The machines, plant and test equipment behind every Diameter Casting product.
Stage 1
In-house pattern making for accurate, repeatable castings.
An in-house pattern shop lets us make and revise patterns without waiting for outside suppliers, which shortens lead times and keeps casting dimensions stable.
Pattern material is chosen to match the job: wood for short runs, aluminium for everyday production and cast iron where tooling life matters most.
Stage 2
Consistent sand quality is the foundation of a defect-free mould.
The sand plant conditions moulding sand to the correct strength, moisture and permeability for each process. Separate plants for machine and hand moulding keep sand parameters optimised for each line.
Used moulding sand is reclaimed rather than discarded. The unit crushes, cools and screens spent sand so it can be returned to the system with consistent properties.
No-bake sand mixers blend sand with chemical binders to produce strong, accurate moulds that cure at room temperature — suited to the larger covers and frames in the product range.
Stage 3
Multiple moulding methods to handle every size and volume.
The Savelli high-pressure line compacts sand under controlled pressure to produce dense, dimensionally accurate moulds at a steady production rate.
The ARPA 450 semi-automatic machines combine machine compaction with operator control, allowing pattern changes without a long changeover and handling a wide range of standard sizes.
Larger or non-standard castings that do not suit machine moulding are handled by skilled hand moulders on a dedicated floor moulding line.
Stage 4
Precision cores for internal cavities and recesses in every casting.
Cores are made using CO₂, resin or phenolic urethane no-bake systems to produce accurate internal features in covers and frames.
Stage 5
Controlled melting and pouring for consistent iron grades.
Induction furnaces provide precise temperature and chemistry control for both cast iron and ductile iron melts. A 750 KW unit with two 1.0 MT crucibles handles main production; a 350 KW unit handles secondary melting.
The cupola furnace provides continuous high-volume iron melting at 5.0 MT per hour, complementing the induction furnaces for sustained production output.
Molten metal is transferred in preheated ladles and poured at a controlled temperature and rate to minimise casting defects.
Stage 6
Clean, accurate finishing for every cover and frame before inspection.
Shot blasting removes sand, scale and surface irregularities from every casting, leaving a clean, uniform surface ready for inspection and coating.
Grinding stations remove gates, risers and flash, and dress the seating faces of covers and frames to the correct profile.
ARC and gas cutting equipment removes heavy gating; welding is available for approved repairs where the product specification permits.
Stage 7
In-house testing at every stage, from melt chemistry to proof load.
The Spectromax spectrometer analyses melt chemistry in minutes before each pour, confirming the iron meets the required grade and logging results for traceability.
The load testing machine applies a controlled hydraulic force to verify that finished covers and frames meet the proof load required by EN 124 — from A15 up to D400 — without leaving the plant.
Hardness testing is applied to samples from each batch as a quick check that material properties are consistent with the melt chemistry and heat treatment.
The metallurgical laboratory examines microstructure and mechanical properties, confirming that castings meet their grade and providing records for export quality documentation.
Sand is tested regularly for moisture, strength and permeability. Results feed back to the sand plant to keep parameters within limits and prevent mould-related defects.
Stage 8
Protected, palletised and loaded for safe delivery to any destination.
Finished castings are coated with bituminous or other protective paint in a dedicated area after shot blasting and inspection, ready for packing and dispatch.
Castings are palletised or crated and loaded into containers for export. Packing is designed to keep products secure in transit and compliant with export documentation requirements.
Stage 9
Safe movement of heavy moulds, ladles and finished castings.
A 5-tonne electric overhead travelling crane handles the safe movement of heavy moulds, ladles and finished castings across the main production floor.
A 5-tonne monorail hoist moves loads along a fixed overhead track, linking workstations and the pouring area without using floor space.
Fork lifts move pallets, finished castings and raw materials around the plant and into containers for dispatch.
Stage 10
Reliable power and services keep production running without interruption.
A dedicated transformer provides stable high-voltage power to the induction furnaces and production machinery, sized for full simultaneous load.
The compressed air system supplies moulding rammers, core making equipment, cleaning tools and other pneumatic equipment across the plant.
The cooling tower removes heat from the furnace and equipment cooling circuits so that water can be recirculated rather than discharged.
Vacuum circuit breaker panels switch and protect the plant's high-voltage supply, providing fast fault isolation and reliable electrical distribution.
Stage 11
Dust control and safe working conditions across the plant.
Dust extraction and filtration systems capture dust and fumes at sand handling, melting and finishing points, keeping the working environment safe and supporting environmental compliance.
Tell us the product codes, quantities and destination and we will take it from there.