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03/ 05Sheet Metal

Ducts, chutes, chassis and heavy steelwork

Industrial ducts and transitions, chutes, feeders and shakers, machine chassis and platforms, and welding repairs to heavy parts — designed, cut, rolled, welded and painted in our own two factories in Egypt.

  • Ducts & chutes
  • Feeders
  • Chassis
  • Welding repairs
Image Gallery Fabrication Catalog In Action Videos
ISO 9001:2015Made in EgyptStainless & 310 heat-resistant
Ducts, chutes, chassis and heavy steelwork — EL Badr Industries Ducts, chutes, chassis and heavy steelwork — EL Badr Industries Ducts, chutes, chassis and heavy steelwork — EL Badr Industries
50 Industrial clients
19+ Years in metal manufacturing
6000 mm Longest crusher rotor rebuilt
ISO 9001 Certified since 2008
The process

From 3D model to the truck

A duct, a hopper or a chassis goes through the same eight steps in our fabrication shop — and nothing is cut until the drawing adds up.

  1. Design & load calculation

    Every chassis, duct and hopper is modelled in 3D first, with its loads, stresses and flat patterns worked out before a plate is cut.

    See it in the catalog

  2. Cutting

    Plate and sheet cut to the unfolded pattern, holes and flanges marked out.

  3. Rolling & forming

    Shells rolled, cones and transitions formed, elbows built up segment by segment.

    See it in the catalog

  4. Welding

    CO₂/MIG, argon TIG and oxy-acetylene — carbon steel, stainless and heat-resistant 310.

    See it in the catalog

  5. Machining

    Flanges faced, bearing seats bored and holes drilled on our own machines, so parts bolt up first time.

  6. Grinding & sandblasting

    Welds dressed and surfaces blasted clean for the coating.

    See it in the catalog

  7. Painting

    Primer and top coat in the customer's colour.

    See it in the catalog

  8. Loading & installation

    Lifted by our overhead cranes onto the truck, and installed on site where needed.

    See it in the catalog
At a glance

Everything we fabricate

The bigger the words, the more of it you will find photographed further down. Tap any one to look it up in the index.

Index

27 things we fabricate and repair

Made to your drawing, your sample or your site measurements. Search the list, or tell us what it has to do and we will design it.

Ducts & air handling

  • Industrial ducts & duct sections
  • Segmented duct elbows
  • Eccentric & concentric reducers
  • Double cone & conical transitions
  • Diverter valve housings & Y-pieces
  • Centrifugal blower housings — repair

Material handling

  • Material transfer chutes
  • Feeders & hoppers
  • Vibrating raw material shakers
  • Screw conveyor flights & special augers
  • Raw material wagon boxes
  • Stainless kneader blades

Chassis & structures

  • Machine chassis & base frames
  • Crusher chassis & platforms
  • Clinker cooler treadmill chassis
  • Stairs, walkways & handrails
  • Piling rig & heavy machine bodies — repair

Process equipment

  • Calciner burners in 310 heat-resistant stainless
  • Formed parts for spiral pipe mills
  • Ceramic tile centering units
  • Tanks, covers & guards

Welding & repair

  • Argon (TIG) welding
  • CO₂ / MIG welding
  • Oxy-acetylene welding
  • Cold spray & metal spraying
  • Crusher rotor rebuilds
  • Stainless & heat-resistant steel work

photographed in the catalog below

Catalog

Fabrication work, photographed

35 photos from our shop floor. Tap any tile to see it full size.

Industrial duct for a cement plant — Large-bore duct sections and elbows rolled, welded and assembled — built entirely in our shop to the plant's specification. Industrial duct for a cement plant Large-bore duct sections and elbows rolled, welded and assembled — built entirely in our shop to the plant's specification. Double cone transition — Two cones joined at a flanged throat — from the unfolded drawing to polished steel. Double cone transition Two cones joined at a flanged throat — from the unfolded drawing to polished steel. Eccentric reducers — Offset reducers made to order, pairing two duct sizes without a pocket for dust to settle. Eccentric reducers Offset reducers made to order, pairing two duct sizes without a pocket for dust to settle. Stainless steel duct elbow — A segmented 90° elbow, every seam welded and the flanges drilled to match. Stainless steel duct elbow A segmented 90° elbow, every seam welded and the flanges drilled to match. Diverter valve housing · design — The Y-piece body of a diverter valve, drawn first so every flange lines up. Diverter valve housing · design The Y-piece body of a diverter valve, drawn first so every flange lines up. Diverter valve housing · finished — Switches material or air between two lines — welded in stainless, flanges faced. Diverter valve housing · finished Switches material or air between two lines — welded in stainless, flanges faced. Material transfer chutes — Flanged transfer chutes for a gypsum plant, fabricated and primed. Material transfer chutes Flanged transfer chutes for a gypsum plant, fabricated and primed. Calciner burner — Oil-firing equipment for a cement plant calciner, made entirely from heat-resistant 310 stainless. Calciner burner Oil-firing equipment for a cement plant calciner, made entirely from heat-resistant 310 stainless. Special screw conveyors — Screw flights for water treatment plants, rolled and welded onto their shafts. Special screw conveyors Screw flights for water treatment plants, rolled and welded onto their shafts. Formed parts for spiral pipe mills — Curved sheet metal parts for one of the region's largest spiral pipe makers — design to finished part. Formed parts for spiral pipe mills Curved sheet metal parts for one of the region's largest spiral pipe makers — design to finished part. Raw material shaker · in the shop — A vibrating raw material shaker for a ceramic plant, on the floor under our overhead crane. Raw material shaker · in the shop A vibrating raw material shaker for a ceramic plant, on the floor under our overhead crane. Raw material shaker · finished — The shaker deck on its red stand, painted and ready to ship. Raw material shaker · finished The shaker deck on its red stand, painted and ready to ship. The team behind the shaker — The engineers and fabricators who built it, with the finished machine. The team behind the shaker The engineers and fabricators who built it, with the finished machine. Feeder hopper for a ceramic plant — A feeder designed and built to the plant's specification, standing in our yard at night. Feeder hopper for a ceramic plant A feeder designed and built to the plant's specification, standing in our yard at night. Feeder · under construction — Plates welded into the hopper on its steel legs, sparks still flying. Feeder · under construction Plates welded into the hopper on its steel legs, sparks still flying. Feeder · handed over — The finished feeder with the team that built it. Feeder · handed over The finished feeder with the team that built it. Feeder · on site — Standing in daylight outside the factory, ready for its conveyor. Feeder · on site Standing in daylight outside the factory, ready for its conveyor. Clinker cooler treadmill chassis — Assembly, welding, grinding, sandblasting, painting and loading — a cement plant cooler chassis, stage by stage. Clinker cooler treadmill chassis Assembly, welding, grinding, sandblasting, painting and loading — a cement plant cooler chassis, stage by stage. Crusher chassis · design — A crusher platform modelled in 3D, with the stresses and strains calculated before cutting. Crusher chassis · design A crusher platform modelled in 3D, with the stresses and strains calculated before cutting. Crusher chassis · the full structure — Columns, platform, stairs and handrails — the whole frame checked on screen first. Crusher chassis · the full structure Columns, platform, stairs and handrails — the whole frame checked on screen first. Crusher chassis · built — The same chassis installed on site with the crusher sitting on top. Crusher chassis · built The same chassis installed on site with the crusher sitting on top. Wagon box · 1 — design — A raw material wagon box for a cement plant, modelled and numbered part by part. Wagon box · 1 — design A raw material wagon box for a cement plant, modelled and numbered part by part. Wagon box · 2 — manufacturing — Plates cut, drilled and welded into the box on the shop floor. Wagon box · 2 — manufacturing Plates cut, drilled and welded into the box on the shop floor. Wagon box · 3 — finished — Primed and ready to go back on the wagon. Wagon box · 3 — finished Primed and ready to go back on the wagon. Crusher rotor, 6000 mm — A 6 m × 1 m cement crusher rotor rebuilt by cold-spray welding, then re-turned and its bearing seats restored. Crusher rotor, 6000 mm A 6 m × 1 m cement crusher rotor rebuilt by cold-spray welding, then re-turned and its bearing seats restored. Metal spraying — Building a worn journal back up by spraying, before it is machined to size. Metal spraying Building a worn journal back up by spraying, before it is machined to size. Spraying a roll — A roll surface restored on the lathe — cheaper and faster than a new one. Spraying a roll A roll surface restored on the lathe — cheaper and faster than a new one. TIG weld bead — Argon (TIG) welding on stainless — a clean, even bead. TIG weld bead Argon (TIG) welding on stainless — a clean, even bead. Pipe butt weld — A full-penetration weld joining two pipe sections. Pipe butt weld A full-penetration weld joining two pipe sections. Fillet weld on a bracket — A structural fillet weld on heavy plate. Fillet weld on a bracket A structural fillet weld on heavy plate. Circular seam — A ring seam laid around a flange, pass after pass. Circular seam A ring seam laid around a flange, pass after pass. Hub repair — Welding up a worn hub before it goes back on the lathe. Hub repair Welding up a worn hub before it goes back on the lathe. Stainless pipe joint — A TIG root and cap on a stainless pipe fitting. Stainless pipe joint A TIG root and cap on a stainless pipe fitting. Multi-pass joint — Heavy section welding, each pass shown in the heat tint. Multi-pass joint Heavy section welding, each pass shown in the heat tint. Weld on a turned part — Welding and machining under one roof, so repairs come back to size. Weld on a turned part Welding and machining under one roof, so repairs come back to size.
On film

Steel, cut and welded

Straight from our Facebook page — press play on any of them.

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Building a clinker cooler chassis Every stage of a cement plant's cooler treadmill chassis, from assembly to loading. Open on Facebook
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Cold-spray repair of a 6 m crusher rotor A 6000 × 1000 mm cement crusher rotor rebuilt by cold spraying and re-turned. Open on Facebook
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Centrifugal blower overhaul A worn-out centrifugal blower brought back to as-new condition. Open on Facebook
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A 1600 mm stainless kneader blade Fabricating a kneader blade for a paper mill in stainless steel. Open on Facebook
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Ceramic tile centering unit Designed, built and assembled: the unit that squares each tile before it is cut. Open on Facebook
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Pile-drilling machine body repair Rebuilding the body of a piling rig for a deep-foundation contractor. Open on Facebook
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Plastic crusher on the boring mill A plastics crusher housing set up on the boring machine for its repair. Open on Facebook

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Clients

50 companies who trust us

Cement, ceramic, steel, food, glass and more — the plants whose ducts, chutes and chassis we build and repair.

All products

Have a part to manufacture?

Send us your technical drawings — or even the worn-out part itself — and our engineering team will get back to you with a detailed quotation.

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Contact

Get in touch

Two factories at your service — El Marg (Cairo) and Belbeis (Ash Sharqia). Send us a message and we will reply within one business day.

Contact info

Contact form

El Marg Factory — Cairo
Belbeis Factory — Ash Sharqia