Keokuk Steel Castings
3972 Main Street Rd
Keokuk, IA 52632
319-524-2661

David Phillips, Regional Sales Manager

Founded 1936

Primary Product

Valve, pump, pressure retaining, locomotive, transit and military steel and alloy castings. Casting weight range is 1- 3500 lbs.

Metals Produced

Carbon steel
Carbon-manganese steel
Low alloy steel
Ferritic stainless steel
Martensitic stainless steel
Austenitic stainless steel
Duplex stainless steel
Inconels
Hastaloys
Monels

Capacity/month – 1400 tons

Quality System Qualifications

ISO 9002 registered. Certificate issued by Lloyds Registry Quality Assurance.
ASME Boiler Code, Section NCA-3800 compliant (Quality system for production of metallic components for nuclear power plants).
Federal Regulation 10CFR50, Appendix B compliant (Quality system for design and operation of nuclear power plants).
MIL-I-48208A and MIL-I-45662 compliant (Military quality system requirement).
Compliant with a wide variety of industry and customer developed quality systems requirements.

Product Quality Approvals

Product is compliant with the requirements of Lloyds Register of Shipping. Covers castings in carbon, carbon-manganese, low alloy, austenitic stainless, and duplex stainless steels up to 1500 kg.
Product is compliant with the requirements of TUV AD-Merkblatt W0 / TRD 100; covers GSC-25 grade castings (German equivalent of WCC).
Qualified, by the US Army ballistics testing to manufacture cast armor, TECOM Projects 1-EG-965-000-792 and 1-EG-965-000-783 APG.

Trade Associations

Steel Founders Society of America (SFSA)

Core/ Mold Sand Mixer Control

Core and molding continuous sand mixers are controlled by “Smart Pump” system:
Computer control
Automatic shutdown for abnormal conditions
Continuously monitors/adjusts mass flow of sand mix components
Mechanical reclamation system
GIW mechanical reclaimer equipped with cooler classifier
Reclamation capacity – 20 tons/hour

Core Making

Five "Blow" type core machines: Ashland "Isocure" binder system Silica sand (Zircon sand - less than 1%) Served by one 100 lb/min single screw Pacemaster mixer One large core line: Ashland "Pepset" binder system Silica sand (Zircon sand - less than 1%) 250 lb/min Pacemaster twin screw mixer Three shell core machines: Two U-180s and one Dependable 400 Pre-coated Silica or Zircon sand Core Wash: Zircon (alcohol based) Applied using brush and/or spray

Molding Lines

"Loop" molding line: Ashland "Pepset" binder system Silica sand (new and blended (85%) 1000 lb/min. Kloser mixer Flaskless molds 200 molds/shift "Large" molding line: Ashland "Pepset" binder system Silica sand (new and blended(60%)) and Zircon sand 1000 lb/min. Strongscot mixer 80 molds/shift Shell molding line: Two twin Chicopees Pre-coated Silica or Zircon sand 600 molds/shift

Tap Ladles:
Arc Furnace, 19000 lb. capacity, "teapot" configuration
Induction furnace, 3500 lb. capacity, "teapot" configuration

Pouring
700 Lb. "Teapot" ladle:
3500 Lb. "Teapot" Ladle:
6000 Lb. "Teapot" Ladle:

Cleaning

Riser / Rigging removal and casting contouring:
Air / Gas torch
"Arc Air" process
Blast Equipment:
Four "tumble" units - 2 tons/load each
Three "walk-in" units - 1 ton/load each
One "turntable" unit - 2 tons/load
Steel shot or grit
Finishing and welding operations are organized into "cells", which process castings with common configurations, customers, and requirements.

Heat Treatment

Four large ‘box” type gas-fired ovens:
12’x12’6’
10,000 lb capacity
400ºF to 2400ºF
Quench tanks

Special Products Department

Processes orders with unique or extensive inspection requirements. Cleaning/welding processing records maintained for each casting.

Welding

All welding procedures qualified in accordance with ASME Section IX. All welders qualified in accordance with ASME Section IX. Repair welding processes used: SMAW GMAW GTAW FCAW

Nondestructive Examination

All NDE personnel qualified to ASNT SNT-TC-1A (Levels I,II,III).

Radiography

Two MEV Linitron
350 KV x-ray unit

Magnetic particle inspection

8 Dry MPI machines
4000 amp
6 inch prod spacing
2 Wet MPI machines
3 AC/DC MPI Yokes
All ferromagnetic materials can be inspected

Dye penetrant inspection

Color contrast method
Used to inspect non-ferromagnetic materials

Chemical Testing Laboratory

Spectro Labs vacuum optical emission spectrometer; 30 channels covering all major, minor and trace elements of interest. Capable of analyzing all alloy types produces.
LECO Model CS-300 carbon and sulfur determinator
LECO TC-136 nitrogen and oxygen determinator

Mechanical Testing Laboratory

Tinius Olsen 60,000 lb. Tensile Tester equipped with electronic controls and flat bed recorder.
Tinius Olsen Charpy Impact Tester with 265 ft-lb capacity and related low temperature (to -321º) testing equipment.
Wilson Rockwell Hardness Tester
King Portable Brinell Hardness Tester and related equipment.

Sand Testing

Continuous process control using “smart pumps”.
Daily process audits on new and reclaimed snad:
Tensile strength
Loss on Ignition(LOI)
Grain size distribution

Dimensional Inspection

Two Layout Tables:
One 150"x70" - equipped with digital CMM (with computer interface)
One 100"x70" - equipped with analog portage machine