Australian Casting Foundry
Our steel casting foundry in Maryborough specializes in creating custom solutions for mining and a range of other industries.
With over 130 years of experience, our Queensland foundry specializes in high-integrity cast steel products.
BY THE NUMBERS
Years in operation
Tonne monthly casting capacity
Tonnes pour capacity
Casting Foundry Capabilities
Our steel casting foundry manufactures a wide range of components for multiple industries, including mining, recycling, sugar, cement, oil and gas, heavy transport, power generation, and mineral processing.
Our propriety melting process produces clean, high-quality steel. Clean steel has fewer impurities, which makes it more robust and durable.
With a total pour capacity of 22 tonnes, our foundry has the greatest single pour capacity in Queensland and the capability to manufacture cast lips for the broadest range of mining-class machines in the world.
Some of the components we manufacture include:
- Bucket lip fabrication and casting
- Dragline rigging components
- GET components
- Shredder components
Our Certifications & Accreditations
AS/NZS ISO 45001: 2018
AS/NZS ISO 9001:2015
Australian Foundry Institute
American Foundry Society
Castings Technology International
Reducing Our Carbon Footprint
We’re always looking for ways to reduce our environmental footprint, and one way is by recycling reclaimed steel. Steel is infinitely recyclable and produces net zero emissions.
Our manufacturing process almost exclusively uses recycled scrap steel to produce new, world-class mining components. We recover scrap steel from our customers and all waste steel from our own manufacturing process.
As part of our Queensland foundry’s casting process, we use virgin silica sand blended with reclaimed sand to create molds. Molten steel is poured into the sand molds. As the steel cools, it takes the shape of the mold. The sand is then conditioned to be reused to make new molds.
In 2021, we installed a new sand reclamation plant so we could recycle more sand effectively. This has decreased our consumption of new sand by ~50%. Not only does this reduce the need for new sand, but it also means fewer truckloads to dispose of waste sand, further reducing carbon emissions.
Advanced Casting Technology
We’re proud of our industry-leading casting equipment. With our proprietary melting process, our two electric arc furnaces produce stronger and purer steel than achievable with induction furnaces. We use two state-of-the-art Optical Emission Spectrometers (OES) for chemical analysis to ensure our quality is always up to standard.
Five in-house heat treatment ovens to bring steel up to tensile strength with superior impact strength at -40C.
By keeping this process in-house, we retain the highest quality control standards while increasing efficiency. We’re able to work at a variety of temperatures, including 850-1150C (anneal, normalize, and quench hardening), 500-690C (temper), and 150-200C (stress relieve, age).
Skilled and Experienced Team
Our expert team bring a combined experience of 600+ years to our Australian foundry. Onsite metallurgists and casting designers ensure that work is to the highest standard. We use Solidworks for drafting and modeling of products and Magma Software to create casting simulations, all in service of the world’s best castings.
We work with a wide variety of allows at our steel casting foundry, including:
- Carbon & Low Alloy Steel
- Manganese Steel
- Ni Resist
- High Chrome & Ni-Hard Wear Resistant Iron
- Cast Iron
Learn More About Our Foundry
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We thrive on building collaborative partnerships with the world’s best miners.
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