1. CAST IRON SUPPORTS OUTDOOR STREET LIGHTING

2. SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING 1.Classification: As per application As per materials 2.Manufacturing process: Previous research. Building Moulds. Smelting pieces. Mechanize Finishing Packing/Handling. 3.General Characteristics: Differences between cast Iron/Aluminium 4.Quality control possible faults 5.Summary, comments & conclusions

3. SUPPORTS OF CAST IRON APPLICATION Columns Brackets MATERIALS Cast Iron. Cast Aluminium Others no ferrics

4. MANUFACTURING PROCESS OF CAST IRON LIGHT FITTING  Previous research.  Building Moulds  Smelting pieces  Moulding  Positioning  Closing boxes  Fusion  Rinding  Fettled  Mechanize  Drill  Winch  Adjustments  Finishing  shotpeened  Putty / finishing  Primer coating  Finishing coated - colour  Camera de polymerisation  Packing / handling.

5. No norm no standardization / certified Research of R. to finite parts. PREVIOUS RESEARCH

6. BUILDING MOULDS

7. SMELTING PIECES PROCESS

8. MODEL - MOULD - PIECE Positive model Negative Mould positive part

9. Mold Mold with inner part

10. MELTING / MELT DRAIN

24. RINDING

25. FETTLED

26. MACHINING WINCH DRILL ADJUSTMENTS

27. Energetic mechanical pickling – shotpeened. Primer coating - epoxy 2 components 50/60 μ application polyurethane 2 components 90 μ Polymerisation chamber Packing FINISHING

28. SHOTPEENED ENERGETIC MECHANICAL PICKLING

29. PUTTIED / FINISHING

30. PRIMER APPLICATION Primer - epoxy 2 components 50/60 μ Application of polyurethane in 2 components 90 μ

31. POLYMERISATION CHAMBER

32. PACKING / HANDLING

33. GENERAL CHARACTERISTICS OF OUTDOOR STREET LIGHTING IN CAST IRON Reproduction of forms Great similarity of pieces Section & Strongest Texture Synonymous of quality Recyclable 100% without cost raw material

34. REPRODUCTION FORMS PART MODEL

35. GREAT SIMILARITY OF PIECES

36. SECTION & STRONGEST BS 3000

37. TEXTURE DETAIL OF BS 3000

38. SYNONYMOUS OF QUALITY MATARÓ, SPAIN PROJECT

39. SYNONYMOUS OF QUALITY TARRAGONA, SPAIN PROJECT

40. SYNONYMOUS OF QUALITY SEVERALPROJECTSSEVERALPROJECTS ALICANTE VALENCIA

41. RECYCLABLE 100% WITHOUT COST RAW MATERIAL PEAR FURNACE LOADING

42. CHARACTERISTICS OF CAST IRON Type EN-GJL-200 As per norm: EN 1561 Type EN-GJS-500-7 As per norm: EN 1563 Differents degrees R. of stretching. Good behavior to oxidation. –Non reduction section. - Oxide = Protection Grey cast iron (traditional) Ductile cast iron (> R)

43. Norm EN 1706 Many alloys according to application. Great difference of €/Kg. Acording quality Danger In “normal” alloys, porous oxide Progressive Oxidation Galvanic Par with fastening bolts & Columns. CHARACTERISTICS OF CAST ALUMINIUM

44. QUALITY CONTROL Metallurgical quality control T hicknesses control with ultrasounds Hardness control Primer micron-size control & painting by ultrasounds Adherence control Chamber control of foggy salt Ultraviolet chamber control Effort in point control in test machine. POSSIBILITY OF FAULTS

45. METALLURICAL QUALITY CONTROL

46. THICKNESS CONTROL WITH ULTRASOUNDS

47. HARDNESS CONTROL

48. PRIMER MICRON-SIZE CONTROL & PAINTING BY ULTRASOUNDS

49. ADHERENCE CONTROL

50. CHAMBER CONTROL OF FOGGY SALT

51. ULTRAVIOLET CHAMBER CONTROL

52. EFFORT IN POINT CONTROL IN TEST MACHINE

53. SUMMARY, COMMENTS & CONCLUSIONS Historically, light fitting with gas were only of casting Possibility of recovering old forms Project quality Possibility of mixed lamp post + slender + economic Cast iron Lamp post - Progression of oxidation - Galvanic Par Brackets of cast aluminium, thickness 1/3 Columns no approved Pay attention to the quality Are hte supports “for all the life” Sevilla, supports catenary tram with outdoor street lighting Sculptures up to 8 Tn. Differents pieces not catalogued Class I. to control gear is essential earth wire.

54. BINEFAR CASTING OF BIG PIECES BINÉFAR (SPAIN)

55. MONZÓN HANDLING & LOGISTIC MONZÓN (SPAIN)

56. SABADELL CASTING OF SMALL PIECES & HEAD OFFICES SABADELL (BARCELONA-SPAIN)

57. R. ROS ALGUER S.A. CASTING & LIGHTING Joan Ros Casanovas Engineer Metallurgical Presentation at TECNICAT 5 february 2009 www.fundicionros.com