Robotic Precision and Metallurgical Safety in EN 14399-1 Assemblies

High-strength structural bolting systems are critical components in modern steel construction. In large-scale infrastructure projects, reliability begins with the smallest elements — fasteners. Combining robotic manufacturing, advanced galvanizing technologies, and certified testing procedures, Kaleliler delivers EN 14399-1 compliant high-strength structural bolting assemblies for demanding global projects.

Robotic Production: Consistency at Scale

At Kaleliler, quality is engineered into every stage of production. The company operates state-of-the-art robotic production lines that ensure dimensional accuracy and process stability.

Through advanced automation, Kaleliler achieves:

• Zero-Error Geometry: Robotic precision guarantees that every bolt, nut, and washer meets strict European dimensional tolerances.
  
• Consistent Performance: Automated systems maintain uniform quality across high production volumes, supporting major international infrastructure projects.
  
• Controlled Process Parameters: Critical parameters such as temperature are carefully monitored to ensure stable and homogeneous heating during the hot forging process.
  

Advanced Galvanizing and Hydrogen Embrittlement Prevention

One of the most critical challenges in high-strength (10.9 grade) bolting systems is Hydrogen Embrittlement (HE). To address this risk, Kaleliler operates an in-house Hot-Dip Galvanizing (HDG) facility designed to preserve both coating integrity and mechanical performance.

Key elements of the process include:

• Ultrasonic Surface Preparation: High-frequency ultrasonic cleaning significantly reduces the need for aggressive acid pickling, minimizing hydrogen absorption during surface preparation — a critical factor for 10.9 grade fasteners.
• Robotic Galvanizing Control: Immersion times and temperature levels are precisely managed through robotic systems, ensuring uniform coating thickness while maintaining the mechanical properties of the steel.
  

Certified Quality and Comprehensive Testing

All EN 14399-1 assemblies produced by Kaleliler are CE marked and fully compliant with relevant European standards. The company’s accredited laboratories conduct comprehensive validation procedures, including:

• Suitability Testing (K-Class): Verification of torque-preload characteristics for structural safety.
• Mechanical Testing: Tensile, yield, and hardness analyses.
• Coating Verification: Measurement of coating thickness and corrosion resistance performance.
  

A Global Strategic Partner

Approximately 40% of Kaleliler’s production is exported directly, with Germany and the broader European market representing primary destinations.

The company also serves as a solution partner for leading Turkish contractors in major international projects. Kaleliler bolting systems have been used in landmark structures such as Istanbul Airport, Osmangazi Bridge, BMW Factory in Hungary, Kuwait Airport Terminal II Building, and Barcelona Stadium.

Why Kaleliler?

• Certified Safety: Full CE marking and compliance with EN 14399-1 and EN 15048-1 standards.
• Technological Capability: Robotic manufacturing and ultrasonic cleaning technologies.
• Proven International References: Trusted by European clients and global contractors.
  

Kaleliler: Where Robotic Precision Meets Structural Integrity.

Berdan Cıvata, a provider of critical fasteners for over 3,000 wind energy projects worldwide, produces high-strength anchor cages, tower assembly bolts, and blade studs, covering essential components, from the foundation to the blades. We remain an approved supplier in global markets for seven of the world’s top 10 wind turbine manufacturers.

Founded in 1980 by Mechanical Engineers Hasan and Yunus Şemsi in a 150 m² workshop in Tarsus, Mersin, Berdan has experienced significant growth over the years. In 2000, we relocated to our first factory, spanning 5,000 m² in the Mersin- Tarsus Organized Industrial Zone, with a team of 25, including two engineers. Today, we operate in facilities covering 48,000 m², with 28,000 m² dedicated to indoor production. Our team now includes over 60 engineers and approximately 400 employees, and we continue to be a trusted partner for high-strength and critical fasteners.

Our capabilities include machining, rolling, threading, heat treatment, and various surface treatment processes such as patented hot-dip galvanizing, electro-galvanizing, zinc flake, and Teflon coatings. These treatments are conducted in our state-of-the-art surface treatment facilities. Products are rigorously tested in our industry-leading, accredited test laboratory before being delivered to our clients.

Our products have been pivotal to some of the world’s most significant infrastructure projects. We provided the 10-meter-long, 700 kg anchors that support the towers of Europe’s second-longest suspension bridge, Osmangazi, and the world’s longest suspension bridge, the 1915 Çanakkale Bridge. For the Anamur-Cyprus Peace Water Project, we provided B7/2H grade bolts with a 100-year corrosion resistance for the 80 km pipeline running 250 meters underwater. Additionally, we supplied over 800 tons of fasteners for the Kuwait International Airport project and all fasteners for the 93,000-seat Lusail Stadium, the venue for 10 matches, including the final, of the 2022 FIFA World Cup in Qatar.

As the only Turkish company, our journey into the wind energy sector began in 2008 when we participated in the Wind Energy Fair in Husum, Germany. This marked the start of our collaboration with global wind energy giants. Today, we have supplied fasteners for over 3,000 wind turbine projects worldwide. Our clients include renowned names, such as GE from the USA, Nordex and Enercon from Germany, Vestas from Denmark, Siemens from Spain, and Goldwind from China. We have also provided fasteners for the Konya-Karapınar project, Europe’s largest solar power plant, with a capacity of approximately 1,550 MW.

In addition to supporting green energy, we harness natural resources to meet our own energy needs, sourcing 53% of our requirements from our 2.5 MW rooftop solar power plants. Our goal is to increase this to 90% in the future.

At Kaleliler, our state-of-the-art production facility is at the forefront of fastener manufacturing, specializing in the production of bolts, stud bolts, anchor bolts, nuts, and custom fasteners. Utilizing both hot forging and cold forming techniques, we work with a diverse range of steel and materials to meet the stringent demands of various industries. Our in-house heat treatment capabilities further ensure the durability and performance of our products.

Our production process is fully integrated, encompassing in-house electro-galvanizing and hot-dip galvanizing facilities. Additionally, we offer Geomet and Zn-Nickel coating solutions through our network of approved suppliers, providing comprehensive surface treatment options that meet the highest industry standards.

The hot forging process at Kaleliler is a key differentiator, particularly in the production of large-scale bolts and specialized fasteners. This method allows us to deliver superior strength and reliability, catering to the needs of critical applications. In our precision machining section, we produce custom components tailored to the unique requirements of diverse sectors.

Kaleliler’s production facility is equipped with an extensive range of advanced machinery and equipment, enabling us to achieve rapid and high-quality production. Our capabilities include an automatic cutting unit, hot forging unit, machining unit, thread rolling unit, heat treatment unit, surface treatment unit, and a fully equipped quality control laboratory.

Our product range is extensive, featuring KLR-marked bolts and screws with diameters ranging from M12 to M72 and lengths up to 900 mm, threaded rods and studs from M8 to M220, nuts from M20 to M72, anchorage bolts, and custom-bent items like U-Bolts and J-Bolts. Alongside our production capabilities, we maintain a comprehensive inventory of stock items to meet immediate needs across all fastener types.

Recent investments at Kaleliler have significantly enhanced our production capacity and quality standards. Notably, the commissioning of our fully automated hot-dip galvanizing facility, with a daily capacity of 40 tons, represents a major leap forward. This facility is fully managed by robotic systems, ensuring precision and consistency across all processes. The integration of environmentally friendly ultrasonic and mechanical surface treatment methods also minimizes the risk of hydrogen embrittlement, a critical concern in high-strength fasteners.

Further strengthening our capabilities, a new hot forging line has been commissioned, doubling our production capacity in this area. Equipped with an automatic feeding system and advanced robotics, this line ensures stable and controlled forging processes, enhancing both efficiency and product quality. Our commitment to digitalization is reflected in the integration of an automation system with our existing ERP infrastructure, facilitating more accurate data analysis and driving overall productivity.

In line with our continuous improvement philosophy, Kaleliler has also invested in cutting-edge quality control technologies, including a torque testing device capable of testing bolts up to M72—a first in our industry. These advancements reinforce our position as a trusted supplier, particularly in the steel construction and wind energy sectors, where reliability and precision are paramount.

Kaleliler remains dedicated to innovation and excellence, setting new benchmarks in fastener production through our comprehensive and technologically advanced manufacturing processes.