At Brafer’s two fabrication plants – one in Araucária (Paraná State) and the other in Rio de Janeiro, we fabricate steel structures using the latest technology available on the market, in both the production management and the operational area. Combining the two fabrication units, Brafer’s average production capacity is 4000 tons per month.

In order to manage the production we use a specially developed software for the metallurgical industries. The system integrates all the stages of project execution, from planning to shipping, ensuring the tracking of 100% of the materials used on each part and allowing for real-time monitoring of each project status.

Our fabrication sectors are prepared to manufacture parts from 1 kg to 100 tons using modern and safe equipment for the movement of materials with overhead cranes that have a capacity of up to 100 tons.

The cutting of the materials is 99% done on CNC machines with high definition plasma, which guarantees the perfect geometry and finishing, within strict fabrication tolerances. The machines feature plasma and oxy-fuel cutting with a capacity of up to 4” (100 mm) in thickness; the holes are made with special high-performance drills.

The shaping of the materials is performed internally in 800-ton press brakes, in a variety of sections. Subsequently, folded profiles are bored and engraved with CNC machines. The assembly and welding at Brafer is performed by welders qualified by the AWB standard, and the ABS and DNV offshore certification standards.

This team has mig/mag, flux-cored wire, coated electrode, submerged arc and electrofusion welding equipment. Additionally, we have a line for fabrication transmission towers, substations and mobile telephony with a capacity of 900 tons equipped with several machines for the cutting of CNC angle brackets with capacity for L 8” x ¾”.

For this type of contract there is an area provided with a crane for carrying out the pre-assemblies on project validation. The sum of all this makes Brafer a modern company with high quality products, in line with the expectations of our customers.

Welded Profiles Factory

With a production capacity of 900 tons/month, at Brafer’s welded profiles factory all the sheets are prepared for cutting (oxyfuel) through shot blasting with an automatic jet for the cut to be perfect. The shot blasting is also necessary in order to avoid discontinuities in the submerged arc welding process (SAW).

The assembly of the profiles is performed on a bench with a capacity for profiles of up to 2500 mm in height and 700 mm in width, with a maximum weight of 20 tons. The process of submerged arc welding is very efficient, depending on the specifications of the customer full penetration and fillet welding is performed. All the profiles are straightened in a specific machine. After the straightening, an inspection process is performed on the profiles according to the NBR 5884 standard.

Equipment involved in the process:

Sinto Automatic jet (shot). (1x) Oxyfuel Cutting Bench. (1x)

Submerged arc welding equipment. (2x) Cutting and Drilling Besides the profiles factory, the sector has a complete and modern line of CNC machining which serves the process of cutting, drilling, engraving, and trimming on bars of laminated and welded profiles with dimensions of up to 1200x600x15000 and a total weight of 4500 kg per processed part.

On the machines, the parts are produced automatically with a measurement system using tongs with a servomotor for measurements with very strict tolerances. The drills feature 3 lines of drill bits positioned to make holes of up to 40 mm in the edges and cores of the I, H, PS, U beams, angle brackets, sheets and square and rectangular tubes. The drill bits used can be of high-speed structural steel or solid carbide drill, which allows for drilling with bigger feeds. The computing resources are integrated with Engineering and Planning through a management software that combines productivity and accuracy ensuring the product quality.

This sector also features a finishing and final inspection process of the parts to be dispatched, the remainder being self-inspected throughout the fabrication process by operators properly trained for the task.

Production Capacity: 1200 tons per month

Equipment involved in the process:

Saw (2x)

Drill (2x)

Drill and Saw (1x)

Robot (cutting and trimming) (1x)