Innovative solutions for electric heat

Services and engineering

offers its customers a broad range of standard products. In addition, we develop individual solutions to order for the customer for tasks from the area of electrical resistance heating, focusing on heating elements and insulation.

Berghütten supports its customers from the idea, planning, calculation and construction, through to the production and installation. We provide a responsible engineer and an experienced team for your project. Here, we combine forward-looking technologies and modern production processes with decades of experience in the area of electrical heating.

Whether in development and implementation of a new project, repair of a faulty furnace, or installation: our work is always customer-focused, efficient and on time.

Resistance wire and services

Top-quality heating conductor wires - available quickly and flexibly for SMEs

It is often essential to be able to acquire high-quality resistance wire from a respected brand such as Berghütten quickly. Small and medium sized companies especially understand this challenge, due to the increased flexibility in procurement and production. One of the unbeatable advantages of Berghütten is the availability of resistance wire in a wide range of sizes and material grades which we stock in our warehouse. Take advantage of our large inventory and feel free to ask at about the availability of the size and quality you need. We are happy to ring or email you back with details on the availability of the resistance wires that you need.

Semi-finished and intermediate products

Are you buying our resistance wire and plan on processing it further? When relocating, restructuring or changing quantities or variants, new questions of vertical integration or the full or partial relocation of production processes often arise. For many years Berghütten has been a manufacturing company with a versatile production capability of its own along with an external production capacity.

Smaller quantities by the spool

The smallest amount or unit of resistance wire available from Berghütten is a spool. Unlike our competitors, we require a minimum invoice value of only €150 per shipment (for Berghütten resistance wire products).

Smaller quantities as a ring

Resistance wire wound from>2.0 mm comes in a ring. Depending on the wire diameter and alloy, the standard weight of a ring varies between 30 and 50 kg. With some exceptions, we also offer part rings in weights between 5 and 25kg from our own production of heating elements (partially available in stock). You may wish to purchase part rings for cost-effective use in repair work or smaller production orders.

Rapid despatch

For resistance wire orders readily available in stock (of the relevant size, quality and quantity), we will ship your order the same day, if it is a matter of urgency and you request it, as long as you place your order by 11.00 that day.

Materials certificate

On request, we can provide you with a certificate to accompany your delivery. It confirms the alloy composition and physical test values in the form of a batch test certificate of the original smelting. We are happy to offer this to you free of charge.

Certificate of origin

Do you need a certificate of origin for your delivery for customs clearance or other reasons? No problem.

Special packaging

We offer a variety of packaging and shipping options for your business or for your customers:

IPPC packaging (sea freight), wrapped in cling film with desiccant for long-term storage,
Oversize and special sized parcels, shipped in neutral packaging direct to your customer without stopover,
Thermally insulated packaging,
Environmentally friendly packaging (e.g. free of Styrofoam chips).

Straightened rods

If you need metal rods in standard lengths of 3,000 or 4,000 mm and standard diameters of 8.0 mm, 10.0 mm or 12.0 mm, then you’ve come to the right place. We always have these in stock in standard qualities and we can deliver them to you on short notice. In addition, we manufacture straightened rods out of resistance wire in stock according to customer specifications.

e.g. 350 pcs / CrFeAl 135 / Ø 3.6 mm / 2,850 mm long.

Rewinding

On customer request, we rewind spools available in stock with resistance wire to specified fixed weights or run lengths. Furthermore, we rewind to custom sizes, e.g. 100 meter spool for hot cutting wire or 20 meter spool of NiCr 80/20, Ø 65 mm for welding wire on spool SP 1A 79/35/14.

Wire recovery

Berghütten provides a one year warranty for fixed spools maintained in professional, horizontal storage at uniform temperature. If you have stocked spools which have been loosened by age, improper storage or other reasons, we also rewind goods and make it possible to restore them to their original state.

Test samples

Are you planning a new product or improving an existing one and need resistance wire of a specific size or quality for experimental purposes?

Do get in touch. We will come up with a personalised solution to support you! And should you need more than just material for your testing, our engineers and product managers will gladly assist you in engineering and development.

Customised labelling

If you would like your own individual label or tag to appear as a product label on each spool, we are happy to meet your individual needs.

Make-and-hold orders

If you need large quantities of resistance wire for your continuous production and its availability is a high priority in your business, then look no further. We can set up make-and-hold orders for you for medium-sized order volumes which offer you greater planning security.

We stockpile the supplies of resistance wire you need, which you can draw upon incrementally at any time. You can therefore ensure the continuous availability of resistance wire for your production at quantifiable rates for longer periods of up to 6 months. Many of our customers use this method of make-and-hold orders for their businesses with great success.

Engineering services advice, calculation, construction

We advise, calculate, design

The range of industrial applications in the area of electrical heating is so diverse and extensive that it is often impossible to fulfil the demands with standardised products. Nonetheless, the cost-conscious technician, engineer and businessman tries to allow for and adhere to certain standardisations in the development and construction of industrial furnaces and thermal plants.

Heating elements and insulation are wearing parts with varying durability depending on load and use. The actual concept, calculation and construction of heating elements have a critical impact on this and are determining factors in future operating costs.

As a leader in the field of electric heating, it is key for us to solve our customers’ problems and implement solutions through our own design and development department. Our team of engineers and technicians is ready to help from the initial idea through to the consulting, analysis and design to assembly on site.

For our work, we have modern tools such as CAD construction and calculation programmes for dimensioning or determining heat transfer. For many new applications, we construct prototypes for trials, which are developed through to readiness for series production in co-operation with our customer.

Measuring faulty heating elements and newly made products

We measure, produce and deliver

Downtime in a furnace implies an incalculable loss of production for you as well as many further problems. Particularly in this case, quick and flexible action is required. If a furnace fails due to worn out or faulty heating elements, we respond immediately. The constant availability of heating conductor materials of various qualities and sizes in our central warehouse guarantees our ability to act quickly in an emergency. We are equipped and prepared accordingly.

For the regular maintenance of industrial furnaces and thermal plants too, it is sensible to produce construction documentation in time for all of the relevant heating elements and to keep this up to date. For a unit that is important for processes and production, it still makes sense to have the relevant spare parts such as heating elements in stock in the works. The costs of replacement parts often bear no relation to the costs of a loss or stoppage of production.

The aforementioned method is appropriate even for the “regular case” of changing the heating elements and if necessary the insulation on a regular cycle or maintenance interval. You can also send us your new or used heating elements by arrangement or we can come to you on site in the factory and measure your heating elements. As well as the geometry, we also measure the ohm value and assess the wear.

Installation services by appointment

We install, connect and start up with you

If you do not have a team of your own to install the heating elements and for maintenance or if your furnace manufacturer is not interested in servicing, we would be happy to take over installation on time of heating elements and insulation produced in advance at Berghütten. If desired, we will assist you until the industrial furnace or thermal plant is electrically connected and start it up together with you until everything is working.

We prefer to overhaul and assemble transportable industrial furnaces, furnace rings or sections in our works in Dietzenbach. However, our range of services also includes assembly on site in your factory or on your construction site.

Give us a date for restarting of your industrial furnace or thermal plant. We will produce a precise schedule and installation plan and agree it with you.