Segments & SprocketsThe Widest Choice

A Company ofThyssenKrupp

BERCO S.p.A.

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BercoMoving Your Business Ahead

Leadership inUndercarriageFor about 90 years Berco’sleadership and research hasresulted in the greatestundercarriage value. Quality is the critical linkthat assures the maximumproductivity of yourmachine. No one hasinvested more than Berco to assure dependable High QualityUndercarriage. Bercostarts with the highestquality steel, then controlshardened depth along withother performance features. As a result Berco’sundercarriage is second tonone for extended wear lifeand value.

Getting the Most from your Undercarriage Since 1920 Berco hascontinued to innovate andimprove undercarriageperformance. High-qualitymaterials and carefulmanufacturing processesensure that Bercoundercarriage componentsare reliable, durable andwear at a predictable rate.Longer life and controllablewear mean that you get maximumundercarriage performanceat the lowest operatingcost. At Berco we call it “Best UndercarriageValue”

Berco Process ControlBerco builds value &durability into everyundercarriage component.Berco controls processescritical to durability andvalue, such as: design, rawmaterial, heat treating,manufacturing and becauseBerco has control overthese processes, our undercarriages wear ata predictable rate and canbe managed as a system.

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Segments & SprocketsThe Widest Choice

Berco SprocketsDeep induction hardened and excellenthardened depth pattern on entire toothprofile provide long wear life. Either fromcast steel or from hot forging, Bercosprockets guarantee maximum resistanceand durability even in the most severeapplications. Accurate machining of hubsand flanges provide perfectinterchangeability.

Your Best Undercarriage Value• Cast steel or hot forged steel for optimum

internal grain flow • Single Shot Induction hardening for high

surface hardness (HRC > 50)• Effective hardened depth 4÷10 mm for

HRC45 • Specific low alloyed boron steel (low

alloyed steel for cast version) for highhardenability

• Tempered to resist cracking and chipping• Optimized design to reduce stress

concentration areas• Hunting tooth design extends wear life• Accurate machining of the mounting

surfaces ensure best performance

The Widest Choice• Sprockets, sprocket rims and

bolt-on type• More than 600 different

configurations to match any chain orapplication

• For track-type machines ranging from 1 to 400 ton

• The choice of the leading OEMs

Customer Satisfaction Considering that more than 50% of yourmaintenance costs will go into maintainingthe undercarriage, it is not surprising thatBerco represents the best choice when thetime comes for the replacement. And thebest choice is confirmed by the largenumber of Satisfied Customers that Keep Choosing Berco

The Widest Choice• 3, 4, 5 and 6 teeth • More than 80 different segment groups,

to match any chain or application • For track-type machines ranging

from 8 to 110 ton• The choice of the leading OEMs

Berco SegmentsAre through hardened for improved wearresistance. High surface, depth and corehardness mean Berco segments providelong wear life, resistent to bending,breakage and maximum hardwareretention. The bolt-on design reducesyour machine downtime.

Your Best Undercarriage Value• Hot forged for optimum internal

grain flow • Through hardened for high surface

hardness (HRC > 50) and tough core(HRC 45)

• Specific low alloyed boron steel for highhardenability

• Precise design and accurate machiningof the mounting surfaces ensure bestperformance

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Adding Value to Our ProductsAdding value to Your Business

Making a Superior Product

Rapid prototyping

Stress analysis at extremetemperatures

3D modeling of a sprocket 3D modeling of a segment die FEM analysis of a forged sprocket

Electron microscope withmicroanalysis

Reliability Test on components(ex. rollers) are carried out todetermine life and performancein a variety of field applications.

Artificial Intelligence andVision techniques are currentlybeing developed toautomatically inspect 100% ofcomponents. This reducesdefects (ex. after forging orheat treatment) attributable tomanufacturing to almost zero.

Huge efforts are also devotedto the development of New Materials andimprovement of the Heat Treating Processes, toguarantee longer product lifeand Superior Products.

Having supplied leading OEMsfor decades, Berco’sEngineers and productspecialists can help you designand manufacture the rightundercarriage, using high techsoftware, tools and expertise.Berco can also help you reducedevelopment and engineeringtime, tooling expenses andfacility costs. Berco AddsValue not only to our productsbut also to Your Business.

It all begins in the design stage,Berco Research &Development engineersemploy state of the artcomputer design. The use of3D modeling and finite elementanalysis (FEM) allow us todesign and evaluate acomponent before it is built.

Our Rapid Prototypingenables Berco’s engineers tooptimize a design beforespending money in tooling.

Berco Metallurgy Laboratoryemploys advanced machinessuch as an electron microscopewith microanalysis, aspectrophotometer, tribometersfor wear tests, MTS presses forstatic and fatigue tests onmaterials and components.

Photo-elasticity and straingauge techniques arecommonly used for stress andfatigue analysis on individualand assembled components.

Stress analysis at extremetemperatures (-70°C ÷ 250°C)are also carried out.

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With a capacity of over 13,000 ton of finished product the BercoSprocket & Segment Department manufactures more than 160,000components per year. Segments. From the central warehouse the raw materials aretransferred to one of the automatic cutting & forging stations.Segments are then drilled and machined, while through hardeningcomplete the process.Sprockets. Both cast and hot forged (in a 32,000 ton press)sprockets are induction hardened on the entire tooth profile.Afterwards they are machined in vertical lathes and drilled indedicated machining centers. Final inspections of the productsguarantees the Total Quality of all components.

Automated Processes Automatic QualityThe entire production process isfully automated and computercontrolled via ComputerManufacturing Technologysystems. This guarantees highlyreliable processes and constantquality of the products.

The Right Product at The Right TimeA vast variety of raw materialand flexible manufacturing givethe competitive advantage ofshort lead times while matchingyour specific need. That’s what we also callCustomer Satisfaction.

Heat Treated to Treat You Even BetterQuality materials and state-of-art manufacturing are notenough to guarantee the qualityof the finished products. That’swhy the heat treating is carriedout making sure that all processparameters (temperaturegradients, time, quenchingtemperature, etc.) are constantlymonitored online. Hardeningupgrade mechanical propertiesfor superior wear resistance andlonger product life.

State of the Art ProductionState of the Art Components

Through hardening

Single Shot Induction hardening

Heat treating automated station

Sprockets machining

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We Care

Leadership in EnvironmentalDevelopment

Not only do we care about ourcustomers supplying qualityproducts manufactured under ISO 9001 certified processes, but also we care about theEnvironment.

Since Jan 2000 Berco is ISO 14001 certified and hasadopted EnvironmentalProcedures throughout the entiremanufacturing process. We havean Environmental Strategy andwe continuously check on theprogress made toward the setObjectives.

Getting More out of Less.Reduction of energy consumption,improved use of materials andminimization of waste, allows for alower impact on the environment. We have given preference toenvironmentally friendlytransportation like trains and boatsand we have begun redesigningour packaging in order to userecyclable materials. We havechanged our painting processesand now use environmentallyfriendly water-based paint, with areduction in the amount ofpollutant emissions. We haveadopted a closed loop coolingsystem that reuses the water fromour heat treatment processesinstead of emitting it into theenvironment.

Customer Service

We have a large dealer networkcovering 70 countries in theworld. They have been inbusiness for decades, theyknow the business and theyknow it from their customers’point of view. They understandcustomers’ needs and theyknow that their success is tied totheir customers’ successes.

We support our dealers with ourprofessional sales force. Wetrain them, we provide themwith the right marketing toolsand advanced technologicalsystems. We have developed acomputer based integratedsystem BOPIS (Berco OnlineProduct Information System)enabling a dealer technician touse a laptop computer from thefield to consult our databaseand easily find the right answer.

We back you, wherever youare. We work with our dealers toestablish a parts and servicepresence near you, in order toalways have the right product atthe right time in the right place.It is customer satisfaction thathas built our Berco TrackRecord.

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Leader in Quality

Leader in the Environment

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01003.WR411GB00C

BERCO S.p.A.

Via 1° Maggio, 23744034 Copparo (Ferrara) ItalyPhone +39 0532 864 111 Fax +39 0532 864 259www.berco.cominfo@berco.com

Your Berco dealer:

Published by Berco Communication Dept.

ISO 9001 Cert. n. 0029/5

ISO 14001 Cert. n. 0009A/3

All manufacturers’s names, numbers, symbols and descriptions are used for reference purposes only. All parts listed are of Berco original production.The specifications and processes described in this brochure are subject to change without notice

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