BRITISHRAILHEADSRAILHEADSMADE-ONBARPOSTTOPS-PUNCHEDFLATSREPLICATION Heritage Range www.brooksforgings.co.uk | tel. +44 (0)1384 563356 | sales@brooksforgings.co.uk
Introduction 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. We are the Heritage Ironwork Replication Specialists... 7/56 hot forged directly onto bar to any length required. 14/60 hot forged directly onto bar to any length required. OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS1
Casting is a process where molten metal is poured into a mould, which contains a hollow cavity of the desired shape. The shape is created by pressing a physical sample into the sand, leaving a mirror impression of the original material. The moulds are single use but low cost.
These are featured in our full Artistic Catalogue containing over 1500 components, many of which are unique to Brooks Forgings. Do please contact us today to request our latest copy.
Casting is best suited for low volume replication. An impression is taken from a physical sample and railheads are cast using molten metal.
Casting
Alongside the components we produce here in the UK, we also over a comprehensive range of imported decorative components.
Forging is best suited to medium to high volume replication. Railheads can also be forged directly onto bar to create a clean one piece look with added strength and resilience.
+44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.ukBRITISHMADE Main Processes 2
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Hot Forging Forging is a process that manipulates the raw material stock into the desired shape or form. Blacksmiths have performed this process by hand for centuries. Present day forgers use special tooling for the forging process known as ‘forging dies’ that contain the impression of the final desired shape. This process achieves a clean and consistant component that requires no additional fettling.
13/22 hot forged directly onto bar to any length required. Cast railhead example. Not available for purchase.
Cast components often require additional fettling to remove seams and imperfections left by the process. The final component can also be brittle.
Heritage Projects OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS 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. Heritage Replication for National Lottery Funded Jewellery Quarter Cemeteries Project The main ‘top’ railhead on bar design ready for final supply. The ‘bottom’ design hot forged in 30mm hexagonal bar. 3
The ‘bottom’ underbar design ready for final supply. 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 via our client who completed the final fabrication and erection of the fencing on-site.
We were only provided with a couple of old drawings, one for the main ‘top’ railhead design and another for the ‘bottom’ underbar design. Our skilled engineers were able to recreate them in a digital format using the latest CAD software.
Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 4
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.
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.
From here, new modern production drawings and physical 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.
3D printed plastic samples were supplied for approval. Forging simulation is performed before any tooling is produced. Railheads in situ at the Jewellery Quarter. The fencing was fabricated and erected by our client. 3D Digital renders of the final approved design.
The balustrade consists of 2 separate designs produced using the same material, requiring tooling for 2 different head formations and 2 different base formations.
OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS
The Garden Bridge was a £175 million pound project to build a 366m-long ‘floating garden’ over the River Thames. Originally planned to begin in January 2016 it was set to become a world-class landmark, showcasing the UK’s expertise in design, engineering and landscaping. However, the project did not go ahead due to budget restraints.
Brooks Forgings in-house production and design team analysed the design and spent several weeks designing tooling to ensure the best quality component could be produced using the most effective manufacturing Itprocess.wascrucial that the profile of the material blended cleanly into the head and fluted base of the balustrade components with no mismatch or unclean edges.
Balustrade Prototypes For £175M London Garden Bridge Project
Heritage Projects
A total of 4 die sets were produced using the latest Solidworks CAD and CAM software. This allows the production of 3D models, product & tooling drawings and simulates both tooling and die cutting processes. In-house production team for tooling design and manufacture. Material is gathered using the horizontal upset forging process.
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Designers for the project had generated an ambitious design for the balustrade that would have spanned a total of approximately 1000 meters in various locations throughout the Conventionalproject. balustrade is typically produced from round or square material, however, the material chosen for this project had a ‘flower’ shaped profile. Selected to be aesthetically pleasing and in keeping with the theme of the project, it created several challenges in the manufacturing process.
The forged head design blends beautifully into the special bar. The fluted base in the final bent condition.
The fluted base in the final forged condition, ready for bending.
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The tooling was extensive and required on a short lead time. One of the largest tooling sets produced for a balustrade project! The 13 CNC machines at Brooks Forgings are WIFI enabled, allowing remote programming and problem-solving from the central control room by one of several technical engineers. The tooling for the project was created using this process, sent remotely to one of several vertical CNC machines for Theproduction.headdesigns are formed using 2 gathering processes (see below) and a final forming blow providing the distinctive shape. This is followed by a clipping process to remove any excess material. The fluted base is formed using 2 gathering processes and a final form using a die press tool. The stages of the forging process can be seen above.
Railheads 10/1 20mm180x45mm g Base 10/2 16mm120x25mm g Base 10/3 20mm170x43mm n Base 10/7 16mm150x38mm g Base 10/15 20mm200x20mm g Base 10/16 25mm220x25mm g Base 10/14 16mm150x16mm g Base 10/27 16mm150x16mm n Base 10/28 20mm200x20mm n Base 10/29 25mm220x25mm n Base 11/13 20mm190x54mm g Base 13/17 16mm170x40mm u Base 13/46 16mm170x30mm n Base OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS 10/4 20mm185x20mm g Base 10/13 12mm130x12mm g Base 10/26 12mm130x12mm n Base 10/18 16mm150x16mm g Base 10/17 12mm130x12mm g Base 7 RAILHEADS ARE MADE TO ORDER. HOT FORGED IN-HOUSE IN THE UK
10/23 16mm150x16mm g Base 10/24 20mm200x20mm g Base 10/25 25mm220x25mm g Base 13/18 20mm220x55mm u Base 13/21 25mm280x25mm g Base 13/22 20mm200x30mm g Base 13/20 16mm200x20mm g Base 13/40 20mm125x30mm g Base 13/42 20mm162x77mm g Base BRITISHMADE The railheads and railheads on bar featured in our Heritage range are hot forged here in the TheUK.highest quality materials are used by our skilled craftsmen to keep the designs of yesteryear alive for future generations to enjoy. 13/45 hot forged on bar at our UK factory. ONLY available from Brooks Forgings. 10/22 12mm130x12mm g Base 10/19 20mm150x20mm g Base 10/20 20mm200x20mm g Base 10/21 25mm220x25mm g Base Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 8 13/43 20mm136x74mm g Base
Railheads OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS 13/44 136x90x28mm30mm n Base 13/45 20mm200x80mm u Base 14/24 20mm150x48mm g Base 14/25 20mm175x40mm u Base 14/26 16mm140x35mm n Base 14/27 16mm150x36mm n Base 14/50 20mm230x60mm n Base 14/59 20mm135x20mm g Base 14/28 20mm155x27mm g Base 14/29 20mm75x23mm g Base 14/38 12mm145x40mm u Base 14/47 16mm200x28mm g Base 14/48 20mm200x38mm g Base 14/49 25mm200x46mm g Base 14/60 16mm150x28mm n Base 14/34 20mm150x20mm g Base 14/37 16mm95x30mm g Base 9 RAILHEADS ARE MADE TO ORDER. HOT FORGED IN-HOUSE IN THE UK 14/44 16mm120x16mm n Base Also available in 40mm Base 14/64
BRITISHMADE The railheads and railheads on bar featured in our Heritage range are hot forged here in the TheUK.highest quality materials are used by our skilled craftsmen to keep the designs of yesteryear alive for future generations to enjoy. 14/24 hot forged on bar at our UK factory. ONLY available from Brooks Forgings. 14/61 16mm150x38mm u Base 14/63 20mm140x20mm g Base 14/62 45mm150x48mm n Base 14/65 20mm190x25mm g Base 14/66 20mm150x20mm g Base 14/68 20mm100x40mm g Base 14/67 20mm205x40mm g Base 14/38 hot forged directly onto bar to any length required.14/48 hot forged directly onto bar to any length required. Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 10
Railheads OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS 14/85 22mm140x52mm n Base 14/87 20mm200x69mm g Base 14/88 16mm200x67mm n Base 14/83 25mm200x45mm n Base 14/84 22mm200x22mm g Base 14/86 20mm190x38mm g Base 14/69 16mm170x30mm n Base 14/74 25mm220x25mm g Base 14/70 14mm123x75mm n Base 14/75 16mm150x16mm g Base 14/76 25mm150x25mm g Base 14/80 25mm180x68mm g Base 14/79 35mm177x35mm n Base 14/81 20mm142x40mm g Base 14/82 12mm200x12mm n Base 14/71 20mm180x20mm g Base 14/72 22mm215x22mm g Base 14/73 25mm200x50mm g Base RAILHEADS ARE MADE TO ORDER. HOT FORGED IN-HOUSE IN THE UK 11
14/91 20mm130x20mm g Base 14/94 12mm95x36mm n Base 14/92 22mm200x32mm g Base 14/98 38mm171x38mm g Base 14/92 hot forged directly onto bar to any length required. 14/89 20mm210x20mm g Base 14/90 20mm130x45mm u Base 14/93 12mm100x24mm g Base 14/96 20mm125x28mm g Base 14/97 25mm175x25mm g Base 14/99 20mm150x30mm n Base BRITISHMADE The railheads and railheads on bar featured in our Heritage range are hot forged here in the TheUK.highest quality materials are used by our skilled craftsmen to keep the designs of yesteryear alive for future generations to enjoy. 13/42 hot forged directly onto bar to any length required. Only from Brooks. Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 12 14/100 20mm235x24mm g Base
Punched Bars OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS Plain Solid Punched - Diamond Holes u Code Bar Size Hole (100mmCentresgap) Suits ClearanceBarSize 23/1 30x8x2000mm 112mm 12mm u 23/2 40x10x2000mm 112mm 12mm u 23/3 40x12x2000mm 116mm 16mm u 23/4 50x10x2000mm 120mm 20mm u 23/5 60x12x2000mm 120mm 20mm u Plain Solid Punched - Square Holes g Code Bar Size Hole (100mmCentresgap) Suits ClearanceBarSize 23/6 30x8x2000mm 112mm 12mm g 23/7 40x10x2000mm 112mm 12mm g 23/8 40x12x2000mm 116mm 16mm g 23/9 50x10x2000mm 120mm 20mm g 23/10 60x12x2000mm 120mm 20mm g Plain Solid Punched - Round Holes n Code Bar Size Hole (100mmCentresgap) Suits ClearanceBarSize 23/11 30x8x2000mm 112mm 12mm n 23/12 40x10x2000mm 112mm 12mm n 23/13 40x12x2000mm 116mm 16mm n 23/14 50x10x2000mm 120mm 20mm n 23/15 60x12x2000mm 120mm 20mm n 23/16 30x10x2750mm 110mm 12mm n 23/17 40x10x2750mm 110mm 16mm n Plain Hollow Box Section Punched Code Bar Size Hole (100mmCentresgap) Suits ClearanceBarSize 23/20 60x40x2750mm 125mm 25mm u 23/21 50x25x2750mm 125mm 25mm n 23/33 50x25x2750mm 120mm 20mm g 23/34 50x25x2750mm 120mm 20mm n ALL OF OUR PUNCHED BAR IS MANUFACTURED IN-HOUSE HERE IN THE UK. This enables us to supply punched bar in custom lengths, thicknesses and hole centers in a choice of solid or hollow material. The punching pattern, size and spacing can also be varied along the same bar. Our standards are listed here but do let us know if you require a bespoke solution. 23/13 punched bar with 16mm diameter holes. Punched hollow box section for reduced weight. 13
BRITISH MADE 8/1 30mm n X 190mm 8/2 40mm n X 220mm 8/3 50mm n X 240mm 8/4 60mm n X 260mm 8/5 70mm n X 270mm 8/6 80mm n X 280mm 8/7 30mm g X 200mm 8/8 40mm g X 200mm 8/9 40mm g X 240mm 8/10 50mm g X 300mm 8/11 60mm g X 320mm 8/12 70mm g X 320mm 8/13 80mm g X 320mm 8/14 30mm g X 190mm 8/15 40mm g X 220mm 8/16 50mm g X 240mm 8/17 60mm g X 260mm 8/18 70mm g X 270mm 8/19 80mm g X 280mm 14/64 40mm g 215x72mm Post Tops POST TOPS ARE HOT FORGED IN-HOUSE USING TRADITIONAL METHODS. MADE TO ORDER. Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 14 8/20 30mm n X 190mm 8/21 40mm n X 220mm 8/22 50mm n X 240mm 8/23 60mm n X 260mm 8/24 70mm n X 270mm 8/25 80mm n X 280mm 8/10 post top hot forged at our UK factory. Special bespoke post tops for heritage project. Our range of post tops are fully hot forged at our UK factory. Just like our railheads and railheads on bar, we can also replicate existing designs using forging, casting or even fully machined Ourmethods.standards are listed here but do let us know if you require a bespoke solution.
Railheads On Bar 3/1 20mm 4/21 12mm 4/1 16mm 4/3 20mm 4/22 25mm 4/23 30mm 4/41 12mm 4/42 16mm 7/1 20mm 4/43 25mm 6/9 12mm 6/11 16mm 6/13 20mm 4/40 22mm 6/15 25mm 6/24 16mm 6/25 25mm 6/20 20mm 6/27a 16mm 6/27 20mm 6/27c 25mm 7/29 40mm 6/26 25mm Our 40mm 14/64 post top combined with the 20mm 6/27 railhead that is forged directly on the bar. Only available from Brooks. OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS15 RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
6/28 hot forged directly onto bar to any length required. 6/29 hot forged directly onto bar to any length required. BRITISH MADE Our 40mm 8/9 post top combined with the 16mm 6/28 railhead that is forged directly on the bar. Only available from Brooks. 6/28 16mm u 6/29 16mm 6/36 20mm 6/37 16mm u 6/38 20mm 6/39 20mm 6/40 20mm Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 16 RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
Railheads On Bar Our 40mm 8/2 post top combined with the 16mm 6/46 railhead that is forged directly on the bar. Only available from Brooks. OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS 6/45 20mm 6/44 16mm 6/46 16mm 6/84 12mm 6/85 16mm 6/86 20mm 6/87 25mm 6/48 20mm 6/47 20mm 6/49 12mm 6a/11 12mm 6a/12 16mm 6a/1 20mm 6a/13 25mm 6a/30 30mm 17 RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
7/25 hot forged directly onto bar to any length required. 7/27 hot forged directly onto bar to any length required. post top combined with the 16mm 6a/31 10mm 6a/20 12mm 6a/21 16mm 6a/7 20mm 6a/22 22mm 6a/23 25mm 6a/24 30mm 6a/25 40mm 6a/26 12mm 6a/27 16mm 6a/9 20mm 6a/28 25mm 6a/29 30mm 7/24 20mm 7/25 20mm 7/27 25mm u 7/30 20mm 7/28 20mm Our 40mm 8/15 post top combined with the 20mm 7/30 railhead that is forged directly on the bar. Only available from Brooks. BRITISH MADE Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 18 RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
7/33 20mm 7/38 20mm Railheads On Bar RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS 7/31 25mm 7/32 16mm 6/18 20mm 7/35 20mm 7/36 20mm 7/34 20mm 7/37 16mm7/34 hot forged directly onto bar to any length required. Only from Brooks. 19
7/39 22mm 7/40 20mm 7/43 22mm 7/45 20mm BRITISH MADE Our 40mm 8/9 post top combined with the 16mm 7/32 railhead that is forged directly on the bar. Only available from Brooks. 7/41 12mm 7/42 25mm 7/44 22mm 7/41 hot forged directly onto bar to any length required. 7/31 hot forged directly onto bar to any length required. Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 20 RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
7/47 16mm 7/46 20mm u 7/49 20mm 7/50 20mm 7/52 12mm 7/51 22mm 7/48 20mm 7/54 20mm Railheads On Bar Our 40mm 8/2 post top combined with the 16mm 7/47 railhead that is forged directly on the bar. Only available from Brooks. OUR HERITAGE RANGE IS MADE IN THE UK USING THE HIGHEST QUALITY MATERIALS21 RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
7/55 25mm u 8a/13 16mm 8a/15 20mm 8a/23 12mm 8a/24 16mm 8a/21 20mm 8a/25 25mm 8a/26 30mm 8a/17 20mm 8a/19 22mm 8a/30 12mm 8a/5 16mm 8a/7 20mm 8a/9 22mm 8a/31 25mm 7/47 hot forged directly onto bar to any length required. 8a/1 hot swaged directly onto bar to any length required. 8a/27 12mm 8a/1 16mm 8a/3 20mm 8a/28 22mm 8a/29 25mm Our 40mm 8/9 post top combined with the 20mm 7/49 railhead that is forged directly on the bar. Only available from Brooks. BRITISH MADE Tel: +44 (0)1384 563356 E-mail: sales@brooksforgings.co.uk www.brooksforgings.co.uk 22 7/56 20mm RAILHEADS FORGED DIRECTLY ON BAR TO YOUR REQUIRED LENGTH
Brooks Forgings Ltd, Doulton Road, Cradley Heath, West Midlands, B64 5QJ, United Kingdom www.brooksforgings.co.uk | tel. +44 (0)1384 563356 | sales@brooksforgings.co.uk
