Expocet Ltd specializes in the procurement and supply of large-scale Steel and Iron Castings for the world’s most demanding industrial applications. We bridge the gap between heavy-duty UK manufacturing facilities and global OEMs, providing robust components that meet stringent safety and structural integrity standards.

By utilizing advanced floor moulding and large-scale pit moulding techniques, we offer a reliable supply chain for oversized components that require exceptional mechanical properties and durability.

Technical Capabilities & Weight Ranges

We offer extensive capacity for heavy-section castings across a variety of ferrous metals, catering to projects that exceed the limits of standard automated production lines.

• Steel Castings:

  • Weight Range: 50kg – 10,000kg (10 Tonnes)

  • Materials: Carbon Steels, Low & High Alloy Steels, and Manganese Steels.

• Iron Castings (Grey & SG):

  • Weight Range: 100kg – 20,000kg (20 Tonnes)

  • Materials: BS EN 1561 (Grey Iron) and BS EN 1563 (SG / Ductile Iron).

• Moulding Processes: Floor Moulding and Pit Moulding utilizing chemically bonded (Air-Set) sand systems for superior mould stability.

Engineering Excellence for Large-Scale Projects

Producing large-scale castings requires specialized technical oversight to manage cooling rates and minimize internal stresses. Expocet ensures:

• Methoding & Simulation: Advanced casting simulation software to optimize feeder placement and ensure sound, defect-free castings.

• Structural Integrity: Rigorous testing for heavy-section components to verify material properties throughout the entire cross-section.

• Material Precision: Careful alloying to meet specific requirements for impact resistance, tensile strength, and wear durability.

Turnkey Finishing for Heavy Components

Handling and finishing 20-tonne components requires specialist infrastructure. Expocet manages the entire process:

• Heavy-Duty Machining: Access to large-scale CNC boring, milling, and turning facilities.

• Heat Treatment: Large-capacity furnaces for stress relieving, normalizing, and quenching/tempering.

• Non-Destructive Testing (NDT): Extensive ultrasonic testing (UT), magnetic particle inspection (MPI), and radiographic testing to ensure sub-surface quality.

• Surface Protection: Industrial-grade priming, painting, and specialized coatings for harsh environments.

Industry Sectors Supplied

Our large steel and iron castings are the backbone of several critical industries:

• Power Generation: Turbine housings, generator frames, and renewable energy hubs.
• Mining & Quarrying: Crusher frames, mantles, and heavy-duty wear parts.
• Oil & Gas: Large valve bodies, pump casings, and subsea structures.
• Marine & Shipping: Rudder horns, stern frames, and large engine components.
• Construction & Infrastructure: Structural nodes for bridges and heavy machinery chassis.