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DUCTILE IRON FOUNDRY

Equipped with modern high speed, high volume molding and casting machinery, the Romac ductile iron foundry specializes in producing the highest quality castings in the most efficient manner. Modern Casting magazine called the Romac Foundry one of 'America's Best Induction Meltshops".

Ductile Iron Foundry Exterior Photo

HISTORY

Romac purchased the foundry in 1975 to produce castings for our line of pipe products.

In 1995, we expanded on the five acre site, and modernized the entire facility.

The modernization enabled the Romac foundry to produce castings fast and efficiently.

With the new high speed, high capacity equipment, we entered the general foundry business.

Since then we've produced a broad range of castings for numerous industries.

We currently pour two grades of ductile iron.
65-45-12 (our most common grade).
80-55-06 (frequently poured, lower volume).

Induction Furnace

INDUCTION FURNACES

Two 6-ton capacity ABB electric melt furnaces with a shared four megawatt power supply. 8 to 10 tons per hour capacity.

Disamatic Molding Machines

DISAMATIC MOLDING EQUIPMENT

Two Disamatic machines

Mold Cake Size: 25" wide x 20" high x 5" to 14" deep.

Maximum Part Dimensions: 21" x 16" x 10" with some exceptions depending on part shape.

Maximum Part Weight: Approx. 90 lbs.
Average Molds Per Hour: 400 non cored, 260 cored.

Autopour

AUTOPOUR POURING CONTROL

Via one of two five ton Autopour with laser/computer controlled stopper rod pouring system.

Dual laser system creates consistent control for efficient quality and productivity.

One laser identifies the opening in the mold and begins the pour. The second laser identifies when the mold is full and stops the pouring.

Ductile Iron Casting with thin cross section

SPECIALIZED CASTINGS

Romac's foundry reguarly produces specialized castings with thin cross-sections.

Metallurgical Microscope

METALLURGICAL QUALITY CONTROL

Spectrometer integrates with database to record metal chemistry.

Hardness tester to monitor hardness .

Microscope with video displays and picture recording capability to view and document crystalline structure.

Polishing equipment.

In house computerized tensile test machine with dedicated CNC machine center to make pull test bars.

Carbon analyzer.

Written procedures, ISO 9000 aligned.

Two 100B mullor machines with digital sampling and control system.

A full sand lab with equipment to measure and track sand grain fineness, compactability, compressibility, clay content, dead clay, moisture content, shear strength, and percent organics (sea coal).

Core Machine Control Panel

HIGH SPEED CORE MACHINE

High speed core shooter.

Foundry Cores

Foundry Pattern Creation

HIGH SPEED PATTERN CREATION

Our experienced pattern shop techinicians are skilled in the art of pattern making, gating and risering.

Casting patterns can be quickly created from drawings, or solid models.

We continuously test and improve castings with computerized solidification modeling.

Foundry Pattern Storage

PATTERN STORAGE

Pattern storage facility is temperature controled to ensure consistent quality.

Automated Finishing

FINISHING

High volume castings are ground or trimmed under robotic control by of our two ABB robots.

We have a talented staff of finishing technicians trained to finish castings according to specifications listed in our casting matrix manual.

Ductile Iron Microstructure

QUALITY CONTROL

All castings that leave our foundry receive the same attention to detail that our own Romac products get.

Raw materials are scrutinized to ensure conformance to specifications.

Quality technicians sample castings for conformance to requirements and work with our Romac Engineering department to improve our written procedures and training in conformance with our ISO-9000 aligned standards.

Other operations may be available upon request.

USA Foundry Map

LOCATION

125 South Sultan Basin Road
Sultan, WA 98294
USA

(map)


FOUNDRY CONTACT & CASTING QUOTATIONS
Bob GIlmore
Ph: 425.951.6479
Fax: 425.951.6467


PIPE PRODUCTS FOR WATER AND WASTE WATER
REPAIR CLAMPS | COUPLINGS | FLANGED COUPLINGS | EXPANSION JOINTS | SERVICE SADDLES | TAPPING SLEEVES
DISMANTLING JOINTS | SEWER PRODUCTS | RESTRAINT SYSTEMS | HDPE PIPE PRODUCTS | MISCELLANEOUS
TRANSMATE TAPPING EQUIPMENT | VALVE INSERTION

© 2017 ROMAC INDUSTRIES, INC. | 1.800.426.9341