Case Study - Foundry Sand

For many years there has been a requirement for high quality silica sand in the Foundry industry. Foundries use the clean, well graded sand to produce moulds for the production of metal castings which are the basis of engineering and manufacturing industries across the UK.

High purity silica sand is washed and graded to remove any impurities and then dried before it is delivered to the foundry. Because this type of sand has a higher melting point than iron, copper, aluminium and other alloys it can be mixed with a binder to produce a mould that can hold the molten metal when producing a casting. The sand is classified into different sizes which affects the amount of binder required and the final surface finish of the casting.

The sand mould is later broken away from the casting and can be recycled within the foundry or used elsewhere in the production of asphalt or concrete products.

Foundries in the UK vary in size and in type with some capable of producing extremely high quality, specialist parts for the aerospace and automotive industries.

Some will be on a smaller scale that allows them to make individual pieces specific to their customers needs.

All of these foundries rely on the sands specific physical and chemical properties allowing them to make their castings to the very closest tolerances.

Hanson Aggregates at Wrotham in Kent supply various grades of silica sand to a variety of different UK Industries including Foundries across the south of England.

The sand is an essential raw material for all these manufacturing companies and without the special properties of the sand then many of the vital engineering components could not be produced.

The foundries Hanson supply to produce a wide range of ferrous and non ferrous castings that support a diverse range of manufacturing industries across the country and also include exports around the world.

Some of the foundries specialise in supplying gearboxes, wheels, engine manifolds and brake discs to the automotive industry. (See photograph) Others will supply parts to produce water or fuel pumps that keep much of our everyday plant and equipment operating.

One of the foundries we supply is on the cutting edge of the metal casting process and uses sand moulds to create highly specified parts for Helicopters, Aeroplanes and the Royal Navy fleet of Ships and Submarines.

All these vital components that keep our industries working start off as a sand mould or core and with most of them there is no other suitable alternative method of production.

Another example of how the sand is used can be seen in the photograph below when the BAFTA awards are cast in bronze by New Pro Foundries of Wet Drayton. cast in bronze by New Pro Foundries of Wet Drayton.