High Integrity British Manufactured Iron Components upto 5000kg Cast components manufactured in all iron based alloys, raw, fully machined & painted. Reverse engineering with on site Faro arm scanner, full methods and engineering support from prototype through to production requirements.

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WELCOME TO BAS CASTINGS LIMITED – UK
MANUFACTURER OF HIGH INTEGRITY
CASTINGS

2. Castings For Industry
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About Us
Established in 1973, BAS Castings Ltd is a successful and expanding foundry business that has
created a superb, efficient manufacturing facility to produce high integrity iron castings.
Continual investment in modern manufacturing techniques, career training and a commitment to
Quality Management systems has enabled BAS Castings to provide a flexible and modern approach
to our customer’s demands.
The high integrity iron castings we produce are exported world wide and are used in the most
demanding industrial applications. Strict metallurgical controls are in place to ensure that the
chemical and mechanical properties of materials cast meet or exceed national, international and
customers own specifications.
We also have a steel casting plant based in Chesterfield manufacturing high integrity steel castings.
H.I Quality steel manufactures all grades of carbon steels through to duplex stainless steels.
Combined we have over 200 employees with a group turnover of £25 million

3. Castings For Industry
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Health & Safety
• Safety Helmets
• High Vis Jackets
• Safety Glasses
• MUST BE WORN AT ALL TIMES WHILST INSIDE THE WORKS
• Ear protection must be worn in designated area’s
In the even of a fire alarm, please report immediately to nearest assembly point
Stay with the guide while in the works at all times
Vehicles must be parked in designated areas. BAS Castings Ltd accepts no liability for loss
or damage whilst on site
In the unlikely even of an incident or accident, Please contact a designated
First Aider (anyone with a red helmet).

4. Castings For Industry
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Plant Detail

5. Castings For Industry
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Plant Layout

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Casting Plant Capacity
4 Induction Furnaces
• 1 Tonne
• 1 Tonne
• 1 Tonne
• 750 kg
Small Section Moulding upto 30” / 762mm (sq)
Medium Section Moulding upto 45”/ 1,143mm (sq)
Heavy Section Moulding upto 100” / 2,540mm (sq)
Shell Moulding

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Material Grades
• CAST IRON GREY IRON • SG IRON - DUCTILE IRON
• NI RESIST CAST IRON
• WEAR RESISTANT IRONS
• AUSTEMPERED DUCTILE IRON
• COMPACTED GRAPHITE
• HIGH SILICON MOLYBDENUM
• CUSTOMER SPECIFICATIONS

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MOULDING
Focused on cost reduction
Castings are manufactured on five dedicated moulding lines that result in the lowest
manufacturing cost whilst achieving the technical criteria required.
Shell Moulding
Castings produced by this method offers the ultimate dimensional accuracy for small
components. Machining allowances can be reduced or even eliminated with tolerances of
0.25mm achievable.
Casting weight range 0.10 – 20 kgs Boxless Moulding
Boxless Moulding
Taking full advantage of the strength of the Alphaset chemically bonded sand system, compact
moulds provide a cost effective method of manufacturing castings. Compact moulds are tailor
made to suit the component size ensuring that material usage is kept to an absolute minimum.
Alphaset is recognised within the industry as offering the best surface finish and dimensional
accuracy of any chemically bonded sand system currently available. Moulds are handled with
self levelling hydraulic manipulators and flood coated to ensure that a superior surface finish
and accuracy for which BAS Castings is renowned is maintained
Small Boxless Moulding: – Casting weight range 0.25 – 25 kgs
Medium Boxless Moulding: – Casting weight range 25 – 200 kgs

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MOULDING
Metal Box Moulds
When component size is too large for boxless moulding we have two boxed sections that
handle large components efficiently and safely. Where economically sized moulding boxes are
not available purpose made boxes are procured. Board mounted production pattern equipment
ensures that complex castings are manufactured efficiently to achieve the lowest production
costs. Step joint and diablo location ensures that the mould halves close precisely giving neat
flush joint lines.
Consultation with our technical staff at the design stage will result in taking the sand casting
process to its extremes enabling cast features to be incorporated resulting in reduced
machining and finishing costs.
Medium Metal Box: – 200 – 750 kgs
Large Metal Box: – 750 – 5000 kgs

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Core Production
Extensive facilities allow complete production flexibility
Cores are manufactured onsite in Alphaset sand, Shell Moulding
and Betaset.
In choosing the core making type we take into consideration the
dimensional accuracy and surface finish required, the size and
quantity of the casting and commercial considerations.
We aim to provide the best and most cost effective solution for all
of your casting requirements.

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ADDED VALUE
Providing cost effective post-casting operations
We welcome the opportunity to supply post casting operations such as machining and
fabrication.
We have a carefully selected network of approved machining subcontractors that cover the
spectrum of machining requirements.
The ability to provide post-casting operations can provide an ideal commercial solution for our
customers. The foundry is then in total control of all quality and logistics.
We also offer services for the following:
•Pattern making
•Painting
•Surface hardening
•Pressure testing
•Third party certification
•Non destructive testing
•Chemical analysis

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Casting Development
MAGMA is a world-wide leading developer and
supplier of software for simulation and optimization
of casting designs and processes

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QUALITY CONTROL
Ensuring our customers needs and expectations are met
Our quality management system is approved under BS EN ISO 9001. We also hold
accreditations issued by Lloyd’s Register, DNV-GL, ABS, TUV, BV and KR. From receipt of enquiry
presentation of a fully detailed technical and commercial offer, production planning/liaison and
manufacturing processes we aim to provide the highest and most professional service to our
clients.
Castings are produced to meet highly demanding operational requirements. In addition to
chemical, mechanical testing and close process controls, the quality of the iron casting is
proven by Non Destructive Testing (NDT), machining or sectioning.
First off castings are checked dimensionally and reports issued accordingly with the submission
of the sample. Machined components are inspected on a 3 axis coordinate measuring machine
checking the components to three decimal places. The surface quality of the casting can be
confirmed by either Magnetic Particle or Dye Penetrant testing. Internal soundness can be
checked by radiographic (X-ray) or Ultrasonic testing. All NDT is carried out by fully qualified
personnel working to national, international or customers specific standards.
It is the aim of our business to manufacture iron castings right first time. By combining today’s
casting technologies with our highly skilled technicians we are able to accept demanding iron
casting requirements with confidence.

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QUALITY CONTROL
Ensuring our customers needs and expectations are met
Chemical tests are done in house via spectro prior to and during casting to help ensure quality
of metal, we can confirm results at external contractors should a customer request it.
Mata-check tests are carried out prior to Knock out of moulds again to help ensure quality of
product.

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Approvals

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Investment
• Additional shot blast with rotary table for smaller
components
• Plasma cutting – Removing runner systems, feeder’s a
safer and more efficient process
• Replacement of existing cooling towers
• Additional new cooling towers

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Investment
• New transformers, required to run the new VIP units and compressors
• Addition of 2 new VIP units, one will run the existing spare 1 tonne body,
the second will run a new body when installed

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Investment
• New server - Installation Complete, all systems showing a marked increase in speed and stability.
• Stage 2 – Return of Account package onto BAS server (was online with I.T. company) - Completed
• Stage 3 – install office 365 to all PC’s, this will increase system stability and commonality - Ongoing
• Stage 4 – Move e-mail to Office 365, gives easier access when away from site - Ongoing
• Stage 5 – New share system to further improve speed and stability of network - Ongoing
• 3 x new compressors, computer
controlled, self regulating and
high powered

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Investment 2019/2020
• Extension Small Section – Set to increase production capacity by 20%
• Extension Large Section – Set to increase production capacity by 50%

20. Castings For Industry
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Investment 2019/2020
• CCTV system monitor internal and external providing 24hr safety and security
• New furnace – Capacity to be agreed, infrastructure already in
place which will shorten time to commissioning.
• Extension to onsite pattern manufacturing capacity

21. Castings For Industry
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PRODUCT GALLERY
204 kg – 400-18LT
1600 kg – 400-15
305 kg – 400-15
24 kg – Ductile100 kg – Ductile

22. Castings For Industry
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PRODUCT GALLERY
35 kg – ADI
40 kg – Ductile
200 kg – Ni-Resist 40 kg – Ductile

23. Castings For Industry
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Market Sectors - Defence

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Market Sectors - Defence

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Market Sectors – Marine Propulsion

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Market Sectors – Brake Systems
170 kg – Ductile

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Market Sectors – Marine Engine Piston Rings

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Market Sectors – Water Propulsion

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Market Sectors – Industrial Turbines
300 - 400 kg – 400-15

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Market Sectors – Industrial Turbines

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Market Sectors – Electric Bow Thrusters

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Market Sectors – Wave Energy

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Market Sectors – Energy Recovery

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Market Sectors – Energy Recovery

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Market Sectors – Energy Recovery

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Market Sectors – Renewable

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Market Sectors – Petrochem
1500 kg – Ductile
2000 kg – Ductile

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Market Sectors – Cryogenic Pumps

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Market Sectors – Construction

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Market Sectors – Electric Vehicle

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Market Sectors – Compressor Housing

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Market Sectors – Valve Casing
Top 400 kg
Bottom 1300kg
Ductile Iron

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Market Sectors
1100 kg – Ductile Iron

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Market Sectors

45. Castings For Industry
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Plant Location
BAS Castings Limited
Wharf Road Industrial Estate
Pinxton
Nottinghamshire
NG16 6LE
Tel: +44(0)1773 812028
Fax: +44 (0)1773 861948
sales@bascastings.com