Specialist manufacturer of steel castings up to
12,000 kgs
Fabrications up to
30,000 kgs
Bonds Hold Ltd
BondsFoundry@Crook
BondsFoundry@TowLaw
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BondsPrecision@Alston
Darwins@Sheffield
Manufacturing capability for single steel castings up to 12,000 kg
Ability to fabricate 30,000 kg casting
Quality, bespoke-engineered products to international standards
Experience in the manufacture of 150+ grades of steel
Competitive delivery times
240 employees and growing (excludes Darwins)
Bonds Group Statistics
Sales €m
25
20
15
10
5
0
2008 2009 2010 2011 2012 2013 2014
• Balance Sheet net worth €10 million
• Low gearing with 17% debt ratio
at 30/09/14
Export-led organisation
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Sell to >25 countries across the group
45% of sales direct export
Trade executed in various currencies: £, $, €
Recipient of Queen’s Award for international trade
BondsFoundry@TowLaw
– Chemically bonded sand system
– 150+ grades of steel
– Accreditations:
• DNV ISO 9001 (combined with Crook)
• Approval for Manufacture: Lloyds, DNV,
ABS, GL, BV
• Approval for supply to: Siemens, Alstom,
Flowserve, Rolls Royce, Crane, Weir,
Howden
• Working in accordance with NORSOK M650 and ExxonMobil
• 105 Employees
BondsFoundry@Crook
– £4m investment in new foundry with latest equipment and
technology
• New investment £860K in finishing, storage and fabrication
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Capable of producing castings from 50 kg to 2,500 kg
DNV ISO 9001 certified (combined with Tow Law)
Four furnaces ranging from 1T to 3T
10 acre site
BondsPrecision@Alston
– EcoShaw ceramic moulding method ideal for castings which need high
definition, accuracy and integrity
– Accreditations:
– BS EN ISO 9001:2008
– NORSOK M-650
– ExxonMobil and Statoil approvals 90 Employees
Bonds Acquire Darwins
Darwins Castings
• Foundry Type: Sand moulding, specialist, jobbing
and high integrity
• Size: £5 million turnover; 60 employees
• Weights: 1kg – 3,000kg
• Materials: carbon, stainless, duplex, super duplex, high
alloy steels and nickel based alloys – all from the same
pattern
Darwins Castings - Products
• Pump Sector: bowls, impellers, suction casings
and diffusers
• Valve Sector: bodies, bonnets, discs and
covers
Organisation – Bonds Group
Organisation – Bonds Foundry (1)
Organisation – Bonds Foundry (2)
Material Expertise: 150+ grades of steel
Material type
Applications
Carbon Steel
General engineering applications and for use in specific oil and gas explorations and production.
Upstream and downstream processes and both sour and sweet environments.
Alloy Steel
Providing high strength, low temperature impact properties and high temperature creep resistance.
High Alloy Steel
Imparting high strength for critical applications.
Austenitic
Stainless Steels
A range of austenitic grades imparting resistance to a wide range of corrosive environments.
Martensitic
Stainless Steels
A range of martensitic grades imparting resistance to cavitation at relatively high temperatures
including steam turbines and excellent toughness especially at low temperatures.
Duplex and Super Duplex
Stainless Steels
A range of duplex and super duplex stainless steel grades for high strength combined with corrosion
resistance; particularly resistant to sulphide stress corrosion cracking and localised attack
(pitting/crevice).
Super Austenitic Stainless
Steels
Providing resistance to high corrosion environments in sea water, high chloride and extreme sour
service applications and erosion corrosion.
Nickel-based Super Alloys
Imparting good mechanical strength and impact resistance. high resistance to creep at high
temperatures. Excellent corrosion and oxidation resistance.
Long history of supplying castings to marine industry
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For cruise and commercial ships we have made castings for stabiliser, steering
equipment and stainless propeller bosses and associated equipment.
We are also experienced in the manufacture of: stern tubes, stern bosses, stem bars ,
gudgeons and suction mouths for dredgers.
9T Stabilizer Crux in carbon steel
[2T] King Pins in carbon steel
‘A’ and “I” Brackets to BAE Systems for
the Royal Navy’s T45 Destroyers, RCB 2,
Babcock & Royal Schelde on “grey” ships
4-year contract (plus 1 year extension)
with UK Ministry of Defence for supply
and refurbishment of anchors for the
British Navy
Recent Marine Castings
RCB 2 ship 1 boss
RCB 2 rudder bearing pattern
Irish OPV - Stem
Irish OPV – I and A frames
Customers:
3D scan RCB 2 Pattern
River Class Batch 2 (RCB 2)
• BondsFoundry@TowLaw
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Magma Simulation – Arm Casting
River Class Batch 2 (RCB 2)
• BondsFoundry@TowLaw
• Magma Simulation – RCB 2 boss
Development/ Strategy Bonds Group
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Further investment at BondsFoundry@Crook
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Fabrication and Pattern storage facilities at Crook
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5.5m product envelope
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30T capacity (T26 optimised) - complete
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New pattern Store (s) on Crook site – under construction
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Integrated inspection and finishing of all castings to Crook
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Total Investment £840K
Further investment at BondsFoundry@TowLaw
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Crane and extraction upgrades –South Works
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Integrated heat treatment facility including quench North Works
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Total investment @ £1.5M
Further Investment at BondsPrecision@Alston
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Building for expansion improved layout and reduced costs
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Total Investment @ £1.2M
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Technical expertise and continuous investment in plant ensures integrity of castings
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Dedicated project manager ensures on-time delivery and co-ordinated working with machinists
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Commitment to invest in further project specific requirements: e.g grinding, scanning etc.
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Acquisition of capacity
Inspect
CROOK
FACILITY
Construction Area
Weld
Melt
Mould
Cores
Dress
Shape
New Fabrication Area
Quality Culture
• Manufacturing to an established ISO 9001:2008
system and in a transition to the 2015 standard,
Bonds operate to the spirit of being quality conscious.
• Quality management principles and new concepts
have been detailed by our UKAS independent auditor.
• Bonds recognise that the 2015 version of ISO 9001 is
the most significant revision since the standard was
first published in 1987.
Quality Culture
• Recognition that management responsibility
becomes leadership.
• Leadership and commitment shall be applied by
top management. Reviews currently in place for
the quality policy and quality objectives.
• Strategic direction shall be commensurate with
the systems objectives.
• An intrinsic approach to quality shall be the
culture.
Quality Culture
• The system drives continual improvement and
develops leadership via management.
• Bonds recognise that the top management are now
explicitly required to maintain a focus on consistently
providing products and services that conform to
customer requirements.
• Quality is not a one off activity.
• Top management have established the quality policy,
which will be implemented and maintained at the
highest level.
Improvements
• Improvements in Quality are driven through continuous
improvements methods using real time data. Bonds recognise that
this is a new clause in 9001 (10.1). Bonds look ahead and use lessons
learnt approach to meet future requirements.
• Review of non conforming product and process innovation are led by
both quality and production management.
• Bonds use a ‘defectology’ format to review quality performance via
Pareto analysis and statistics.
• Quarterly reviews with the customer base are conducted as part of
continuous improvement programmes.
• Bonds engage with customers at the earliest stage to ensure the
process is defined to deliver.
• A lessons leant philosophy is used to review contract performance and
where applicable CAPA applied to prevent reoccurrence /
improvement.
SQA (external provision).
• Bonds take procurement seriously and use only
approved suppliers via the QMS.
• Key suppliers are identified.
• Bonds work closely with the supply chain to ensure
that products and services meet the high expectations
of the business.
• Emphasis on section 8.4 of ISO 9001 to address all
forms of external provision. A risk based approach.
Planning – actions to affect risk and
opportunity.
• Sub clause 6.1.1 of 2015 version of 9001 is a new and key
requirement.
• Planning involves process realisation through application of
quality objectives, changes and resources.
• Bonds apply quality tools such as ITP’s for process control
linked to proven procedures and instructions.
• Bonds acknowledge that risk should be measured through
controlled planning procedures, however, we also focus on
opportunity.
Non conformance / dimensional example.
• The following slides show the innovative techniques applied to
the manufacture of port and starboard brackets using 3D
scanning equipment.
• Scanning of patterns, castings and the ‘material removal’
process enabled a planned approach to problem solving for
dimensional accuracy.
• The iterative process enables castings to be evaluated over a
number of complex surfaces finding the best possible solution to
achieve the required outputs.
• Emphasis on corrective measures rather than preventive are
commensurate with the new ISO standard where areas for
opportunity and improvement are focussed upon.
RCB 2 – In- Process Scanning to 3D model
Ship 1 – Port and Starboard. Starboard after welding and Port prior to
welding – agreed hold points.
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RCB 2 – In- Process Scanning to 3D model
Port prior to weld – details to machinist to compensate on inboard arm
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RCB 2 – In- Process Scanning to 3D model
Machinist finished machined bore and compensated for inboard arm on
port bracket – agreed with BAE
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RCB 2 – In- Process Scanning to 3D model
Starboard at machinist
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RCB 2 – In- Process Scanning to 3D model
All arms and patterns scanned and checked against lay down in Crook
Fabrication facility
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TJM input – use scan data
RCB 2 – In- Process Scanning to 3D model – Starboard Arm – no action
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Visit our group website at:
www.bondsfoundry.com