STONECAST
STONECAST
What is stonecast?
Stonecast is material made from mineral fillers, quartz gravel, sand,
STONECAST
stone flour and a small percent epoxy-binder. All those ingredients get
mixed into a homogeneous mass which then gets filled into a mould
made of wood, steel or plastic. During the filling process the mould gets
vibrated in order to condense and de-aerate the mixture. After a few
hours the part is ready to be demoulded. Depending on the degree of
accuracy demanded the part is ready for mounting.
Why stonecast?
Higher Damping
STONECAST
In mineral cast the reduction of vibrations is 6 times faster than in
GG-25 and approximately 8-10 times faster than in steel.
Higher Damping in Stonecast
Damping in grey cast iron
Why stonecast?
Higher accuracy of the unmachined part
mounting
casting
comparison to the classic process.
Classical steps
mounting
One step Stonecast production
casting
STONECAST
Stonecast parts are poured mostly ready for assembling in
Why stonecast?
Heat stability
STONECAST
Less thermal conductance and high thermal capacity lead to a high
heat stability, which metallic parts cannot reach.
Classic cast
Stonecast
Why stonecast?
Higher finishing accuracy
STONECAST
Higher production level due to casted in inserts,
steel gibs and pipes, etc.
Why stonecast?
Low costs
STONECAST
If the material is used according to its possibilities, there is
• fewer machining, due to a higher accuracy of the blank
• fewer assembly costs
• fewer logistic costs, due to less single parts and machining operations
Why stonecast?
Quickly available
STONECAST
Mineral cast parts are faster available than iron cast or steel parts,
because of the single-step production process.
Why stonecast?
Ecological view
STONECAST
Less power is necessary for the manufacturing of a mineral cast part than
for iron cast or steel parts. Optimal efficiency of the natural resources, i.e.
one kilogramme raw material forms one kilogramme machine part and there
is no emission similar to the manufacturing of iron or steel cast. Mineral cast
can be recycled.
Why stonecast?
Stonecast is recyclable
STONECAST
Stonecast can be dumped on the wast dump, but becomes usually
disposed like construction waste, i. e. the parts get crushed and are
used as high quality road material.
Why stonecast?
Stonecast in comparision
STONECAST
Stonecast in comparison with cast iron and steel characteristic
characteristic values
unit
stone cast
cast iron
steel
density
kg/ dm3
2,3
7,15
7,85
E-Modul
kN/mm3
30 - 40
80 - 140
210
tensile strength
N/mm2
10 - 15
150 - 400
400 - 1600
compressive strength
N/mm2
110 - 125
600 - 1000
250 - 1200
bending strength
N/mm2
25 - 35
250 - 490
-
0,02 - 0,03
0,003
0,002
damping (log. dekrement)
thermal conductivity
W/Kºm
1,3 - 2
50
50
spezific effective heat capacity
KJ/kgºK
1
0,5
0,5
14 - 16
11
12
thermic co-efficient of expansion
SOLUTIONS
Body for balancing machine 400kg
SOLUTIONS
Bed for machining center 3500kg
SOLUTIONS
Bed for milling machine 2800kg
SOLUTIONS
Bed for assembling system 1500kg
SOLUTIONS
Bed for milling Center 4300kg
SOLUTIONS
Machined, pre-mounted structure for wire erosion machines 1000kg
SOLUTIONS
Bed for tool grinding machine
ready for assembly 2600kg
SOLUTIONS
Bed for tool grinding machine 2800kg
SOLUTIONS
Bed for tool grinding machine 600kg
Advice
We will gladly give you advise regarding the application for stonecast.
EFFORTS
We help you with the decision and take care that the material will
increase your success. Use our 20-years of experience in development
and production to get the results you need.
Construction
We support you constructing the stonecast parts. We get you all the
EFFORTS
information you need to be able to handle the material. We award youif you wish – with the complete construction created on progressive
CAD systems.
Mould making
Together with competent partners we are able to perform different types
EFFORTS
of moulds equivalent to the demanded accuracy and number of pieces.
Forms made off:
• steel
• aluminum
• wood
• plastic
or other compositions
Production
We are equipped with a production area of over 3000 qm and a crane
EFFORTS
capacity of 15 tons maximum. the material gets processed in a
automatic mixing machine, whereby the variance comparison of the
components of each load is logged related to each poured section. In
the case of deviations the system switches off automatically. The silo
system has a capacity of 200t. The production program covers sections
with piece weights of 200 - 7000 kg, with a maximum size of 2500 x
4000 mm, with daily casting.
Mould / processing
Moulding enables series-produced items the production of final
EFFORTS
accuracies without machine cutting. In the process of moulding the
contour of a special moulding device is transferred over special flasking
plaster to the workpiece. With the appropriate accuracy of the moulding
device, accuracies in the micrometer area are possible. Alternatively to
moulding, in co-operation with experienced partners we can offer you
conventional handling by milling, fine milling, grinding etc. Important to
remember is that you can order assembly finished sections directly
from us.
MOULDING
ASSEMBLING
MACHINING