1. Steel Casting Opportunities
David Poweleit
Steel Founders’ Society of America
780 McArdle Drive Unit G
Crystal Lake, IL 60014

2. Logical Opportunity for Steel Foundries
Steel Construction
Use steel already
Weight not a concern
Need cost-effective connectors
Weldability, strength, flexible geometry
Architectural “look” important
Steel Castings
Safety critical applications
Demanding environments
Significant loading requirements
Welded into fabricated structure
Economical and reliable
Connectors for structural elements

3. Castings Are Tough
Steel Castings in Red

4. Construction Problems
Tolerances
Erection costs/welding
Aesthetic flexibility
Minimize footprint
Crane time
Design freedom

5. Existing Applications
Crystal Cathedral
ATLSS connector
Shelf brackets
Ornamental components

6. Bridge Applications Cable clamps Sockets Splices Equalizer beams Links
Rockers
Bearings
Drains
Will be used on new Bay Bridge and new Tacoma Narrows Bridge

7. German Applications Munich Olympic Arena Highway Bridge
Stuttgart Airport

8. The Challenge Why haven’t castings been used
Paradigm shift in design
Castings offer flexible geometry
Must fully utilize geometry to obtain cost savings
Must analysis cost savings beyond cost of part
Concerns with cast material
How to specify
How to ensure quality/performance
Need to build mutual understanding for casting and construction requirements
Develop sample parts
Compile casting design guide

9. SF/SC Project
Joint project between SFSA, AISC, and Robert Fleischman at the University of Arizona
Objective is to identify and design cast parts for building construction to dramatically reduce cost or provide a new capability
NSF funded GOALI project to provide $347,000 over three years for casting applications in building construction R&D

10. Steel Casting Construction Consortium (SC3) Members
Sivyer
Atchison
Harrison
North Star
Soutwest
Varicast
Atlas
Pacific
A.G. Anderson
Huron
ACIPCO
Fimex