Middle East Rail, Riyadh, 2014

Stephen CantwellHead of RailBRADKEN

RELIABILITY IN HEAVY HAUL

© 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

© 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

© 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, AUSOpened 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.

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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

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Major Customers

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MiningDesign, 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 ProductsUS based foundry and machining division manufactures highly engineered, large, mission critical steel castings for the construction, mining, defence, rail and transit industries

Mineral ProcessingDesign, manufacture and supply of high quality mill liners, crusher liners and engineered parts, both domestically and internationally.

RailDesign, manufacture and supply freight wagons, bogies, drawgear ;maintenance services; equipment leasing; Spare parts

© 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.

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GET & Buckets Wear Plate and Block

Mining Products

Crawler Systems Mineral Processing

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Mill Head SegmentCrawler 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

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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

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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

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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

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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

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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

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• 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

© 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

Thank You