To meet the diverse and exacting demands of modern industrial casting, Tabarestan Steel Foundry (TSF) employs a strategic dual-facility approach. By operating two distinct foundries, each dedicated to a specific casting methodology, we offer our clients the perfect balance between massive scale and micron-level precision.

Whether the requirement is for a massive 10-ton gyratory crusher part or a delicate, 6mm slot for grate plates, TSF possesses the specific technological infrastructure to deliver the optimal solution.

Foundry No. 1: The Heavy-Duty Powerhouse (Sand Casting)

Process: Advanced Sand Casting Our first facility is dedicated to the art and science of sand casting, a robust and time-tested method ideal for producing large-scale, heavy-weight components.

The Application: This foundry is the backbone of our heavy industry supply chain. The sand casting process allows for exceptional flexibility in component size and weight, ensuring the structural integrity required for parts used in punishing environments like mining, cement, and steel rolling.

• Durability: Produces parts with the internal soundness to withstand high impact and stress.
• Scale: Capable of handling massive tonnage, making it the method of choice for SAG mill liners, center part of pallet cars, gyratory crusher parts, heavy duty slurry pump parts,...

Foundry No. 2: The Center for Precision (Replicast Technology)

Process: Ceramic Moulding with Polystyrene Patterns In a major technological leap, TSF acquired the license for Replicast technology from the prestigious British company CTI (formerly CDC) in 2000. This innovative process revolutionizes the casting of high-quality components by utilizing expanded polystyrene patterns encased in a high-grade ceramic shell.

The Replicast Advantage: This technology bridges the gap between traditional sand casting and expensive investment casting. It enables the production of lightweight components with exceptional dimensional accuracy and superior surface finish. By utilizing a vacuum-assisted pouring process, Replicast delivers "near-net-shape" castings that redefine quality standards.

Key Technical Benefits:

• Superior Surface Quality: The ceramic shell produces an ultra-smooth finish, significantly improving aesthetics and fluid flow performance in parts like pumps and valves.
• Exceptional Dimensional Accuracy: Tighter tolerances mean the casting matches the design blueprint with high fidelity, essential for high-accuracy applications.
• Unconstrained Design Freedom: The process eliminates the need for core making or draft angles. This allows engineers to design complex geometries and undercuts without the manufacturing limitations of traditional molds.
• Metallurgical Purity: There is no chemical reaction between the molten metal and the inert ceramic mold, preserving the absolute integrity of the alloy’s chemical composition.
• Defect-Free Structures: The use of vacuum-assisted pouring actively removes gases, effectively minimizing or eliminating blow holes and porosity.
• Cost & Time Efficiency: Because the parts are cast closer to their final shape, machining requirements are drastically reduced, saving clients significant time and tooling costs.
• Ideal for Complexity: It is the perfect solution for small, lightweight, and intricate castings across the oil, gas, and automotive industries.

Select the Right Technology for Your Project 

Do you need the massive durability of Sand Casting or the intricate precision of Replicast? TSF offers both under one roof. Consult with our engineers to determine the most cost-effective path for your components.