architecture - goodwin steel castings can carry out a finite element analysis of the casting to...

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A R C H I T E C T U R EC O N C E P T • C A S T I N G • C O M P L E T I O N

A R C H I T E C T U R E

C O N C E P T • C A S T I N G • C O M P L E T I O N

Jackfield BridgeEngland.

Paddington StationLondon.

Ludwig Erhard HausBerlin.

Goodwin Steel Castings Ltd has become synonymous with high standards of precision manufacturing over a history of 130 years.

We are able to supply large machined castings from 200kg to 18,000kg, fabricated castings to 30,000kg and assemblies up to 70,000kg from carbon steels, stainless steels, duplex stainless steels and cutting edge materials such as super nickel alloys.

The foundry is supported by our sister company, Goodwin International Ltd, located 8km away which satisfies our CNC machining, fabrication and assembly requirements.

Goodwin Steel Castings Ltd supplies predominantly to the construction sector, oil and petrochemical, power generation and renewable technology industries.

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Eden House,Central London.

Eden House Detail.

STEEL CASTINGSFOR CONSTRUCTION

In-House Design Resources -Solid Modelling.

Goodwin manufacture steel castings that allow the building professional freedomof design to achieve unique and architecturally attractive components for bridgesand buildings. Components can be decorative only or utilise the high strength ofsteel to carry structural loadings.

Complexity and fabrication can be simplified with a steel casting. The castingprocess allows the production of simple or complex shapes with high strength,ductility and toughness with excellent surface finish. Further processing includingCNC machining, fabrication, welding and painting can be undertaken to enhance the finished product.

Early consultation with Goodwin will provide confidence in specifying and provide an opportunity to optimise design to obtain lower costs and shorter delivery lead times.

www.goodwinsteelcastings.com

Feature columns.

Public art.

REaSoNS To SPECIFy CaSTINGS

• Extensive choice of shape and range of sizes

• Desirable surface finish

• Large range of steel grades

• High dimensional accuracy

• Streamlined shape for minimum stress concentrations

• Shape for maximum strength and minimum weight

• Single integral components

• Ease of integration into overall structure

• Simplifies complicated fabricated junctions to form elegant connections

• Eliminate fatigue sensitive joints

• Isotropic material properties

• Excellent low temperature performance for specified grades

Castings for oil rig connection nodes.



CONCEPT TO CASTING

Three Dimensional design stage drawing.

Computer solidification simulation.

Goodwin will work closely with the professional design team or contractor to assist in the production of an optimised and competitive solution to their casting needs. We appreciate that development work will be needed during the early stages of design, prior to a tendering process, so we are prepared to invest our time without commitment.Detailed below is an outline of the interaction between a professional design team

and Goodwin:

oUTLINE SKETCHan outline sketch or drawing indicating the principal dimensions, material properties and structural loadings is forwarded to Goodwin.

INITIaL DESIGNGoodwin generates a detailed three dimensional drawing using the sketch concept and adding features essential to the casting process such as fillets and moulding taper. If required we can carry out a finite element analysis of the casting to check structural adequacy.

a computer simulation of the solidification of the casting is run to optimise the shape, predict shrinkages and design out detrimental residual stresses. a drawing is then returned to the professional team or customer, detailing the finalised shape, fully dimensioned with the tolerances that can be achieved both for cast dimensions and any machining.

QUoTaTIoNS & PRoGRaMMEa detailed quotation with a manufacturing, inspection and test plan programme is provided for each enquiry.


Melting & pouring.

PaTTERN MaNUFaCTUREour in-house pattern shop produces the patterns from which the castings will be manufactured. The patterns will be used to create the sand moulds into which molten metal is poured.

MELTING & PoURINGMetal is melted in one of either two electric arc furnaces or two induction furnaces and, if required, transferred to the aoD (argon-oxygen decarborisation) vessel for refining. Here, volatile elements are removed from the mix, helping to reduce the impurities and inclusions in the steel.

Molten metal is dispensed from the furnace or aoD vessel into a ladle. The ladle is then positioned above the mould before pouring the molten metal into the mould. The metal is then left in the mould to cool until it solidifies. This process can often take days rather than hours. once cooled, the casting is “knocked out” of the mould and given a preliminary fettling.

TESTING & MaCHININGFollowing fettling, the casting is heat treated in order to optimise its mechanical properties followed by NDT (non-destructive testing) such as radiographic, magnetic particle or ultrasonic inspection.

The casting then undergoes machining down to the specified dimensions. Here internal cavities or features too complex for the casting process are cut into the component. any further fabrication will also take place at the machine shop.

Following any testing, final dimensional inspection is conducted before the casting is packed and shipped to its destination.

Pattern inspection.

CNC machining.

Wembley Stadium is the home of the English National football team, has a 90,000 spectator capacity and is one of the largest covered football stadiums in the world.

an all-seater stadium, Wembley is bowl shaped with a partially retractable roof supported by a 133m high tubular lattice arch spanning a world record 315m. The iconic arch has a 7m lattice, erected 22° off true and supports all of the north roof and most of the retractable roof on the southern side of the stadium.

High tensile cables from the roof are fixed to the lattice arch via high load capacity, bespoke low alloy steel sockets manufactured and supplied by Goodwin.



Location of cable sockets.

High tensile strength, cast cable socket.

WEMBLEY STADIUM

PROjECT WEMBLEY STADIUMLOCATION LONDON ARCHITECT FOSTER & PARTNERSSTRUCTURALENGINEER MOTT MACDONALD

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Cabinet offices - Whitehall, LondonGoodwin manufactured and machined stainless steel columns and glazing arms for the refurbished walkway canopy. Early involvement with the architect at design stage ensured the aims of the design concept and buildability were achieved.

Triton Square - Knightsbridge, Londonover 250 feature columns for a scenic lift were manufactured for this significant office building which includes a large financial trading floor. Each feature column was fabricated from a combination of castings and plate. The finished items were painted and then inspected by the architect, arup associates, prior to packing and despatch.

Halkin arcade - Knightsbridge, LondonNew column capitals were manufactured for the redevelopment of this Grade II listed building which houses many fine restaurants and retail units in this prestigious area of London.



PROjECTS IN THE CAPITAL

Triton SquareKnightsbridge, London.

Halkin arcadeKnightsbridge, London.

Cabinet officesWhitehall, London.

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Cabinet offices Whitehall, London

Paddington Station is one of the great Victorian Stations, Grade 1 listed, with construction dating from 1838 as the London terminus of the Great Western Railway. Much of the mainline station dates from 1854, designed by Brunel, with the world’s first Underground railway following in 1863.

The station needed to be redeveloped to establish an international identity and to provide facilities for the Heathrow Express. The redevelopment included extensive improvements to the existing building’s fabric and functional use together with a new addition, creating a passenger waiting area and check-in facility. This structure was covered by a long span, lightweight and trussed glass roof together with a smaller scale steel spine roof.

The lightweight glazed roof has a saw-tooth form with slender tubular members and a cable bottom tension chord. a 22% Cr duplex stainless steel casting provided an aesthetically pleasing and simplified solution to the three dimensional connection of the tubular members and tension chord.

Public information is displayed on two banks of plasma screen monitors cantilevered from a central support.



PADDINGTON STATION

PROjECT PADDINGTON STATIONLOCATION LONDON ARCHITECT NICHOLAS GRIMSHAW & PARTNERSSTRUCTURALENGINEER WS ATKINS CONSULTANTS

a combination of duplex stainless steel spiders, manufactured by Goodwin, and glass was a natural choice for the new addition as a modern update to compliment the style of the original Victorian architecture.

BCSa Structural Steel Design award presented to Goodwin Steel Castings Ltd.

Detail of cast node to roof truss.

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Stratford Regional Station is on the Jubilee Line Extension linking central London with Greenwich and is the main arrival point for visitors to the olympic park.

The building is formed by a single curved roof springing from an upper level, which sweeps up to a tall glazed wall orientated towards the railway tracks and the nearby town centre. The building outline creates a single major space for the various train services using the station.

a complicated connection of the tall glazed wall, circular hollow section ring beam, wind bracing and roof was simplified with an elegant steel casting.

at the haunched side of the building the entire curved roof bears on the upper floor which in turn is suspended on four cast steel bearings which Goodwin manufactured. In this way, ease of assembly was achieved, coupled with architecturally pleasing lines. Individual steel roof arches bear onto the upper floor with castings that continue the sweeping lines of the roof.

Wilkinson Eyre architects received several honours for this project including short listing for the Stirling Prize.



STRATFORD STATION

PROjECT jUBILEE LINE EXTENSIONLOCATION LONDONARCHITECT WILKINSON EYRESTRUCTURALENGINEER HYDER CONSULTING LTD

one of the 16 off base castings.

Detail of tall glazed wall.

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The prestigious Ludwig Erhard Haus was designed by British architect Sir Nicholas Grimshaw to house the Berlin Stock Exchange, the Chamber of Commerce and the Local Federation of Industrialists. Lettable office space and conference facilities were also a requirement of the brief.

all upper floors are suspended from fifteen elliptical arches to give flexibility for both usage and servicing.

Goodwin were commissioned to manufacture 316 stainless steel cast footings to all of the elliptical arches.



PROjECT LUDWIG ERHARD HAUSLOCATION BERLINCLIENT IHK - BERLIN CHAMBER OF COMMERCEARCHITECT GRIMSHAWSTRUCTURALENGINEEER WHITBY & BIRD

Stainless steel cast foot assembled and in position, consisting of two cast cladding elements and a single foot piece.The castings were grit blasted and then acid pickled in order to achieve a uniform and pleasing finish.

an anti-vandal turnbuckle assembly, designed and manufactured by Goodwin, used to locate and fix the completed casting. The turnbuckle assembly is made up of investment castings (a process for casting small components) and machined bar.

LUDWIG ERHARD HAUS

Model wooden pattern for the foot casting.

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Picture courtesy of The Institution ofCivil Engineers

Jackfield Bridge, EnglandJackfield Bridge is located in the centre of the Severn Gorge World Heritage site in Shropshire near Ironbridge. Goodwin manufactured the feature circular casting between the supporting tubular pylons.

Tsing Ma Bridge, Hong KongThe Tsing Ma suspension bridge carries both vehicular and railway traffic between the centre of Hong Kong and Chep Lap Kok airport.

With a 1,377m span and significant road and rail loadings the bridge must also sustain severe wind loadings during typhoon conditions. Goodwin manufactured cable bands that can be subjected to such traffic and wind loadings.

Jiangyin Bridge, ChinaThe Jiangyin suspension bridge, opened on the 50th anniversary of the Chinese Revolution, carries a six-lane highway 1,385m across the yangtze River and connects the cities of Jiangyin and Jingiang.

Goodwin supplied cast, machined cable bands that were supplied with a zinc metal spray paint system for superior corrosion resistance.



GLOBAL SUSPENSION BRIDGES

a 12 bolt 1800mm cable band assembly undergoing dimensional inspection prior to packing.

“It is a credit to all, that this, and all previous shipments have been to programme, the record of achievement is excellent. May I also acknowledge the co-operation, technical support and professional manner in which business has been conducted throughout.”

Peter Robinson, Tsing Ma Project ManagerKvaerner Cleveland Bridge

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Jackfield Bridge, England

Jiangyin Bridge, China

Tsing Ma Bridge, Hong Kong

Hardanger Bridge is a 1,310m span suspension bridge that will cross the Hardangerfjord linking oslo and Bergen replacing a ferry connection. The height of the supporting towers above sea level will be approximately 186m with a maritime clearance of 55m.

Goodwin won the contract to supply cable bands and the cable saddles that have been installed at the top of the supporting concrete bridge pylons to carry the massive loads from the supporting deck cables.

Each splay saddle comprised of a machined 13Cr4Ni stainless steel bearing welded to a carbon steel plate box section.

Expert knowledge from Goodwin was required to weld the two dissimilar steels in the splay saddles to prevent distortion of the fabrication.



HARDANGER BRIDGE

PROjECT HARDANGER BRIDGELOCATION NORWAYCLIENT NORWEGIAN PUBLIC ROADS ADMINISTRATIONMAIN CONTRACTOR STATENS VEGVESENDESIGNER FORUM ARKITEKTER

13,500kg tower saddles.

26,500kg splay saddles and cable bands.

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oakland Bay Bridge spans the San Francisco Bay carrying traffic on an upper and lower deck. The main section of the western approach is a suspension bridge connecting San Francisco to yerba Buena Island whilst the eastern approach was, prior to the Loma Prieta earthquake in 1989, a cantilever bridge connecting the island to oakland.

During the earthquake, a section of the eastern span collapsed onto the lower deck of the eastern bridge.

Reconstruction of the eastern span took the form of a suspension bridge supporting a 10 lane highway with an estimated traffic flow of 270,000 vehicles per day.

Goodwin supplied the cast steel cable bands for the bridge.



OAKLAND BAY BRIDGE

PROjECT OAKLAND BAY BRIDGELOCATION SAN FRANCISCO, USACLIENT CALTRANSMAIN CONTRACTOR AMERICAN BRIDGE COMPANY / FLUOR jVDESIGNER TY LIN INTERNATIONAL

Goodwin manufactured 118 carbon steel cable bands in differing sizes (from 2 to 6 tonnes assembled weight) for this bridge.

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This facility is used to lift Royal Navy nuclear submarines out of the water for refits and maintenance. By using the Syncrolift, work can be carried out on a submarine without the space restrictions of a traditional dry dock.

The facility, located in Scotland, is housed in a covered dock building and is 165m in length with a lifting capacity in excess of 25,000 tons.

Goodwin manufactured high tensile steel hanger beams that anchor the platform hoist system together with stainless steel submarine guide rails.

as the hanger beams are a critical element of the lift, the mechanical, chemical and toughness characteristics of the castings were carefully controlled and monitored.



PROjECT FASLANE SUBMARINE BASELOCATION SCOTLANDDESIGN ENGINEER NEI SYNCROLIFT, MIAMICONSULTINGENGINEEER BABTIE, SHAW & MORTON

a submarine approaches the Faslane base near Glasgow. This is one of the few facilities in the world where a nuclear submarine can be lifted out of the water.

Goodwin produced 120 fully machined stainless steel guide rails to meet the specified stringent tolerance requirements.

FASLANE NUCLEARSUBMARINE SYNCROLIFT

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FoUNDRy CaPaBILITy• Finite Element analysis solidification simulation

• Melting by electric arc and induction furnaces – refining by aoD (argon-oxygen decarburisation) vessel

• Non-destructive testing by ultrasonic, magnetic particle, dye penetrant, radiography by 8.5MeV linear accelerator. In-house aSNT level III

• Gas fired heat treatment with a capacity of 50 tonnes to a temperature of 1,300°C. Furnace, air, forced air and water quenching cooling

• In-house pattern shop

• Fully qualified welders

• Test house for mechanical, corrosion and chemical analysis

• Fully equipped CNC machine shop for machining, fabrication, painting and assembly

• 24 / 7 Shift working at the foundry and machine shop



FACILITIES

aoD refining vessel.

Heat treatment facilities.

Dye Penetrant Testing.


D E L I V E R I N G

E X C E L L E N C E

E V E R Y T I M E

Magnetic particle crack detection.

8.5Me linear accelerator.

NDT (NoN-DESTRUCTIVE TESTING) Goodwin can undertake extensive in-house NDT testing including: radiographic, ultrasonic, dye penetration and magnetic particle inspection techniques.

SURFaCE FINISH oR RoUGHNESSall Goodwin castings for the construction sector meet the requirements of BS EN 1370, Surface Roughness Inspection by Visual Tactile Comparators.

REFERENCESCastings in Construction, SCI P172BS EN 10340 Steel Castings for Structural UsesBS EN 1559 Parts 1 and 2 Founding -Technical Conditions of DeliveryBS EN 10002 Tensile TestingBS EN 10045 Charpy Impact TestBS EN 10204 Inspection DocumentsBS EN 1369 Magnetic Particle InspectionBS EN 1370 Visual Surface ComparatorsBS EN 1371 Liquid Penetrant InspectionBS EN 12680 Ultrasonic InspectionBS EN 12681 Radiographic Inspection

Ultrasonicinspection.

CaRBoN, STaINLESS & DUPLEX STEELSGoodwin has the expertise to produce cast steels for all applications in the construction industry including carbon, stainless, duplex stainless steels and super nickel alloys.

Within Europe, BS EN 10340 ‘Steel Castings for Structural Uses’ provides specifications for the chemical composition and mechanical properties for appropriate steels. Carbon steel grades G17Mn5 and G20Mn5 are suitable for many applications with tensile and toughness properties similar to hot rolled structural sections.

Stainless steels GX2CrNi9-11 (formerly 304L) and GX2CrNiMo 19-11-2 (formerly 316L) perform well in architectural applications. The pleasing surface finish combined with the inherent corrosion resistance removes the need to paint or protective coat.

Duplex stainless steels offer a significant advantage over GX2CrNi9-11 and GX2CrNiMo 19-11-2 with much improved mechanical and corrosion resistance properties. Resistance to stress corrosion cracking and pitting corrosion makes duplex an excellent choice for seawater applications.

Goodwin are able to produce cast steels to national and international standards.



MATERIALS

alloying elements.

Carbon SteelFerrite & Pearlite Micro-Structure.

Duplex Stainless SteelFerrite & austenite Micro-Structure.


Dimensional checking.

CERTIFICaTIoN aND TRaCEaBILITyEvery melt in the foundry is supplied with an Inspection certificate 3.1 to BSEN10204 which details tensile, toughness (Charpy) and integrity testing together with chemical analysis. If required, we can supply a 3.2 certificate for independent witnessing of testing.

Each inspection certificate has a unique identification number, generated by our management system software, which is copied onto to each casting to ensure traceability.

all documentation is retained electronically and can be reproduced as required in the future.

GooDWIN INTERNaTIoNaL The machine shop is well equipped with a wide range of CNC and conventionally controlled machines including:

• Vertical boring - Swing 4013mm, Turn ø 3708mm, Turn Height 3505mm, 6 position tool changer

• Vertical boring centres - Turning 3000mm diameter x 3500mm high, 2070 ram travel, 12 position tool changer

• Horizontal boring - X axis 850mm, y axis 760mm, Z axis 780mm, 60 position tool changer

• CNC Lathes - 5 axis machining heads available for all boring machines

Cable band.

CNC horizontal borer.

Goodwin Steel Castings is part of the Goodwin Engineering Group and one of the foremost, independent producers of high alloy and high quality integrity castings in Europe.



APPROVALS & CERTIFICATES

aCCREDITED MaNaGEMENT SySTEMSQuality (ISo9001) Environmental (ISo14001) Health and Safety (oHaS 18001)

MaNUFaCTURING aPPRoVaLSLloyds Register (LR)american Bureau of Shipping (aBS)Det Norske Veritas (DNV)NoRSoKRolls Royce

Queens award for Enterprise

RIBa approved CPD Provider

The Welding Institute

British Constructional Steelwork association

Casting Metals Federation

Goodwin are able to supply CE marked castings to BSEN10340

Steel Construction Institute

CONTACTS & LOCATION

Goodwin Steel Castings is easily accessible from the M6 motorway at junction 15 or 16 and then along the a500. From the M1 motorway, take junction 24a and then the a50 to Stoke-on-Trent.

Brian QuinnSales DirectorTel +44 (0)1782 220244Mobile +44 (0)7766 315829Email [email protected]

Peter StokoeConstruction Sector Sales ManagerTel +44 (0)1782 220338Mobile +44 (0)7854 474470Email [email protected]

STOKE-ON-TRENT

GOODWINSTEEL

CASTINGS

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M6 Jct16

M6 Jct15

A500

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STAFFSUNIVERSITY

Manchester Airport1 hour by car

Birmingham Airport1 hour by car

Heathrow Airport2½ hours by car

Goodwin Steel Castings LtdIvy House FoundryStoke-on-TrentST1 3NRUnited Kingdom

Tel +44 (0)1782 220000Fax +44 (0)1782 208060Email [email protected] www.goodwinsteelcastings.com

While every effort has been made in the compilation of this brochure to ensure accuracy, no guarantees are given and it is the responsibility of the user to verify all information. Given the need for continuous competitive improvement we reserve the right to modify our scope of supply as outlined in this brochure as is considered appropriate to each market place.

Ivy House FoundryStoke-on-Trent

ST1 3NRUnited Kingdom

Tel +44 (0)1782 220000Fax +44 (0)1782 208060

Email [email protected]


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