Sheffield Forgemasters was contracted to produce a series of 11 ultra-large castings which in total required over 6000 tonnes of molten steel. This posed a number of manufacturing challenges.
Firstly, there was the sheer volume of molten steel required for each component, the largest required over 600 tonnes of steel for a single pour.
Secondly, castings of this size require a vast amount of modelling, simulation and planning before they go to manufacture. The ultra-large size means that very few foundries are capable of manufacturing them so experience is relatively limited.
Finally, was the large amount of space required, not only to mould, cast, and store but also to manoeuvre and transport components of this size.
The combination of challenges and the short time scale placed Sheffield Forgemasters in an almost unique position to fulfill the requirements.