During casting shakeout, the molds are knocked out after pouring and cooling on the shakeout deck of a 40,000-pound-per-hour mechanical reclaim system. Sand is reprocessed mechanically or thermally and returned to storage.
The normal processing of rough castings begins with blasting before the removal of gates, sprues, and risers. There are two cleaning methods available – shot blast with steel shot (the cleaning envelope is 8 feet in diameter and 4 feet deep) or grit blast with an iron-free medium (used on stainless steel).
Castings are sorted by size and metal type, then ground to remove extraneous material. Most fettling is done manually using two swing-frame cutters and grinders. Air grinders are used for hand cleaning of castings. The plant also has air arc facilities for cutting stainless steel and other high alloy material.