fulfilled on time and excess stock held in our warehouse for future urgent requirements.

Specialised Traction Rods Keep Locomotive Refurbishment Project on Track

Brooks Forgings Ltd — 08/11/2022

Brooks Forgings has a diverse range of manufacturing capabilities that enables the production of fully bespoke components for many applications worldwide. Throughout our extensive history, we have assisted many restoration projects requiring the resilience and aligned grain flow only found with forging processes.

The latest addition to our portfolio is the production of fully bespoke forged locomotive Traction Rods for a fleet refurbishment. A total of 6 Traction Rods are required for each electric locomotive, a critical component connecting each wheel bogie assembly to the carriage to aid with stabilisation and alignment.

The traction rods are unique by design and many challenges were presented to and overcome by our experienced engineers. The head measures 100mm thick with an outer diameter of 189mm, a bored inner eye of 127mm diameter, and is angled at 4 degrees in relation to the main rod with extremely tight tolerances. The rod, 1965mm in length, features several reductions in diameter to accommodate two thread forms, starting at 53mm diameter and dropping down to 48mm for an M48 midpoint thread. This reduces further to an M36 thread at the end.

Special wooden packing cases were designed and produced to eliminate movement and evenly spread the weight load during transport. This is to ensure that the traction rods arrived with the end-user safely and undamaged. Brooks Forgings offer this service as standard for fully bespoke projects.

Special Forged Eye Bolts in ASTM A320 Grade L7 For Petrochemical Pressure Vessels

Brooks Forgings Ltd — 22/06/2023

Brooks Forgings Ltd is one of the world’s leading manufacturers of eye bolts primarily focusing on the production of non-standards in special materials. Eyebolt blanks in common materials are held in stock for rapid conversion to customer requirements.

The petrochemical sector demands the use of exotic materials as they are commonly developed to withstand harsh environmental conditions. Brooks Forgings was approached by a client requiring a fully bespoke eye bolt produced from ASTM A320 L7 material. The thread diameter was 3/4” inch UNC over 75mm and the overall length was 205mm. The eye was 62mm outer diameter and 40mm thick, drilled to 28.5mm inner diameter.

A total of 14 units were required for 2 special pressure vessels being constructed and installed by the end user. The eyebolts were phosphate and xylan coated as per customer-specified requirements.

If you have any requirements for forged, machined, or fabricated eyebolts please contact our experts today with your drawings and full requirements. sales@brooksforgings.co.uk

Forged Eye Bolts in ASTM A320 L7

Forged Eye Bolt Range

Brooks Forgings Expand Product Development & Tooling Design Services

Brooks Forgings Ltd — 26/07/2016

Brooks Forgings Ltd is a diverse manufacturing company specialising in the Hot Forging, Machining, and Fabrication of metal components.

We have prepared this article to inform potential customers of the numerous processes that a single component can travel through during its production life.

The recent addition of a 3D printer and the latest QForm forging simulation software, working in unity with existing SolidWorks software, has the potential to transform the way the company does business in the early stages of product development.

Please contact our team today for more information.

1. 3D Design

Solidworks is industry-leading 3D design software that provides part, assembly, and drawing capabilities with the added benefits of stress analysis, cost estimation, rendering, and animation.

Brooks Forgings currently has 3 seats enabling 3 fully trained design engineers to use the software at one time.

Typically, when a client approaches Brooks Forgings with a viable component for manufacture, they can only provide a worn physical sample or obsolete drawings. The first step in production is to take all of the available information and create a new scaled model in Solidworks. Once generated it enables the creation of detailed digital 2D drawings, 3D renders and can even be exported in a format for 3D printing.

2. 3D Printing Additive Manufacturing

3D printing enables the low-cost production of prototype parts with incredible accuracy.

A physical and dimensionally accurate component can be 3D printed and handed to the client, giving them the ability to finish machine and even implement into a sub-assembly for final suitability testing.

The benefits of this capability are particularly evident in the early stage of production. Forging is an industry with high outlay costs and production of tooling and purchase of raw materials often reaches in excess of £20,000. 3D printing can assist in avoiding costly mistakes caused by the production of incorrect dies and ultimately scrap material.

3. Stress Analysis

Various types of Stress Analysis are incorporated into the latest Solidworks package, enabling Brooks Forgings engineers to carry out simulation on either individual parts or assemblies by using finite element analysis. This process can improve and validate performance and reduce the need for costly prototypes or revisions later on in the project.

This also enables us to evaluate product structure and design suitability and make alterations to suit various requirements. We can also input various material properties making the system fully customisable

4. QForm Forging Simulation

QForm is forging simulation software that enables the development and optimisation of tooling and accurately simulates and analyses the forging process.

Why is this so important? It is possible to identify flaws such as inadequate impression filling, laps or folds, and flow-through defects.

Further optimisation of the process can be achieved by varying starting material diameter, forging forces and analysis of die tooling stresses to improve durability and longevity.

The combination of 3D printing and QForm enables Brooks Forgings to improve lead times and the overall efficiency of the manufacturing process by eliminating forging defects and final application suitability issues before final production tooling and samples are physically produced.

5. Die Cutting & Sinking

We have an extensive on-site tooling room that provides complete control and flexibility throughout production. Our machining department plays a key role, enabling a quick turnaround of forging dies when required.

This process is combined with the latest CAM software that gives us the ability to run die cutting simulation to identify potential errors in final tooling production. Tooling is a crucial part of the overall manufacturing process and is the most costly.

6. Drop Forging

The Drop Forging process is just one of many offered by Brooks Forgings Ltd. The shackle in this case study was manufactured using our Banning GOA 1250 drop hammer. Our forging processes utilise induction heaters that are automated with automatic hopper feeds. This supplies the operator with a constant and controlled supply of billets at optimal forging temperature.

7. Machining

We currently have 13 CNC machines enabling us to finish machine components as batches come off the forging production line. For the machining of the drop forged shackles in this case study, special quick release jigs were designed and made by our tool room. Two sets of jigs were used, one that allows the facing of the shackle ends and the other to drill the final pin hole.

Brooks Forgings Completes Challenging Production of Hot Formed Ladle Lid Lifting Bridles

Brooks Forgings Ltd — 25/01/2023

Brooks Forgings are always thinking outside of the box when it comes to the production of highly specialised components, utilising our years of expertise and comprehensive range of in-house manufacturing processes.

Our client approached us regarding the production of a newly designed Ladle Lid Lifting Bridle requiring aligned directional grain flow. This required a combination of hot forming and fabrication processes that Brooks Forgings can offer.

The profiled blank for the ladle was produced from S355J2 steel measuring 2500mm long X 510mm wide X 60mm thick, with grain flow running along its length. The weight of the blank, 540kg, was just one of the challenging factors involved. Our production team meticulously planned and ensured the required handling equipment was in place.

Specialised force dissipating tooling had to be produced to minimise distortion of the 60mm thick section when bending to an inner radius of 100mm. Heating furnace apertures were modified to accommodate the hot-forming process. Rather than heating the entire plate, the heat was localised on the area requiring bending.

If you have any requirements for similar components or forming processes, please contact the Brooks Forgings sales team today. We are more than happy to assist you.

Hot Formed Ladle Lid Lifting Bridles

Horizontal Counterblow Forging - Low Production Cost for High Volume Forging in the UK

Brooks Forgings Ltd — 20/06/2014

Horizontal Counterblow Forging is just one of many forging processes offered by Brooks Forgings Ltd.

This process can achieve a more uniform product, using less energy compared to other forging processes. High volume and consistent production of excellent quality forgings with improved lead times.

We believe that the introduction of Counterblow Forging will enable us to offer the lowest possible production cost for medium to high volume forging in the UK.

A forged billet with 6 component impressions (see below) takes only 15 seconds to produce, equating to a complete forged and clipped component every 2.5 seconds.

Counterblow forging machines operate on the basis that two bodies of equal mass are accelerated towards each other at the same speed. When they collide the reaction forces are equal and opposite to each other concentrating the complete absorption of energy within the bodies themselves. When forging stock is placed between the bodies, it is deformed by the impact energy created by the blow.

The impact energy is pre-set and is regulated by precise timing controls to provide consistent energy levels for metal deformation. Savings are made because only the required amount of energy is used for the size and complexity of the product being manufactured.

See the video on our YouTube Channel: www.youtube.com/BrooksForgingsLtd
Visit our website: www.brooksforgings.co.uk
Tel: +44 (0)1384 563356 Fax: +44 (0)1384 563357

Heritage Replication for National Lottery Funded Jewellery Quarter Cemeteries Project

Brooks Forgings Ltd — 15/09/2020

Brooks Forgings specialise in the replication of decorative heritage ironwork components. By using a combination of physical original samples, photographs, and the latest digital design software we can create new tooling and reproduce components that are faithful to the original.

This service is common for many heritage restoration projects, replacing lost or damaged components, but is also used for modern builds or expansion projects that must incorporate ironwork designs used in the local area.

The Jewellery Quarter Cemeteries Project is the latest to utilise our heritage replication services. Funded through a partnership by The National Lottery Heritage Fund, Birmingham City Council, and the Jewellery Quarter Development Trust, the £2.3 million restoration project focuses on the Key Hill and Warstone Lane cemeteries. Both are listed on the Historic England Register of Parks and Gardens in recognition of their historic importance.

The client provided us with two physical samples, one for the main ‘top’ railhead design and another for the ‘bottom’ underbar design. Our skilled engineers meticulously reverse-engineered those samples, recreating them in a digital format using the latest CAD software.

From here, 3D printed plastic samples were produced for customer approval against the original design, and forging simulation performed to ensure that the unique hexagonal bar transitioned correctly into the railhead design.

A total of 2600 railheads were forged directly onto hexagon bar in varying lengths from 1395mm up to 1930mm underhead. The smaller underbar design, 115mm tall, was manufactured in 2350 quantity total.

Brooks reinforce their future with CE and National Highway Sector Scheme approval

Brooks Forgings Ltd — 30/07/2014

Brooks Forgings are proud to announce that we have recently been audited for and successfully obtained CE and National Highway Sector Scheme approval. These approvals are essential for the continued manufacture and supply of components to the Civil Engineering sector.

CE marking demonstrates a products compliance with applicable EU legislation and its legitimacy to be placed on the market within the European Market. As of the 1^st of July 2014 CE marking became mandatory for fabricated structural steelwork components. Our approval permits the supply and distribution of Non-Preloaded and Preloaded High Strength Bolting Assemblies.

The National Highway Sector Scheme (NHSS) approval is a bespoke quality management system based on, but not duplicating, the ISO 9001 standard. Split into several schemes it is designed to ensure that work is carried out to the highest standards. Brooks Forgings are now fully approved for the manufacture and distribution of Mechanical Fasteners up to M100 in accordance with National Highway Sector Scheme 3.

These new approvals reinforce our dedication in meeting the strict requirements demanded in the industry.

Our certificates and full scope of supply can be viewed on our website.

Tel. +44 (0)1384 563356 Fax. +44 (0)1384 563357
www.brooksforgings.co.uk

M90 Hammerhead T Bolts for New Fossil Free Kiln Expansion Project in Sweden

Brooks Forgings Ltd — 05/10/2022

The removable hammerhead foundation system is used in heavy industry installations all over the globe. The fabricated tube assembly and forged t-bolt are produced to very specific requirements with no off-the-shelf solution available. Over the years, Brooks Forgings has made a considerable investment in its capabilities and range of production tooling to be in a position to offer bespoke requirements to the DIN 261 and DIN 7992 hammerhead standard with sizes ranging from M24 up to M100 and 6-meter lengths.

Our latest production was for a client requiring the manufacture and delivery of 68 total DIN 261 hammerhead t-bolts in grade 8.8 material and M90x4550mm in size, each weighing 220 kilograms.

The combination of weight and length presented us with several challenges from safety and logistics to simply achieving a consistent production workflow. A dedicated production team was assigned to the project and through a combination of meticulous planning and utilisation of special lifting and moving jigs we were able to fully optimise the manufacturing process. Brooks Forgings is the only UK company capable of producing these hammerhead bolts in the lead time required.

These particular M90 hammerhead bolts were shipped to an expansion project located in Sweden that involves the installation of a new fossil-free kiln used during pulp production. With the launch scheduled for Q4 2021, it was essential that the bolts were manufactured and supplied on time so the foundation works could commence in preparation for the final delivery and commission of the equipment.

The bolts were shipped via land on dedicated transport and supplied complete with extensive quality documentation to fully support the material supplied.

If we can supply you with similar requirements please do not hesitate to get in touch.

Collaboration between Brooks Forgings and W.H.Tildesley on prestigious forging project

Brooks Forgings Ltd — 14/03/2018

Brooks Forgings were given the opportunity to manufacture and export a requirement for 14 highly specialised lifting bail bars that are used to lift crucibles of molten aluminium at a treatment plant located in Bahrain.

This was the first collaboration project between Brooks Forgings and W.H.Tildesley since them joining the Brooks Engineering Group in April 2017.

We believe that we are one of a very limited number of manufacturers worldwide who could undertake and complete this project successfully.

The bail bar had to be hot forged to achieve the directional grain flow required for strength and resilience. It was obligatory to provide full traceability and testing at all stages of production. This was supplied to the customer at each stage for approval. The project entailed numerous processes including upset forging, drop forging, hot bending, machining and an extensive testing regime.

Starting with fully certified and ultrasonically tested AISI 4140 round material, Brooks upset forged both bar ends using one of 16 forging cells on-site. These pre-formed ends were then drop forged by WHT using their 5T Banning power hammer. This stage of the process was critical as both ends had to be formed perfectly parallel. Specially designed jigs and fixtures were used to assist in meeting this requirement.

The components were hot bent to a 51° angle using specially designed tooling, followed by heat treatment to specific parameters in a fully calibrated furnace. Extensive testing was carried out including tensile and charpy with a 15.6T proof load test and magnetic particle inspection witnessed by Lloyds.

All tooling for the project was designed and manufactured in-house. Each bail bar was installed in a test jig that was specifically designed to mirror the final application. Packed suitably in custom built wooden cases and exported via air freight.

The Brooks Engineering Group can offer a wide range of manufacturing processes under one roof, enabling us to offer an unrivalled service and supply numerous industries with bespoke components that are not available elsewhere in the industry.

www.brooksforgings.co.uk

enquiries@brooksforgings.co.uk

DIN 7992 Hammerhead Bolt Manufacturing

Brooks Forgings Ltd — 11/06/2013

At Brooks Forging we have the manufacturing capabilities to hot forge hammerhead bolts to DIN 186, DIN 188, DIN 261 and DIN 7992. Sizes up to M100 and lengths of 6000MM are achievable.

Our range of in house manufacturing capabilities enables us to rapidly manufacture specialist components and non-standard items to our customers exact specifications.

Case Study
A recent project, for a client in Europe, was the production of hammerhead bolts to DIN 7992 in grade 10.9 material, finished in black oxide. Sizes M48 to M100 and lengths from 1900MM to 3100MM.

Forged on site at our manufacturing facility in Stourbridge, West Midlands, special lifting jigs were put in place to assist the forging operators. With the average bolt forging weighing 135KG, safety was of upmost importance.

The ends were drilled and tapped M16x32MM, to enable the use of lifting eyebolts when moving the bolts on site. The ends also included directional slots, used as a visual aid during installation.

Testing was carried out to customer specifications. This included Ultrasonic, Magnetic and Liquid Dye Penetrant examination as well as Brinell and Charpy testing.

A complete Quality plan was provided for each bolt size, a strict requirement, ensuring full tractability for every stage of production.

Brooks Forgings Manufacture Heavy Duty Mooring Rings for Monaco Project

Brooks Forgings Ltd — 09/04/2019

Brooks Forgings specialise in the manufacture of non-standard forged, fabricated and machined components and are one of the leading British manufacturers of bespoke Mooring Rings and Chain Link Adjusters for the marine industry.

A recent project was commissioned by a French company that required the production of 21 heavy duty mooring rings, in grade 8.8 material, for a dock refurbishment project in Monaco.

The mooring ring is made up of a 600x350x35mm thick base plate, 200mm inner diameter ring from 50mm diameter material and u-bend also in 50mm diameter material. The rings were hot bent and flash butt welded in-house. Unlike standard welding procedures, flash butt welding uses no foreign material and allowed us to complete the necessary heat treatment to 8.8 grade specification.

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Brooks Forgings Certified for ISO 9001, ISO 14001 and OHSAS 18001 with Lloyd's Register

Brooks Forgings Ltd — 20/05/2020

Brooks Forgings are proud to announce that they are now certified with the Lloyd's Register for ISO 9001, ISO 14001 and OHSAS 18001.

Lloyd's Register was the first certification body to gain accreditation from the United Kingdom Accreditation Service (UKAS). For this reason, we are confident that we are working with an industry champion that has the experience, expertise, and professionalism to carry out our assessments.

ISO 9001:2015 - Quality Management

Gaining certification from Lloyd’s Register demonstrates that our quality management system (QMS) follows a robust and globally recognised approach that’s focused on continually improving our processes and managing business risks to meet the needs and expectations of our customers.

ISO 14001:2015 - Environmental Management

Environmental Management System certification to the ISO 14001:2015 standard helps demonstrate our ongoing commitment to improving environmental performance and puts a greater emphasis on proactively improving environmental performance and embeds environmental management within our strategic plans.

OHSAS 18001:2007 - Health & Safety Management

Lloyd's Register technical specialists were instrumental in the development of OHSAS 18001 that was developed in response to the demand for a recognisable health and safety management system standard that could be externally assessed and certified.

Achieving OHSAS 18001:2007 with Lloyd's Register demonstrates our commitment to reducing accidents and occupational health issues through a safer working environment.

Special Forged DIN 261 Hammerhead T-Bolts in Duplex Material For Subsea Project

Brooks Forgings Ltd — 26/05/2023

Brooks Forgings specialise in the production of Hammerhead T-Bolts to DIN 261 and DIN 7992 specification.
We hold tooling for all hot forged sizes, made to your exact requirements.

We were approached by a client in the early stages of a new subsea project requiring a substantial amount of M48 X 1950MM DIN 261 Hammerhead Bolts. Given the critical nature of the final application, our client requested that the components be produced from Super Duplex material that is known to provide excellent yield and impact strength, and resistance to both corrosion and stress corrosion cracking.

A strict production and quality plan was prepared as the material needed to be heated and handled correctly during all forging and post-production processes. Forged nuts and washers were also produced in Duplex material, supplied and assembled with each Hammerhead T-Bolt. All components were etched with a batch and heat treatment reference for full traceability.

The packaging was specially designed and produced for the project and required to safely transport the bolt assemblies. This was due to weight and dimensional stipulations set by our clients’ couriers who were tasked to airlift the boxes via helicopter to several sites across the project.

Forged Super Duplex DIN 261 Hammerhead T-Bolts

Forged Hammerhead Bolt Range

BROOKS FORGINGS CELEBRATE 55TH ANNIVERSARY

Brooks Forgings Ltd — 20/10/2015

Brooks Forgings Ltd, a leading UK manufacture of forged, machined and fabricated components, is celebrating its 55th anniversary.

Established in 1960, the company has grown to become a leading UK manufacture of forged, machined and fabricated components. Thanks to a substantial expansion in 2010, the companys facilities now cover an impressive 95,000 sq. ft. over two sites located in the West Midlands.

The expansion in 2010 saw the relocation of the manufacturing plant to a new 45,000 sq. ft. site, formally Hayes Tubes, located in Balds Lane, Stourbridge. This has given the company room to grow through continued investment in its capabilities, reinforcing its future in British Manufacturing.

Now with over 20 manufacturing processes including:

Upset Forging
Drop Forging
Open Die Forging
Horizontal Counterblow Forging
Hand Forging
Machining
Thread Rolling
Ring Rolling
Fabrication
Robot Welding
Flash Butt Welding
Bending - Hot & Cold
Pressing Hot & Cold
Swaging & Pointing
Tensile & Destructive Testing
Computer Aided Design & Machining
Marking & Traceability

It is this diversification that enables the company to offer a one-stop-shop service to its customers requiring forged, machined and fabricated components. One of the key advantages is improved lead times. For example, when components come off the forging line they can immediately move to a secondary operation such as hot bending or machining and then to final assembly/fabrication. This rotational method of production also offers full traceability and improved quality control.

The vacant manufacturing facility at Doulton Road, Cradley Heath, was fully refurbished to house new warehousing facilities, allowing a capacity of up to 2500 pallets of stock. Standard components are held in stock, enabling immediate despatch. Our warehousing facilities are offered to customers requiring orders on a call off basis, primarily for components made to customers requirements.

Quality is of upmost importance in the manufacturing industry and Brooks Forgings are constantly keeping up-to-date and in conformance with the latest accreditations. The company currently holds Lloyds ISO 9001 for Quality, ISO 14001 for Environmental and OHSAS 18001 for Health & Safety. In 2014 the company was audited for and successfully obtained CE and National Highway Sector Scheme approval. These give us the independent checks and systems to monitor and improve our in-house performance, giving our customers the independent quality assurance that they expect.

Another step forward in quality management is the recently completed construction of a new central control room. This manages all aspects of production and will play a vital part in the continued growth of company. Several systems will be linked, including software controlled heating furnaces, CNC machines and computer terminals throughout the facility. The newly designed and built furnaces, 4 in total, are capable of reaching temperatures of 1300°C and feature a 7 day start up and shutdown timer along with a separate idle and working temperature setting. Computer terminals will enable us to fully monitor job performance and offer full live route card tracking of components throughout production. Our 13 CNC machines now have full WIFI capability allowing remote programming and problem solving.

Businesses that would like to find out more please contact us on 01384 563356, e-mail enquiries@brooksforgings.co.uk or visit our website www.brooksforgings.co.uk

Brooks Forgings Offer Increased Fabrication and Machining Capacity

Brooks Forgings Ltd — 17/06/2015

Already a reputable supplier of forged metal components, Brooks Forgings Ltd is looking to develop and further establish its machining and fabrication services within the engineering and manufacturing community.

Thanks to continued investment Brooks Forgings has expanded through diversification, now offering over 20 different manufacturing processes and supplying metal components both locally and worldwide to many industries including Civil Engineering, Petrochemical, Power Generation, Defence and Transportation.

In 2013 the company expanded considerably by investing in a second 45,000 sq. ft. manufacturing site based in Lye, Stourbridge. Brooks Forgings now has 16 Hot Forging cells operational covering a diverse range of forging processes, fully supported by a machining and fabrication capacity including 16 CNC machining cells, 5 Robot Welding cells and 2 Flash Butt Welding machines.

Robot Welding

Robot Welding offers numerous advantages when compared to conventional welding methods, including faster welding cycle times, no breaks in production, less wasted material, and a cleaner consistent weld seam. Brooks have reviewed and implemented this process into many existing projects, improving lead times and overall quality.

Flash Butt Welding

Flash Butt Welding is commonly used where high strength is required, typically lifting links, rings and chains. The company is able to flash butt weld 6mm up to 52mm in either square or round material. The main advantages of Flash Butt welding is the speed and the overall strength of the process, there is no foreign weld material used meaning the product can be heat treated afterwards further increasing tensile strength.

For general enquiries or to receive further information regarding our services and capabilities please contact us on 01384 563356 or visit our extensive website www.brooksforgings.co.uk, we look forward to hearing from you.

Special Fabrication Keeps Expansion Of Waste Management Facility On Track

Brooks Forgings Ltd — 12/06/2020

Brooks Forgings specialise in a diverse range of manufacturing processes and products. This has enabled us to offer bespoke project solutions and meet the specific requirements required by our expanding customer base.

Over the last decade, we have grown to be one of the leading suppliers in the waste and recycling sector, expanding our range of components to meet current market demands.

As part of site expansion, a waste management company approached us with a novel idea for a roller track system. The design would allow large containers to be moved in and out of confined space applications where conventional moving and lifting equipment could not be utilised safely. A dual-track, 10 metres in length, was designed and fabricated using a total of 56 rollers (168mm outer diameter) and special shafts that allow lubrication via grease nipples at each end.

The track was fabricated in 8 individual sections to aid with transportation and installation and designed to be bolted down in situ. It is fully serviceable and allows for Individual components to be removed and replaced when required.

It was our extensive in-house manufacturing processes that enabled us to supply the project on-time and from one source. A combination of sawing, robot welding, manual welding, and machining processes was used.

Please click here to visit our processes page to learn more.

Forged Railhead Replication For Partick Pumping Station Restoration Project in Glasgow

Brooks Forgings Ltd — 14/02/2024

Brooks Forgings specialise in the replication of decorative ironwork components required for historic restoration projects throughout the UK and beyond. The production of forged railheads is a specific specialty of ours and can be offered as single units or forged directly to the bar in required overall lengths to minimise fabrication time.

Our latest replication project was for a customer involved in restoration work at the Grade B-listed Partick Pumping Station located in the city of Glasgow, UK.

The existing fencing had to be repaired or completely replaced in sections and required the replication of two railhead designs that matched the original aesthetics.

Brooks Forgings designed and produced tooling to hot forge the replacement railheads required for the project, all supplied as single units to be welded into the final fabrication and installed on-site by our customer.

A total of 410 pieces of each railhead variant were supplied in support of the project (820 total).

If you are involved in restoration projects requiring the replication of existing metal components do get in touch with us by email at sales@brooksforgings.co.uk with more information and drawings.

Super Duplex Special Fasteners from Brooks Forgings

Brooks Forgings Ltd — 27/02/2014

Super Duplex Special Fasteners from Brooks Forgings Ltd

The Non Standard Fastener Specialists

Our range of in-house manufacturing capabilities enables us to rapidly manufacture specialist components and non-standard items to our customers exact specifications.

Case Study
We were approached by a company specialising in the manufacture of pressurised containment vessels. The development of a prototype system required the design and manufacture of a special type of T headed swing bolt, used to secure the housing section of the assembly to the vessel.

The prototype application required the use of fewer bolts but still demanded the strength and safety factor of a conventional installation.

Super Duplex A182 F53 material was used to hot forge blanks to achieve an overall finished bolt length of 650mm. Machine finished with an M52 x 130mm thread and supplied with nuts to suit.

A complete Quality plan was provided ensuring full tractability for every stage of production and certification confirming that the bolts met the strength required for the final application.

Please visit our website: www.brooksforgings.co.uk
Call us on: +44 (0)1384 563356 Fax us on: +44 (0)1384 563357
Email: enquiries@brooksforgings.co.uk

Brooks Forgings Produce Forged Components For The Union Chain Suspension Bridge Restoration Project

Brooks Forgings Ltd — 04/05/2023

Brooks Forgings were approached to take part in the Union Chain Suspension Bridge restoration project, focusing on the manufacture of replacement chain rod ends and various supporting walkway components.

The Union Chain Bridge located in Northumberland spans the River Tweed connecting the Scottish and English borders. Designed by Sir Samuel Brown, the bridge opened in 1820 and was the world’s longest wrought iron construction suspension bridge spanning 137 meters and the first vehicular bridge of its type in the United Kingdom. The Union Chain Bridge is said to be the main influencer in bridge innovation and design which is reflected in the later-constructed Clifton and Menai suspension bridges.

In 2020, essential works were required to preserve the 200-year-old bridge as many of the original critical components had started to deteriorate and show signs of fatigue. The Spencer Group was appointed the project by Northumberland County Council to dismantle, replace, refurbish (where possible), and fully rebuild the bridge to mark its bicentenary.

A total of 550 replacement chain rod ends were drop forged, machined, and supplied by Brooks Forgings enabling the replacement of 275 chain rods from the original 444 used in the construction. The chain rods are joined together to span the length of the bridge on both sides and are the key structural element in its design.

Along each side of the bridge are walkways that are constructed using decorative wrought iron handrail components. Brooks was able to produce a one-piece forged design remaining faithful to the original method of production.

The Brooks Engineering Group can assist with the production of critical forged components in support of historical bridge preservation or the construction of new modern engineering projects. Please get in touch with our team of experts who will be happy to assist with your specific requirements.

Investment in Data Collection Terminals Invaluable for Performance & Costing Improvement

Brooks Forgings Ltd — 10/03/2020

Considerable new investment has been made at our production facility based in Lye, Stourbridge to further improve KPI (Key Performance Indicator) targets.

Several data collection terminals are now located throughout the factory to enable our staff to log on and off jobs, allocate material stock and monitor production rates and volume at various stages.

The system gives us the ability to fully analyse jobs and calculate our true costs for the production and procurement of materials. From this, we can also calculate sold machine-hours and generate pre-emptive maintenance schedules. Production drawings and setup/manufacturing videos can also be accessed and viewed for each production job.

The central control office has the ability to monitor all jobs in progress and identify those that are behind schedule. As part of our on-going improvement scheme, the system is fundamental in improving overall production performance and helps us identify areas for improvement.

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Brooks Forgings is the first company to be issued with ISO 9001, EN1090 and EN15048 by Lloyds Register.

Brooks Forgings Ltd — 27/06/2017

Brooks Forgings Achieves EN1090-1 & EN15048 Approval To The Construction Products Standard For CE Marking.

This is to comply with the Construction Products Regulation 305/2011.

The combination of all three approvals means that our customers can purchase foundation bolting assemblies from one source with improved lead times and in full compliance with CE regulations.This gives us a greater scope of coverage than most other companies supplying the Construction and Civil Engineering sectors.

Compliance with EN1090-1 enables us to fabricate outer assemblies and the recent addition of EN15048 enables the hot forging and machining of non-preloaded structural foundation bolts.

This demonstrates that we have undergone a rigorous audit, where our capability to comply with the current best practices employed in the Construction and Civil Engineering sector was reviewed in detail.

What is the Construction Products Regulation CPR 305/2011?

The Construction Products Regulation (CPR 305/2011) applies to manufacturers, distributors and fabricators of construction products within the European economic area.

To successfully comply with these regulations companies must undergo an assessment by a notified body such as Lloyds Register, and prove their systems and products are fully compliant with all aspects of these regulations. If the organisation is successful they are then awarded the CPR Certification.

This enables them to mark their products with CE Marking indicating their processes and products are fully in compliance and can be marketed across the region without additional testing or barriers to trade.

75 TON ETCHELLS MULTIFORGE RETURNS TO THE HEART OF BRITISH MANUFACTURING AT BROOKS FORGING

Brooks Forgings Ltd — 08/08/2018

The latest addition to our upsetting machine range is a 75 Ton Etchells Multiforge. This increases our forging machine capacity to a total of 27 cells.

This machine has an interesting back story. Originally purchased and exported in 2001 by the General Electric Company located in Bromont, Canada, its primary purpose was for the manufacture of preforms for aero engine blades. This machine was one of the last built by Etchells before they ceased trading in 2004.

Known for its rigid construction, the machine was ideal for holding the split dies together for the extrusion and upsetting operations. The Etchells factory was located in Darlaston, Wednesbury, only a few miles away from the Brooks Forgings manufacturing site in Lye, Stourbridge.

The machine was imported back to the UK in early 2018, travelling over 3000 miles from Canada to bring it back home to the heart of British manufacturing. All machinery that is acquired for our factory is fully inspected and refurbished by our experienced maintenance team. However, this particular machine showed minimal signs of use and was virtually in as new condition.

Following a general overhaul and service, the tooling area was modiłed to accept the full range of tooling we hold for our Mutliforge machines and the machine is now fully installed and commissioned for use on new projects.

For more information on the capabilities at Brooks Forgings, please check out our website here: http://www.brooksforgings.co.uk

Brooks Forgings Continue To Invest In Automated Technology

Brooks Forgings Ltd — 09/08/2019

As part of an on-going development strategy, Brooks Forgings has an active interest in the latest manufacturing technology. Our aim is to increase production capacity and quality, reduce our carbon footprint and remain competitive against foreign manufacturers with low labour costs.

We are pleased to announce that we have recently moved forward with the installation of a FANUC six-axis robotic arm. The robotic arm has been integrated with an automated bar feeder, induction heater, and an Etchells MultiForge machine, creating a fully automated horizontal upset forging production line.

The new automated line will primarily be used for high volume production and offer our experienced workforce the flexibility to focus on our core business strengths of non-standard and special components. It will also provide increased production rates due to an extremely consistent and undisrupted workflow and the overall quality and dimensional accuracy of components will be improved, reducing scrap and waste. Operating costs will also be reduced and this will enable us to be competitive in the international market and ultimately reshore components that were lost to foreign competitors.

We currently have several MultiForge machines at our forging facility and all tooling is cross-compatible via a quick-change system. Programming data can be stored and linked to each tooling set, enabling us to manufacture components on the automated production line as and when required with little downtime.

Brooks Forgings Replicate Special 12.9 Grade Tie Rods

Brooks Forgings Ltd — 27/11/2018

Brooks Forgings specialise in the manufacture of non-standard forged, fabricated and machined components. Our team of skilled operators welcome the engineering challenges that are often presented to us by our customers and their unique requirements.

A recent bespoke project was to replicate a special type of tie rod in grade 12.9 material for a new client in Europe.

We were supplied with a sample for analysis and discovered it was a 2 piece welded fabrication. Our extensive manufacturing capabilities enabled us to offer the component as a one piece item instead. By forging the eye and free flow forging the flat section, the material grain flow remains unbroken and produces a stronger, more resilient component when compared to its fabricated counterpart.

Due to the specific hardness range required, the components were machined and thread rolled M24x2 (fine pitch) prior to a clean heat treatment process.

All components were inspected for straightness after heat treatment and corrected (if required) prior to the final painting process. The final component measures just over a metre in length and a total of 600 were produced in the first batch.

Brooks Forgings Supply Hinkley Point C with Critical Foundation System Components

Brooks Forgings Ltd — 17/08/2021

EDF energy, at Hinkley Point C, is building two new nuclear reactors, the first in a new generation of nuclear power stations that will provide low-carbon electricity for up to six million homes. The new reactors will make a significant contribution to the UK’s initiative to reduce carbon emissions.

One of the main contractors for the project awarded Brooks Forgings with the contract to manufacture and supply a range of foundation bolting assemblies for critical groundworks, in preparation for the installation of various critical infrastructure systems on the Hinkley Point C project.

Believed to be amongst the first British manufactured fastening components supplied into the project, the bolting assemblies utilise the removable DIN 7992 hammerhead t-bolt design, of which Brooks Forgings are the only British manufacturer. Ranging from M24 up to M48 in varying lengths, the bolts locate into a fabricated tube assembly that is welded to BS EN 1090 execution class 2.

Nuclear safety is a priority and extensive quality certification and documentation were required. This included but was not limited to positive material identification (PMI), ultrasonic testing (UT), magnetic particle inspection (MPI), and full mechanicals including tensile, charpy impact tests. This was backed up by an on-site audit that required all documentation and finished components to be made available for inspection.

A total of 5 quality reports were compiled, one for each size/type of foundation bolt assembly. Totalling over 200 pages each, a physical copy was supplied along with fully searchable and bookmarked PDF files to assist in locating critical information swiftly if required.

Another unique aspect of the supply was the stringent packaging requirements. Supplied in FSC and ISPM15 compliant wooden packing crates, the components were not allowed to make physical contact with the wood during transit. To prevent this and minimise rust generation during storage, special Vapour Corrosion Inhibitor (VCI) bags were used to line the interior of the wooden boxes. A full packing procedure, 3D rendered component layout, and packing list for each box was designed by Brooks and supplied for approval.

The advantages of dealing with one manufacturer are evident throughout this project. By having in-house forging, machining, and fabrication capability that is approved to EN15048 and EN1090 execution class 3 we have complete control of production and can ensure all components meet the strict quality, testing, and traceability requirements specified.

Successful audits help Brooks to forge ahead

Brooks Forgings Ltd — 31/07/2013

Brooks Forgings Limited is pleased to announce it has been audited for and successfully obtained certifications in ISO 14001 for Environmental Management Systems and OHSAS 18001 for Health and Safety Management Systems.

This confirms that the protection of the environment and the prevention of pollution is of prime importance, and is essential to the successful operation of the business, and the well-being of future generations. Also, the promotion of good Health and Safety measures is a mutual objective for all management and employees at all levels.

For a copy of all Quality, Environmental and Health & Safety policies and certificates please visit our website www.brooksforgings.co.uk.

Brooks Forgings Ltd Launch New Website

Brooks Forgings Ltd — 09/12/2014

Brooks Forgings Ltd are proud to announce the launch of a brand new website.

We have made substantial investment to develop and transfer over to a fully responsive design, now supporting mobile, tablet and desktop platforms. Already regarded as one of the most extensive websites in the industry, we have taken this opportunity to improve user experience and offer further insight into our manufacturing capabilities.

Our manufacturing and product photo gallery is a new addition we are excited about, currently containing over 2000 images!

We have also added a comprehensive PDF library covering all of our processes and products, all downloadable for future reference from the media section of the website or directly from the appropriate product or process page.

We encourage people to visit our website and welcome any new business opportunities for 2015.

www.brooksforgings.co.uk

Brooks Forgings Fabricates Bespoke Post Tops For Prestigious Footbridge Project

Brooks Forgings Ltd — 21/11/2018

At Brooks Forgings we offer over 20 in-house manufacturing processes that enable us to produce a wide range of standard and fully bespoke components to customer requirements.

A recent order for a prestigious client involved producing a quantity of bespoke post tops to be used as part of a new footbridge project at an undisclosed location in the UK.

The post tops are fabricated using four separate components and when fully assembled stand at an impressive 1125mm tall and weigh around 175kg each.

The base measures 550x550x60mm thick and is fully machined with bevelled edge. The lower collar is machined from solid using a 380mm diameter by 300mm long billet. A 300mm diameter hollow sphere sits on top of the lower collar and is pre-machined to take the pointed top section that is machined from a 110mm diameter by 480mm billet.

Our skilled fabricators fully welded the assembled components to produce the łnished post top as shown in the photo.

Supplying 'Close Net' Forgings to UK Machinists and Fastener Manufacturers

Brooks Forgings Ltd — 11/06/2013

Brooks Forgings have increased production of upset forged blanks also known as uses at their manufacturing centre based in (Lye) Stourbridge, West Midlands.

By heating the bar and forging, the metal can be deformed to create a head, flange, or other shape at any position of the bar. In other words we move the metal to where it is needed

The Benefits to Machining & Fastener Companies:

Save up to 50% on material.

Improved machining cycle times.

Increase shop capacity as a result of reduced cycle times.

Better metal grain flow and strength.

Reduced material waste.

Reduced energy cost.

Reduced tool and tip cost, because of less material removal.

The Benefits to Drop Forging Companies:

Reduce pre-form operations and increased output.

Die cost and size reduced, by removing preforming impressions.

Less requirement to work away from centre-line of ram, reducing wear and stress on expensive components.

Reduced material waste.

Reduced energy cost, through reduced cycle times.

Please contact us today to discuss your requirements.

Brooks Forgings Ltd

BROOKS FORGINGS GROWS SHACKLE FORMING CAPACITY

Marposs Merlin Computer - Latest Addition To Brooks Forgings QC Department

Extensive Manufacturing Processes Help Secure New Orders and Ensure On-time Delivery

Specialised Traction Rods Keep Locomotive Refurbishment Project on Track

Special Forged Eye Bolts in ASTM A320 Grade L7 For Petrochemical Pressure Vessels

Brooks Forgings Expand Product Development & Tooling Design Services

1. 3D Design

2. 3D Printing  Additive Manufacturing

3. Stress Analysis

4. QForm Forging Simulation

5. Die Cutting & Sinking

6. Drop Forging

7. Machining

Brooks Forgings Completes Challenging Production of Hot Formed Ladle Lid Lifting Bridles

Horizontal Counterblow Forging - Low Production Cost for High Volume Forging in the UK

Heritage Replication for National Lottery Funded Jewellery Quarter Cemeteries Project

Brooks reinforce their future with CE and National Highway Sector Scheme approval

M90 Hammerhead T Bolts for New Fossil Free Kiln Expansion Project in Sweden

Collaboration between Brooks Forgings and W.H.Tildesley on prestigious forging project

DIN 7992 Hammerhead Bolt Manufacturing

Brooks Forgings Manufacture Heavy Duty Mooring Rings for Monaco Project

Brooks Forgings Certified for ISO 9001, ISO 14001 and OHSAS 18001 with Lloyd's Register

Brooks Forgings are proud to announce that they are now certified with the Lloyd's Register for ISO 9001, ISO 14001 and OHSAS 18001.

ISO 9001:2015 - Quality Management

ISO 14001:2015 - Environmental Management

OHSAS 18001:2007 - Health & Safety Management

Special Forged DIN 261 Hammerhead T-Bolts in Duplex Material For Subsea Project

BROOKS FORGINGS CELEBRATE 55TH ANNIVERSARY

Brooks Forgings Offer Increased Fabrication and Machining Capacity

Special Fabrication Keeps Expansion Of Waste Management Facility On Track

Forged Railhead Replication For Partick Pumping Station Restoration Project in Glasgow

Super Duplex Special Fasteners from Brooks Forgings

Brooks Forgings Produce Forged Components For The Union Chain Suspension Bridge Restoration Project

Investment in Data Collection Terminals Invaluable for Performance & Costing Improvement

Considerable new investment has been made at our production facility based in Lye, Stourbridge to further improve KPI (Key Performance Indicator) targets.

Brooks Forgings is the first company to be issued with ISO 9001, EN1090 and EN15048 by Lloyds Register.

75 TON ETCHELLS MULTIFORGE RETURNS TO THE HEART OF BRITISH MANUFACTURING AT BROOKS FORGING

Brooks Forgings Continue To Invest In Automated Technology

Brooks Forgings Replicate Special 12.9 Grade Tie Rods

Brooks Forgings Supply Hinkley Point C with Critical Foundation System Components

Successful audits help Brooks to forge ahead

Brooks Forgings Ltd Launch New Website

www.brooksforgings.co.uk

Brooks Forgings Fabricates Bespoke Post Tops For Prestigious Footbridge Project

Supplying 'Close Net' Forgings to UK Machinists and Fastener Manufacturers

2. 3D Printing Additive Manufacturing