CAST IRON SUPPORTS OUTDOOR STREET LIGHTING. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING...

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CAST IRON SUPPORTS OUTDOOR STREET LIGHTING

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Page 1: CAST IRON SUPPORTS OUTDOOR STREET LIGHTING. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING 1.Classification: As per application As per materials 2.Manufacturing.

CAST IRON SUPPORTS

OUTDOOR STREET LIGHTING

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SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING1. Classification:

• As per application• As per materials

2. Manufacturing process:• Previous research.• Building Moulds.• Smelting pieces.• Mechanize• Finishing• Packing/Handling.

3. General Characteristics:• Differences between cast Iron/Aluminium

4. Quality control possible faults

5. Summary, comments & conclusions

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SUPPORTS OF CAST IRON

APPLICATION

• Columns

• Brackets

MATERIALS

• Cast Iron.• Cast Aluminium• Others no ferrics

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MANUFACTURING PROCESS OF CAST IRON LIGHT FITTING

Previous research.

Building Moulds

Smelting pieces

Moulding Positioning Closing boxes Fusion Rinding Fettled

MechanizeDrillWinchAdjustments

FinishingshotpeenedPutty / finishingPrimer coatingFinishing coated -

colourCamera de

polymerisation

Packing / handling.

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• No norm no standardization / certified

• Research of R. to finite parts.

PREVIOUS RESEARCH

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BUILDING MOULDS

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SMELTING PIECES PROCESS

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MODEL - MOULD - PIECE

Positive model

Negative Mould

positive part

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Mold

Mold with inner part

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MELTING / MELT DRAIN

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RINDING

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FETTLED

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MACHINING

WINCH

DRILL

ADJUSTMENTS

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• Energetic mechanical pickling – shotpeened.

• Primer coating - epoxy 2 components 50/60 μ

• application polyurethane 2 components 90 μ

• Polymerisation chamber

• Packing

FINISHING

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SHOTPEENED

ENERGETIC MECHANICAL PICKLING

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PUTTIED / FINISHING

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PRIMER APPLICATION• Primer - epoxy 2 components 50/60 μ

• Application of polyurethane in 2 components 90 μ

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POLYMERISATION CHAMBER

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PACKING / HANDLING

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GENERAL CHARACTERISTICS OF OUTDOOR STREET LIGHTING IN CAST IRON

• Reproduction of forms

• Great similarity of pieces

• Section & Strongest

• Texture

• Synonymous of quality

• Recyclable 100% without cost raw material

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REPRODUCTION FORMS

PART

MODEL

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GREAT SIMILARITY OF PIECES

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SECTION & STRONGEST

BS 3000

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TEXTURE

DETAIL OF

BS 3000

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SYNONYMOUS OF QUALITY

MATARÓ, SPAIN PROJECT

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SYNONYMOUS OF QUALITY

TARRAGONA, SPAIN PROJECT

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SYNONYMOUS OF QUALITY

SEVERAL

PROJECTS

ALICANTE VALENCIA

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RECYCLABLE 100% WITHOUT COSTRAW MATERIAL

PEAR

FURNACE LOADING

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CHARACTERISTICS OF CAST IRON

• Type EN-GJL-200 As per norm: EN 1561

• Type EN-GJS-500-7As per norm: EN 1563

• Differents degrees R. of stretching.

• Good behavior to oxidation.

– Non reduction section.- Oxide = Protection

Grey cast iron (traditional)

Ductile cast iron (> R)

Page 43: CAST IRON SUPPORTS OUTDOOR STREET LIGHTING. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING 1.Classification: As per application As per materials 2.Manufacturing.

• Norm EN 1706

• Many alloys according to application.

• Great difference of €/Kg. Acording quality Danger

• In “normal” alloys, porous oxide Progressive

Oxidation• Galvanic Par with fastening bolts & Columns.

CHARACTERISTICS OF CAST ALUMINIUM

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QUALITY CONTROL

• Metallurgical quality control • Thicknesses control with ultrasounds • Hardness control• Primer micron-size control & painting by

ultrasounds• Adherence control• Chamber control of foggy salt • Ultraviolet chamber control• Effort in point control in test machine.

POSSIBILITYOF FAULTS

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METALLURICAL QUALITY CONTROL

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THICKNESS CONTROL WITH ULTRASOUNDS

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HARDNESS CONTROL

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PRIMER MICRON-SIZE CONTROL & PAINTING BY ULTRASOUNDS

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ADHERENCE CONTROL

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CHAMBER CONTROL OF FOGGY SALT

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ULTRAVIOLET CHAMBER CONTROL

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EFFORT IN POINT CONTROLIN TEST MACHINE

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SUMMARY, COMMENTS & CONCLUSIONS

• Historically, light fitting with gas were only of casting• Possibility of recovering old forms• Project quality• Possibility of mixed lamp post + slender + economic• Cast iron Lamp post

- Progression of oxidation- Galvanic Par

• Brackets of cast aluminium, thickness 1/3• Columns no approved Pay attention to the quality• Are hte supports “for all the life”• Sevilla, supports catenary tram with outdoor street lighting• Sculptures up to 8 Tn.• Differents pieces not catalogued• Class I. to control gear is essential earth wire.

Page 54: CAST IRON SUPPORTS OUTDOOR STREET LIGHTING. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING 1.Classification: As per application As per materials 2.Manufacturing.

BINEFAR

CASTING OF BIG PIECESBINÉFAR (SPAIN)

Page 55: CAST IRON SUPPORTS OUTDOOR STREET LIGHTING. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING 1.Classification: As per application As per materials 2.Manufacturing.

MONZÓN

HANDLING & LOGISTICMONZÓN (SPAIN)

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SABADELL

CASTING OF SMALL PIECES & HEAD OFFICESSABADELL (BARCELONA-SPAIN)

Page 57: CAST IRON SUPPORTS OUTDOOR STREET LIGHTING. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING 1.Classification: As per application As per materials 2.Manufacturing.

R. ROS ALGUER S.A.CASTING & LIGHTING

Joan Ros CasanovasEngineer Metallurgical

Presentation at TECNICAT5 february 2009

www.fundicionros.com


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