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SUPERSONIC TECHNOLOGY

Supersonic technology allows for an effective and at the same time economic non-destructive weld seam testing. Even with wall thicknesses of more than 15 mm it yields excellent test results. 
Especially a lack of fusion in the weld seam between the welding deposit and the parent metal can be recognized clearly and localized, because these flaws are recorded by areas. A supersonic test conducted according to the technical bulletin AD 2000 is always documented in a test report.


X-RAY TECHNOLOGY

A radiographic test of weld seams is conducted with the help of X-ray films and an X-ray tube. The films put on the weld seam are exposed to X-rays, which renders a meaningful evaluation of the quality of the weld seam and the interior state of the weld seam up to a wall thickness of 15 mm possible. 
With X-ray technology, especially pores in the weld seam can be detected. The radiological findings are documented in a test report.

SUBMERGED ARC WELDING

Submerged arc welding is a very safe welding process with excellent welding results. It assures that only little heat enters the parent metal. This maintains the mechanical qualities of the parent metal permanently. Submerged arc welding is characterized by an even weld seam that clearly shows fewer flaws that conventional manual welding processes.

TORQUE TEST STAND FOR GEAR UNITS

The torque test stand serves to check all new or repaired eccentric and planet oil bath transmissions for their nominal and maximum torques in the main drive pinion section. Besides, the braking power, which is so important, can be tested by way of self-locking.


WE WORK ACCORDING TO ...

DIN EN 1247
What does DIN EN 1247 mean for production/business?

Essential changes and additions can be found in the numerous tables that list significant hazards, dangerous situations, safety requirements and/or measures for individual machines. The following new requirements for ladles include:

  • The correct position of the center of gravity of a ladle is essential for operator safety and the handling of the tilting process. Therefore, steel pouring ladles with an auxiliary hoisting-tilting drive must be constructed in such a way that the center of gravity of the ladle is always below the trunnion axis in every operational phase – whether it is empty or filled. A subsequent change of the ladle by raising the tank or by using thinner refractory linings changes the position of the center of gravity substantially. It is therefore not permissible. The center of gravity of ladles operated manually, by compressed air or by electricity must be designed in a way that assures that the existing braking torque of the drive is never overloaded in any operational phase.
  • Most ladles are equipped with gear units. A handwheel, air or electric motor is used to tilt the tank by reducing the gear. For safety reasons the gear units must be equipped with a brake spring that guarantees a dynamic self-locking. This is accomplished when the drive is stopped immediately or after a short time, even if there is still a torque applied on the output side. The current DIN EN 1247 calls for regular tests of the output and brake torques of ladles with a gear unit, to ensure a dynamic self-locking. 
Before, the hanger used to be lowered slowly after the ladle had been emptied. If the hanger was stable while inclined, the brake torque was considered to be ok. If the hanger moved further on its own until it touched the ground, it had to be replaced. It was assumed erroneously that the tilted hanger requires a similar brake torque as a filled ladle during operation. In the future the gear unit will have to be disassembled every 2 years. The output and brake torques have to be checked on a test stand, and the examination data have to be documented.

  • A special hazardous situation exists when a raised ladle falls down. This can be due to wear and tear, fractures and pulling out of structural components. To avoid this, the manufacturer must provide a static strength verification, showing that the required safety factor of 2 is to be expected.
Technical Documentation (PDF)
DGUV, information 209 - 018
This GGVU, Information 209—018 (previously “BGI” – “information from the professional association”) includes recommendations and advice concerning the implementation of regulations issued by the government and by our professional association. The DGVU is an information leaflet of the MMBG on the test requirements and the test extents and the frequency of tests of pouring, transport and slag ladle tests. This information leaflet is to reduce misunderstandings concerning test requirements for ladles, thus avoiding both accidents and damages. Through our close cooperation with the MMBG we are able to give you personal information concerning the DGVU – please contact us by phone or email on this subject.
DGUV, rules 100 - 500
The DGUV (previously “BGR” – “Professional association rules for safety and health at work”) include the current state of industrial safety, and they are a manual for the implementation of accident prevention regulations at work, published by the expert commissions of our professional association. The DGUV, Rules 100 - 500, govern the “Use of Work Equipment”. Chapters 2.21 and 2.8 are of particular interest for our trade. One of them is on the subject of “Running Load Suspension Devices in Hoisting Operations” and the other on "Running a Foundry". Those subjects used to be described under items BGR C 17 and C 19 (now they can be found in Rules 33 and 34). We cooperate closely with the organization NMBG, so we will be happy to provide you with information concerning DGUV, Rules 100 – 500. Please contact us by phone or email on this subject.

CERTIFIED BY …

ISO 9001:2015

In the summer of 2010 the company Foundry Service GmbH was already certified by TÜV Nord according to the state of the art of quality management systems. It was certified according to DIN EN ISO 9001:2015.

But why does the company Foundry Service GmbH work according to the strict regulations in the service and production trades?

Our main objective is to control workflows and interfaces in our company in a way that increases the effectiveness and quality of our work in a purposeful manner. Clearly defined workflows lead to a timely detection of problems and their minimization in the production process. But they also increase the quality and safety of our products. Therefore production times and administrative processing times are reduced.
Besides, all our employees are intimately involved in the processes, receiving available education and training. This means that product and service related improvement potentials are recognized and optimization measures are developed.

The answer could have been shorter and simpler, too:
We wish to continue increasing the good quality and accomplishments of the company Foundry Service GmbH, and we desire to satisfy you as our customer promptly. Therefore we are certified according to the state of the art of the ISO management system.

Evidence of manufacturer qualification
Companies that market steel constructions and other construction products need a qualification evidence that certifies their qualification for the welding of steel constructions. This regulation applies to the international markets as well as to the national market. The qualification certificate is issued by an inspecting authority that is recognized according to building regulations, after the technical staff and the equipment have been checked. The company Foundry Service GmbH was recognized as being qualified for welding according to DIN 18800-7 item 13.1 – 13.3 and the Machinery Directive 98/37/EC.
Evidence of Manufacturer Qualification as a PDF file