BHORUKA FABCONS PRIVATE LIMITED

PARTS SUPPLY BROCHURE

1. Aluminium Manufacturing Chain Page 2

2. Metro

o Metro Parts Page 3 o Metro Interior - Exterior Extrusion Profiles Page 4 – 5o Metro Coach Gangways Frame & Parts Page 6 – 8o Metro Coach Side Wall Panel Page 9o E-Loco Driver Cabin Lateral Window Page 10o BFPL Supplied Metro Rail Projects Page 11o Sessaklein – BFPL Introduction Page 12

3. Automotive

o Side Footstep for SUV’s & MPV’s Page 13o Window Frames for Commercial Vehicles Page 14o Window Frame – Bus Page 15o Windshield Frame for Defence Vehicle Page 16o Roof Rails – Passenger Cars Page 17

4. Electric Vehicles

o Electric Battery Enclosures Page 18o E-Rickshaw Project Page 19

5. Aerospace

o Aluminium Housing for Aircraft Lighting Page 20

CONTENTS Page 1

CONTENTS

6. Project Based Applications

o Radiant Cooling Baffles for Buildings Page 21

o Automatic Doors Page 22o Shutter Profiles Page 23

7. Textile

o Roving Deflecting Tubes Page 24 o Tubes Fit in Textile Machinery Page 25

8. Pneumatics

o Parts for Industrial Air Dryer Products Page 26

9. Electrical

o Heat Sink for LED Street Lightings Page 27

10. Packaging

o Columns for Packing Machinery Page 28

11. Renewable Energy

o Machined Parts for Wind Electric Generators Page 29o Machined Parts for Ropeways Page 30

12. Esteemed Clients Page 31 – 32

ALUMINIUM MANUFACTURING CHAIN Page 2

ALUMINIUM MANUFACTURING CHAIN

Smelting (Primary

Production)

Extrusion(Secondary Production)

Engineering &Value Addition

Primary Aluminum ProductionFoundry

Extrusion

Anodizing

Powder Coating

Machining

Project Management

SPM

Sub Assembly

Designing

Tools &Fixture

METRO Page 3

METRO PARTS

Metro Parts: Threshold Plates Floor Coveings Glass Bracket Door Pillar Profile Rain Gutter External Body Cover Latch Profile Side Wall Weather Strip Moulding GRP Lining Clamp Air Grill Profile Lateral Ceiling Profile GRP Lining Clamp Bracket GRP Panel Locator Bracket Strip Guide Rubber Carrier Profile E-Loco Driver Cabin Lateral Window

Technical Details: Materail Grade: 6063, 6060 Finish : Anodized, Powder Coated or Mill Finish Supply goes in sets or combination of various profiles

as project managment.

METRO Page 4

METRO INTERIOR – EXTERIOR EXTRUSION PROFILES

METRO Page 5

METRO INTERIOR – EXTERIOR EXTRUSION PROFILES

METRO Page 6

METRO COACH GANGWAY FRAMES & PARTS

Gangway Fit in a Metro

Gangways In Application

Metro Parts:

Gangway Frames VMP Hoop Faceplate Frame Parts Clamp Plate Clamp Strips Linking Plate

Technical Details:

Materail Grade: 6063, 6060, 6005 Material Temper: T4 & T6 Part supply involve straight parts, bend

parts & welded frames Finish : Powder Coated & Mill Finish Supply goes in sets or combination of

various profiles as a project managment

Gangway Frame Gangway

METRO Page 7

METRO COACH GANGWAY FRAMES & PARTS

Welded and Powder Coated Parts

METRO Page 8

METRO COACH GANGWAY FRAMES & PARTS

Part Application:

Gangways are connecting system used to connect one coach to other coach of Metro/Rail coaches. The gangway frames and parts supplied helps easy assembly in application and we act as one stop solution provider for these parts being major focus on transport industry

Facility Highlights:

Welding: EN 15085 – CL2 Certified Have certified welders Equiped with TIG,MIG & Arc Welding

Machines Welding fixtures are in place

Bending : Manual Bending Machine CNC Bending Machine Capable to bend customised profiles

Few Extrusion Profiles

METRO Page 9

Technical Details: Aluminium sheet metal grade

5052 H32 Dimension: 3.6 Mtr x 1.7 Mtr Liquid spray painting -- Salt

spray resistance test upto 1000 Hrs

Application:Side wall interior trim panel for Metro coach

METRO COACH SIDE WALL PANEL

Scope of Work: Re-engineering of the existing

GRP Panel to Aluminium Panel

Study of manufacturing feasibility, selection of material and fabrication methods

Tooling development, laser cutting, forming, bending, TIG welding, painting and assemblyFinal Part in Metro Coach

Pictorial View Final Ready Part

METRO Page 10

Technical Details: Fixed and movable frame

developed in Mild Steel Movable frame deep draw

forming Glued window Validation against IP X4 –

sealing effectiveness againstmoisture ingress.

Glued window validation against resistance to disengagement of glass

Application:Driver Cabin Lateral Window for Electrical Locomotives

Scope of Work: BFPL provides complete

scope of product development which includes raw material procurement, component manufacturing, fabrication, assembly and validation.

Pictorial View Final Ready Part

E-LOCO DRIVER CABIN LATERAL WINDOW

Final Part in E-Loco Driver Cabin

METRO Page 11

BFPL SUPPLIED METRO RAIL PROJECTS

FEW BFPL CATERED METRO PROJECTS

METRO Page 12

SESSAKLEIN – BHORUKA FABCONS PVT LTD INTRODUCTION

It gives us great pleasure in announcing the comingtogether of two innovative companies – SessaKlein andBhoruka Fabcons Pvt Ltd (BFPL) – to serve the growingtransport segment In India, especially the rolling stockindustry (Metrorails)

India is one of the fastest growing economies in the worldtoday, and many MNC’s are setting shop in India.Companies are not only manufacturing for India, but alsoserving the overseas market from India. The industrialenvironment and market size makes it an opportune timeto set up the best manufacturing technologies.

Sessa Klein is widely recognized as the best designer andproducer of windows for rolling stock passenger coacheslateral windows and driver cab side windows. The companyis based in Castronno, Italy, not far away from MilanMalpensa Airport. BFPL is a leading downstream player inthe aluminium products supplying various components tothe metrorail and automobile sectors.

The expertise of SessaKlein and the manufacturing set upof BFPL presents a great opportunity for supply of highquality window systems for rolling stock in India.

Windows for Rolling Stock Passenger Coaches

AUTOMOTIVE Page 13

Technical Details: Al Material Grade – 6063 T5 Finish – Mill Finish Part Weight – 3 Kgs Length – 1.78 Mtr Assembled along with Plastic

Application:Side Foot Step for SUV’s & MPV’s

Advantages: Leight Weight Corrosion Resistant Can suit all SUV / MPV vehicles

by changing the length and mounting points.

Forms the primary skeletal structure to hold the plastic assembly of the footrest

Enhances load bearing of the plastic assembly

Pictorial View Machined Part

Finished Part With Plastic Assembly

Product in SUV

SIDE FOOT STEP FOR SUV’s & MPV’s

AUTOMOTIVE Page 14

Technical Details: Al Material Grade – 6063 T4 Finish – Powder Coating

(Matt Black) Part Weight – 0.6 Kgs Length – 1.8 Mtr Assembled along with catch

plate (casting part)

Application:Driver back side window in Commercial truck.

Advantages: Light Weight Ease in Handling Aesthetically good Slotting holes given for

floating of water as a drain slots

Sliding and fixed glasses will be verified with different dimensions during extrusion process only

Ease in Material movement.

Finished Part With Glass Assembly

WINDOW FRAMES FOR COMMERCIAL VEHICLES

Profile

Aluminium Machined Part Product in Transportation Vehicle

AUTOMOTIVE Page 15

WINDOW FRAMES - BUS

Part Before Powder CoatingPictorial View Machined Part

Part After Powder Coating End Application – 9 T Bus

Application:Window Frames for 9T School Bus

Technical Details: Material Grade: 6063 T6 Finish: Powder Coating 1 Combo Set = 15 Frames Child Parts: Brackets, Catch

Plate, Screws and Rivets

Scope of Work: Angular Cutting Bending Slot Punching Drilling & CSK Assembly TIG Welding Powder Coating

AUTOMOTIVE Page 16

Technical Details: Al Material – 6061 T6 Finish – Mill Finish Part Weight – 4.2 Kgs Length – 1.78 Mtr Assembled along with Glass Involves Bending and Welding Can be done with 5xxx grade

sheet metal also

Application:The product is used in defence vehicles as a front side window frame. This Frame is being assembled with toughened glass and protects from outer elements and acts as a safety guard also.

Advantages: Light Weight Corrosion Resistant Ease In Assembly Ease in material movement Strong Protection GuardPictorial View

Design and Final Part

Product in Defence Vehicle

WINDSHIELD FRAME FOR DEFENCE VEHICLE

AUTOMOTIVE Page 17

Application:Roof Rails for Passenger Cars

Technical Details:

Materail Grade: Aluminium 6060, 6063 Material Temepr: T5 & T6 Finish: Powder Caoted Color: Black Color [RAL 9005] Coating Thickness: 60 to 90 Microns Cutlengths: Vary from 827 to 1450 mm

Scope of Work: Involves straight as well as angular cutting

of parts Carry multiple drilling of mounting holes Can supply parts in ‘Straight’ and ‘Bend’

condition

Facility Highlights: Dedicated production line for roof rail

production Development of SPM for Cutting, Linishing

& Bending Separate dedicated team to handle roof

rail production.

ROOF RAILS – PASSENGER CARS

Parts In Passenger VehiclesFew Extrusion Profiles

ELECTRIC VEHICLES Page 18

ELECTRIC BATTERY ENCLOSURES

Aluminum Enclosure Profile Profile in Assembly View

Product in Three Wheeler Application

Application:Battery enclosures for two and three wheelers with quick interchange option at EV Swapping Stations.

Technical Details: Material Grade – 6063 T6 Finish - Anodized Coating Life - Minimum 10

yrs Part Weight - 0.810 Kgs

Advantages: Small & Light Weight Corrosion Resistant Ease of Assembly Optimal Heat Dissipation Robust and Swappable

ELECTRIC VEHICLES Page 19

E-RICKSHAW PROJECT

Pictorial View E-Rickshaw Body Frame

Scope of Work:Converting the existing steel chassis of electric rickshaw to aluminium for weight reduction and in the process optimize the design

Project Stage: Designing

Design Optimisation Stage Wise Approach:Phase 1 – Chassis Welding AssemblyPhase 2 – Middle Structure AssemblyPhase 3 – Top StructureAssemblyPhase 4 – Plastic Parts, Foam & Aesthetical Parts.

AEROSPACE Page 20

Application: Housing for lighting system in the aircraft lights such as commercial jets. It serves as a heat sink to dissipate heat generated in the system

Technical Details: Product : Aluminium Housing Materail Grade : 6063 T5 Cutlength : 163 mm Finish : Chemical Conversion

Coating Involves Helicoil Assembly

Advantages: Resistance to extreme weather

conditions Chemical conversion coating

provides better corrosion resistance which serves in reliable electrical connections to the system

Reduced maintenance and operating costs

Effective heat dissipation

Machined Part With Helicoil Assembly

Extrusion Profile

Helicoil & Insertion Tool

ALUMINIUM HOUSING FOR AIRCRAFT LIGHTING SYSTEM

Aircraft Lighting System

PROJECT BASED APPLICATIONS Page 21

Technical Details: Al Material Grade – 6063 T6 Finish – Powder Coating Length – 3 to 6 Mtr Assembled with end caps

Application:Radiant cooling system to maintain room temperature and hence avoid green house emission gas. Cold Water is pumped through nozzle of the aluminium baffles. Below the baffles conventional cooling fans are installed and when fans are operated cooled air is circulated in the room.

Advantages: 30% more efficient than

conventional cooling systems Environment friendly Higher air quality as no recirculation

needed Power saving Lesser maintenance Longer life Aesthetically good

Aluminum Machined Part

Finished Part With Surface Treatment & Plastic Closure End Caps

Product in Customer Campus

RADIANT COOLING BAFFLES FOR BUILDINGS

PROJECT BASED APPLICATIONS Page 22

Technical Details: Al Material Grade – 6063 T5 Finish – Anodising Length for Header – 3 Mtr to

6.30 Mtr Length for Glass Clamps – 1.1

Mtr to 1.5 Mtr Supporting components

material includes SS, rubber, fastners.

Application:Automated Sliding Door System for Office Buildings, Home Centres, Warehouses, etc.,

AUTOMATIC DOORS

BFPL Value Addition – Extrusion to Assembly

Extrusion +

Anodizing +

Machining

Manufacture and

Assembly of

Supporting

Components

Assembly of

Electrical and

Electronic

Components

Final Assembled

Door

Product in Building

PROJECT BASED APPLICATIONS Page 23

Technical Details: Al Material Grade – 6063 T5 Finish – Anodised or Powder

Coated Length – As per Requirement

Application:Security Shutters for commercial, residential, counter and special applications

Advantages: Different finish and length

requirements as per customer needs.

Corrosion resistant Matching for fitment between

each part and ease of rolling. Perforated shutters can be

provided as per needs

Different Shutter Profiles As Per Needs

Residential Shutters

SHUTTER PROFILES

Commercial Shutters Special Application ShuttersCounter Shutters

TEXTILE Page 24

Technical Details: Materail Grade: 6063 T6 Finish: Anodized Color: Silver Color 10-15Microns Coating

Thickness Every tube is linished before

anodizing Ovality : within 0.5mm Smooth Surface Finsih Cutting after anodizing Cutlengths : ~1650mm

Application:Roving Deflecting tubes are used in Ring Spinning Textile Machines. These machines are used to convert natural and manmade fibers and their blends into yarns.

EXTRUSION PROFILES – ROUND TUBES FINISHED TUBES

TUBES LINISHING SETUP

ROVING DEFLECTING TUBES FOR TEXTILE MACHINERY

TEXTILE Page 25

TUBES FIT IN THE SPINNING MACHINES

TUBES FIT IN TEXTILE MACHINES

PNEUMATICS Page 26

Finished Parts Extrusion Profiles Machined Parts In Assembly Process

Parts in Product Application

Application: Parts are used in Compressed Air Treatment

Products [Air Dryer Products] which are used to ensure the availability of quality air for various applications in the industries.

Air Dryer Products are used in various industries such as automobile, engineering, metallurgy, power, medical, coating & railways

Products: Tower Pipe [6 Ear tube] of DrySpell Top & Bottom Mounting Chamber [E- Block]

of Dryspell

Technical Details:

Materail Grade: 6063 T6 Cutlength: Vary from 180mm to 1580mm Finish: Powder Coated Color: White & Munsald Grey Coating Thickness: 80 to 120 Microns Powdercoating involves masking of threads After powder coating threads correctness

reensured with thread plug gauge

Advantages:

Bhoruka Fabcons supply parts in complete finished condition to the customer ensuring parts can be taken directly for assembly.

PARTS FOR INDUSTRIAL AIR DRYER PRODUCTS

ELECTRICAL Page 27

Technical Details: Al Material Grade – 6063 T6 Finish – Anodizing Part Weight – 4.82 Kgs Length – 480 mm

Application:Heat Sinks for Street Light Applications

Advantages: Ready to assemble form Forms the primary skeletal

structure to hold the LED assembly

Low carbon footprint Precision finished as per

customer requirements.

Pictorial View of Machined Heat Sink

Machined Part

Product in LED Street Lighting

HEAT SINK FOR LED STREET LIGHTINGS

PACKAGING Page 28

MACHINED PART

Application:The product is used in tailor-made packaging machines [‘form, fill and seal machines’ for flexible pouch packing]. These machines are used in various industries such as confectionery and dry or liquid food industries,pharmaceutical industry, medical devices few to mention.

Technical Details: Product: Column Materail Grade: 6063 T6 Finish: Anodized Color: Silver Color

[15Microns Coating Thickness]

Rolled threads Machining after anodizing Weight: 9.04 Kgs/M Part Weight: ~ 14 Kgs

COLUMNS FOR PACKING MACHINERY

EXTRUSION PROFILE

PART IN PACKING MACHINERY

RENEWABLE ENERGY Page 29

Application:These products are used in various capacity Wind Electric Generators and Ropeway Transportation Systems

Technical Details: Rotor Parts Stator Parts Material Grade : 6063 T6 Finish : Mill Tapping done on cross section

area Every part ensured for minimum

hardness of 70 BHN

Wind Electric Generators

MACHINED PARTS FOR WIND ELECTRIC GENERATORS

Stator Cooling Fin In Wind Turbine

Rotor Profile Stator Profile

RENEWABLE ENERGY Page 30

Machined Part

Extrusion Profiles

Ropeways

MACHINED PARTS FOR ROPEWAYS

ESTEEMED CLIENTS Page 31

ESTEEMED CLIENTS Page 32

Bhoruka Fabcons Private Limited

Address Factory and HO:

#427E, Hebbal Industrial Area, Mysore – 570016

Karnataka, India.

Phone: 0821 – 2415290 / 2510351

E-mail: marketing@bhorukafabcons.com

Website: www.bhorukafabcons.com

Marketing Contacts

Bangalore: +91 9632878822

Pune: +91 7219022888