Conbrako is an accredited ISO 9001 and a certiﬁed BBBEE Level 3 company with an annual turnover of R120-150 million. The Consolidated Brake Company, was formed in 1958, in Wadeville, Germiston, to manufacture and supply vacuum braking equipment to the South African Railways. In 1986 the renamed Conbrako was merged with the Railway Division of Dowson & Dobson and Klockner-Becorit Coalequip, which manufactured Air Brake equipment. The consolidated company relocated in 2001 to its present factory (11 000 m2 under cover on a 33 000 m2 site) in Chamdor, Krugersdorp.
Transnet and the South African rail industry remain the major customers of Conbrako. Various railway components manufactured are also exported to Kenya, Uganda, Tanzania, the Democratic Republic of Congo, Mozambique, Botswana and Zimbabwe.
Products Conbrako manufactures and assembles the following major products/categories:
⇒ Air and Vacuum brake equipment (cylinders, dirt collectors, cocks, valves, etc.).
⇒ Handbrakes and handwheels for locomotive and wagons.
⇒ Snubbers for locomotives , coaches and wagons.
⇒ Draw gears and couplers, including for East Africa.
⇒ Pressure vessels manufactured to ASME standards for railways and chemical industries.
⇒ Many other railway items.
⇒ Landmine detecting wheels for the US army in Afghanistan.
⇒ Various sizes of rotor and stator inserts to the mining industry for flotation cells. Conbrako employs some 150 staﬀ and performs the majority of its own machining and fabrication. We employ 2 qualiﬁed engineers, one is a PhD and an international welding engineer (IWE), and 9 qualiﬁed artisans experienced in various ﬁelds.
The facilities at Conbrako include:
⇒ Comprehensive tool room
⇒ Turning Shop.
– 18 CNC lathes up to 650mm swing, 4 with live tooling.
– Capable of machining small intricate parts to large 650mm wheels
⇒ Milling Shop
– 12 vertical CNC machining centers up to 2000mm bed, 8 with fully integrated 4th axis heads.
– 1 horizontal CNC machining centers with a working envelope of 508×508×508mm.
– 3 welding shops
– 2 automatic submerged arc seam welders capable of welding Cylinders up to 2m in length. Welding process is qualiﬁed by ASME IX to weld plates from 1.5 to 10mm.
– 4 automatic submerged arc welders capable of welding plates up to 6m in length.
– 12 welders certiﬁed to ASME IX.
– 10 non-certiﬁed welders.
– 5 Fanuc 6 degree of freedom robot welders. 2 robot welders are coupled with 2 axis manipulators and 400A power packs.
– 35 semi-automatic Panasonic MIG/CO2 welding machines
⇒ Material preparation – New 12 × 3.5m by 80mm thick high deﬁnition plasma cutting machine
– 2 guillotines capable of cutting 10mm mild steel.
– 4 automatic saws.
– 2 bending brakes.
– 14 eccentric presses.
– 5 hydraulic presses of which 2 are 500 ton presses.
– 4 roll CNC rolling machine capable of rolling 10mm thick by 2m wide plate; 3 roll manual rolling machine capable of rolling 16mm thick x 3m wide plate.
⇒ Production grinding up to 1m.
⇒ Sheet metal facilities.
⇒ Spray painting facilities.
⇒ 500 ton Compression / Tension test rig.
– Fully instrumented and calibrated test rig.
– The test rig was designed so that destructive / non-destructive tension and compression testing can be carried out on the premises.
– 1 × 4m bed size
⇒ New 2200m2 heavy fabrication facility under 2 oﬀ 20 ton cranes.
⇒ 650kVA diesel generator allows Conbrako to run at full capacity if there is no municipal power.
Conbrako ﬁrst achieved its ISO-9001 listing in 2007.
Conbrako utilizes, annually upgraded, modern technology such as robotic welding and the latest CNC machines.
Conbrako’s main strengths are machining, fabrication and welding.
Conbrako deals directly with Chinese foundries to import world class castings.
Conbrako uses various sub-contractors for heat treatment, electro-plating, hot dipped galvanizing, shot-blasting and special coatings, laser proﬁling, etc.
Conbrako has 7 commercial vehicles, from 3 to 32 tons payload to deliver all over South Africa.