Sand Casting

Our sand foundry uses the latest airset sand moulding processes available, which enables us to meet each and every customer's individual requirements. The process produces sand moulds of considerable strength varying in sizes from 6" square up to 6 metres in length, without the need of steel moulding boxes. Kiln dried Congleton 80 grade sand mixed mechanically with a resin binder and one of numerous hardeners is poured into a single/multiple impression pattern. Once the sand has been hand rammed into every corner and the remainder strickled off, the mould is left to set.

The setting time is dependent on the hardener used, a one minute hardener for a small mould, such as an elbow and a thirty minute hardener for a large mould, such as a 20ft ring beam. Once set the pattern is lifted from the mould, if any cores are required they are carefully placed into the prints and the mould is closed ready for casting. Six years ago our foundry had a brand new reclamation plant installed which allows us to reclaim 90% of the sand used.

The moulds are broken down into fine grains and 60% virgin sand is added to maintain strength and quality. This process helps us to make savings for our customers by reducing the amount of waste sand we have to have collected. It is also a considerable benefit to environmental issues by reducing waste.

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