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Castings For Industry
www.bascastings.com
WELCOME TO BAS CASTINGS LIMITED – UK
MANUFACTURER OF HIGH INTEGRITY
CASTINGS
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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).
Castings For Industry
www.bascastings.com
Plant Detail
Castings For Industry
www.bascastings.com
Plant Layout
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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.
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
Casting Development
MAGMA is a world-wide leading developer and
supplier of software for simulation and optimization
of casting designs and processes
Castings For Industry
www.bascastings.com
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.
Castings For Industry
www.bascastings.com
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.
Castings For Industry
www.bascastings.com
Approvals
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
Investment 2019/2020
• Extension Small Section – Set to increase production capacity by 20%
• Extension Large Section – Set to increase production capacity by 50%
Castings For Industry
www.bascastings.com
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
Castings For Industry
www.bascastings.com
PRODUCT GALLERY
204 kg – 400-18LT
1600 kg – 400-15
305 kg – 400-15
24 kg – Ductile100 kg – Ductile
Castings For Industry
www.bascastings.com
PRODUCT GALLERY
35 kg – ADI
40 kg – Ductile
200 kg – Ni-Resist 40 kg – Ductile
Castings For Industry
www.bascastings.com
Market Sectors - Defence
Castings For Industry
www.bascastings.com
Market Sectors - Defence
Castings For Industry
www.bascastings.com
Market Sectors – Marine Propulsion
Castings For Industry
www.bascastings.com
Market Sectors – Brake Systems
170 kg – Ductile
Castings For Industry
www.bascastings.com
Market Sectors – Marine Engine Piston Rings
Castings For Industry
www.bascastings.com
Market Sectors – Water Propulsion
Castings For Industry
www.bascastings.com
Market Sectors – Industrial Turbines
300 - 400 kg – 400-15
Castings For Industry
www.bascastings.com
Market Sectors – Industrial Turbines
Castings For Industry
www.bascastings.com
Market Sectors – Electric Bow Thrusters
Castings For Industry
www.bascastings.com
Market Sectors – Wave Energy
Castings For Industry
www.bascastings.com
Market Sectors – Energy Recovery
Castings For Industry
www.bascastings.com
Market Sectors – Energy Recovery
Castings For Industry
www.bascastings.com
Market Sectors – Energy Recovery
Castings For Industry
www.bascastings.com
Market Sectors – Renewable
Castings For Industry
www.bascastings.com
Market Sectors – Petrochem
1500 kg – Ductile
2000 kg – Ductile
Castings For Industry
www.bascastings.com
Market Sectors – Cryogenic Pumps
Castings For Industry
www.bascastings.com
Market Sectors – Construction
Castings For Industry
www.bascastings.com
Market Sectors – Electric Vehicle
Castings For Industry
www.bascastings.com
Market Sectors – Compressor Housing
Castings For Industry
www.bascastings.com
Market Sectors – Valve Casing
Top 400 kg
Bottom 1300kg
Ductile Iron
Castings For Industry
www.bascastings.com
Market Sectors
1100 kg – Ductile Iron
Castings For Industry
www.bascastings.com
Market Sectors
Castings For Industry
www.bascastings.com
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

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Bas Castings Ltd

  • 1. Castings For Industry www.bascastings.com WELCOME TO BAS CASTINGS LIMITED – UK MANUFACTURER OF HIGH INTEGRITY CASTINGS
  • 2. Castings For Industry www.bascastings.com 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 www.bascastings.com 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).
  • 6. Castings For Industry www.bascastings.com 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
  • 7. Castings For Industry www.bascastings.com 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
  • 8. Castings For Industry www.bascastings.com 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
  • 9. Castings For Industry www.bascastings.com 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
  • 10. Castings For Industry www.bascastings.com 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.
  • 11. Castings For Industry www.bascastings.com 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
  • 12. Castings For Industry www.bascastings.com Casting Development MAGMA is a world-wide leading developer and supplier of software for simulation and optimization of casting designs and processes
  • 13. Castings For Industry www.bascastings.com 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.
  • 14. Castings For Industry www.bascastings.com 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.
  • 16. Castings For Industry www.bascastings.com 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
  • 17. Castings For Industry www.bascastings.com 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
  • 18. Castings For Industry www.bascastings.com 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
  • 19. Castings For Industry www.bascastings.com 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 www.bascastings.com 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 www.bascastings.com PRODUCT GALLERY 204 kg – 400-18LT 1600 kg – 400-15 305 kg – 400-15 24 kg – Ductile100 kg – Ductile
  • 22. Castings For Industry www.bascastings.com PRODUCT GALLERY 35 kg – ADI 40 kg – Ductile 200 kg – Ni-Resist 40 kg – Ductile
  • 25. Castings For Industry www.bascastings.com Market Sectors – Marine Propulsion
  • 26. Castings For Industry www.bascastings.com Market Sectors – Brake Systems 170 kg – Ductile
  • 27. Castings For Industry www.bascastings.com Market Sectors – Marine Engine Piston Rings
  • 28. Castings For Industry www.bascastings.com Market Sectors – Water Propulsion
  • 29. Castings For Industry www.bascastings.com Market Sectors – Industrial Turbines 300 - 400 kg – 400-15
  • 30. Castings For Industry www.bascastings.com Market Sectors – Industrial Turbines
  • 31. Castings For Industry www.bascastings.com Market Sectors – Electric Bow Thrusters
  • 37. Castings For Industry www.bascastings.com Market Sectors – Petrochem 1500 kg – Ductile 2000 kg – Ductile
  • 40. Castings For Industry www.bascastings.com Market Sectors – Electric Vehicle
  • 41. Castings For Industry www.bascastings.com Market Sectors – Compressor Housing
  • 42. Castings For Industry www.bascastings.com Market Sectors – Valve Casing Top 400 kg Bottom 1300kg Ductile Iron
  • 43. Castings For Industry www.bascastings.com Market Sectors 1100 kg – Ductile Iron
  • 45. Castings For Industry www.bascastings.com 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