CAST HOUSE

Cast House is said to be "The Window to VALCO", since products from VALCO are shipped to our customers, locally and externally, from this department.

The Vision of Cast House is to deliver Cast Aluminium Products (Sows, Billet, Rolling and Foundry Ingots) that meet or exceeds the customers' quality and delivery expectations.

Cast House transports molten aluminium in crucibles from the Cell Lines and take samples of the metal to determine its chemical analysis. Based on the chemical analysis and the production plan, the molten aluminium is either cast into sows and 22kg ingots or into melting furnaces, where it is processed to customer's chemical specification and cast into Extrusion billet, Rolling slabs or T-ingots.
After casting and inspection, the billet logs are heat-treated in Homogenizing and Forced-Cooling furnaces, sawn to the required length, bundled, weighed and shipped to customers.

Rolling slabs and T-ingots are also inspected after casting, sawn, bundled, weighed and transported to its customers.

Valco Casthouse has the capacity to produce approximately 73,000MT of wrought aluminium products per annum.

PRODUCTS

Aluminium products cast at Valco Cast House include:

LOW PROFILE SOWS

  • Size – 1320mm x 1060mm x 300mm
  • Weight – 700kg

EXTRUSION BILLETS

  • Size – 178mm/203mm

22KG FOUNDRY INGOTS

  • Size – 730mm x 180mm x 90mm
  • Weight – 22kg

ROLLING SLABS

  • Various sizes

T-INGOTS

  • Various sizes

 

Aluminium alloys produced include, the following Aluminium Associations wrought alloy designations:

ROLLING INGOT SLABS

  • AA1xxx
  • AA3xxx
  • AA5xxx
  • AA8xxx

EXTRUSION BILLETS

  • AA6xxx

22 KG FOUNDRY INGOTS

  • Hi Silicon Alloys (notably A356)
  • Pure Aluminium of P1020A and better grades

PROCESSED/UNPROCESSED DROSS

  • Unprocessed – 83% aluminium content
  • Processed – 56.4% aluminium content

 

FACILITIES

VALCO Casthouse, currently, has facilities to produce 7,500MT of unalloyed and Hi-Silicon 22kg Foundry ingots per annum.
This facility would be expanded to produce approximately 30,000MT of this product per annum.

CASTING

  • Direct Chilling casting complex, equipped with state-of-the-art Wagstaff® AirSlip® facility is used in producing approximately 38,000MT of 178mm and/or 203mm diameter extrusion billet and 27,000MT of Rolling Slabs (in various sizes) per annum.
  • All cast products are processed through the Charging and Holding hearths.  Independent Quality Control crew checks the Hydrogen levels in the products during casting using AlSCan® hydrogen tester.  The crew also inspects all green Extrusion billet using an Ultrasonic Flaw Detector after casting.  Additionally, samples are taken and analysed during casting, using an ARL® Quantometer on each cast.  The casting facilities incorporate in-line degassing units and ceramic foam filters to cleaning the metal during casting.

HOMOGENIZATION

  • The department has three (3) P.L.C. controlled electrically-heated batch homogenizing furnaces, with an annual capacity of 38,400MT, to homogenize cast wrought extrusion billet and rolling ingots.

SAWING/PACKAGING

  • Three (3) billet saws and one (1) slab saw are also available to cut cast products to customer specific lengths.
  • Finished products are packaged, labeled, inspected to meet or exceed customers' specifications and requirements.

 

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