Steel Castings

BRC’s mould design process integrates advanced engineering software, including SolidCAST/MAGMA simulation and SolidWorks CAD/CAM modelling. These tools enable the analysis of metal flow and solidification before production.

By validating designs virtually, we reduce trial-and-error, shorten lead times, and improve first-pour success rates.

Once the design is validated through CAD modelling and simulation, BRC proceeds with pattern production. Patterns are manufactured using CNC machining and high-quality materials to accurately replicate the final casting geometry and form the mould cavity.

For complex mould designs, we also utilise in-house 3D printing capabilities.

With completed patterns, the moulding process begins. Mould cavities are formed using sand moulding and core-making technologies selected according to casting size, geometry, and complexity.

BRC applies controlled melting and pouring processes to support consistent steel quality.

• Large Castings: With an annual melting capacity of 130,000 tonnes, BRC operates advanced melting and refining systems to ensure clean and consistent molten steel.
• Small Castings: BRC also maintains dedicated facilities for small steel castings, with an annual melting capacity of 10,000 tonnes and individual casting weights of up to 5 tonnes. Components with maximum dimensions of 4.5m x 2.4m x 1.0m are produced while maintaining strict control over dimensional accuracy and metallurgical quality.

After cooling and solidification, castings undergo shakeout, where sand, runners, and risers are removed using controlled vibration systems.

Used sand is processed through reclamation units before being returned to the sand mixer, where binders and additives are introduced to prepare moulding sand for reuse.

To achieve the desired mechanical properties, BRC’s castings undergo carefully controlled heat treatment cycles. These processes refine the material’s microstructure and enhance the overall durability of each component.

Treatment schedules are tailored to the specific alloy and application, ensuring dependability under the most demanding operating conditions.

Every steel casting is subject to comprehensive inspection and testing protocols. Non-destructive testing (NDT) methods, including ultrasonic, magnetic particle, radiographic, and penetrant inspections, verify the material’s integrity. Dimensional checks ensure conformance with specifications, while mechanical testing, such as tensile, impact, and hardness assessments, confirm performance characteristics.

All testing and reviews are carried out by certified Level II and Level III NDT inspectors, ensuring the highest level of accuracy and compliance. Processes are conducted in line with international standards and certifications, including ABS, DNV, Lloyd’s Register, and ISO.

Following inspection, castings proceed to excavating and grinding, where surface irregularities are removed, and the final geometry and finish are achieved.

Where required, welding repairs are carried out based on inspection results. Welding processes include:

• Shielded Metal Arc Welding (SMAW)
• Tungsten Inert Gas (TIG)
• Gas Shielded Arc Welding (GSAW)
• Flux-cored Arc Welding (FCAW).

Fettling operations are then performed to smooth weld areas and refine surface finishes.

BRC provides both rough and finish machining for steel castings. With CNC lathes, horizontal and vertical lathes, and advanced milling machines, we can handle components up to 8 metres in dimension and weighing up to 80 tonnes.

This combination of capacity and precision enables us to deliver quality castings that meet the most stringent requirements.