Heavy Engineering Casting
The components that that keep India's steel plants, cement plants & CNC MACHIENES running.
Heavy-section, critical-application castings — the pieces that, when they fail, take the whole line down with them. Six core castings, one continuous melt-to-machined process, and an in-house engineering team that will tell you when your drawing is wrong.
The casting envelope
Six core castings. One foundry that pours them all.
Mill Housings
2HI, 4HI, 6HI — up to 120 MT single piece.
Bhawani holds the Indian record for a single-piece mill housing at 120 MT — cast, heat-treated and stress-relieved in our 55-acre facility under Naman Sood's technical leadership. Available across hot and cold rolling configurations for integrated steel plants and OEMs.
- Single-piece weight
- Up to 120 MT
- Configurations
- 2HI · 4HI · 6HI
- Grades
- IS 2708 GR 1/2/3 · GS 240+N · GS20MNS5 · GS30MNS
- Heat treatment
- API 6 compliant · stress relieving up to 10 × 6 × 5 m
- Machining
- VTL up to 2.8 m · plano mill up to 6 m · Skoda boring 200 mm spindle
India's first single-piece 120-MT mill housing — cast and dispatched from this foundry. Detailed engineering note available to qualifying customers under NDA.
Mill housing · 120 MT, single piece
Slag Pots
Up to 75 T. 100 pots a year.
A pot carrying molten slag at 1,600°C is not a procurement line item — it is a safety system. Bhawani engineers each pot against a documented service-life target, not a procurement price target.
A slag pot specified for 10 years that retires at year 4 has cost you twice. The replacement order is the visible cost — the unplanned downtime, safety review and insurance recalibration are the invisible ones. We've written a 12-page briefing on this.
Slag pot · 75 T · Mandi Gobindgarh
Steel Mill Chocks
Hot rolling. Cold rolling. Ready to fit.
Mill chocks live in the most hostile thermal environment in the steel plant. Bhawani's chocks are cast from alloy steel grades specified to the rolling temperature and load profile, heat-treated to API 6 norms, and machined in-house to OEM print.
- Grades
- SAE 4140 · EN 19 · 30CRMONI6/8 · 42CRM04
- Heat treatment
- PNG-gas & oil-fired furnaces · quench tank 6 × 7 × 4 m
- NDT
- Ultrasonic · Magnetic Particle · Dye Penetrant · Brinell
- Machining
- Proof or finish machining to customer drawing
Steel-mill chock · hot-rolling line
Cement Kiln Tyres & Riding Rings
Up to 80 MT single piece.
A cement kiln is the most expensive piece of equipment in a cement plant to take offline. The tyres, support rollers and riding rings that hold it up are not parts where lowest-cost procurement makes sense. Bhawani castings have enabled cement clients to produce up to 4.7 million tonnes in a single financial year, from one plant.
- Kiln Tyres — up to 80 MT, single piece
- Kiln Support Rollers
- Riding Rings, Cooler Tyres
- Girth Gears & gear castings
- Mill Heads, feed & discharge headers
- Grinding Tables — up to 6 m diameter
4.7 million tonnes of cement output in a single FY from one Bhawani-supplied cement plant. Multiple cement majors operating in India on the roster.
Kiln tyre · 80 MT · single-piece
Paper Mill Rolls
Up to 7 metres of continuous casting.
Paper mill press rolls and dryer rolls demand dimensional precision over 7-metre lengths and metallurgical consistency under continuous thermal cycling. Bhawani handles both — and pairs the casting with alloy-steel end journals and dryer end covers cast in the same yard.
- Cast-iron Press Rolls — up to 7 m
- Dryer Rolls
- Alloy-Steel End Journals
- Dryer End Covers
- Press Roll Shells
Press roll · 7 m cast iron
Machine-Tool Castings
Beds. Columns. Cross rails. Up to 60 MT.
Bhawani is a primary casting supplier to India's heavy machine-tool industry. The entire casting for India's largest gantry mill — a 150-MT load-capacity machine — was poured in our yard.
- Heavy Machine Beds — up to 60 MT
- Cross Rails — up to 40 T single piece
- VTL Castings — up to 10 m capacity
- Lathe Beds, head stocks, pillars, columns
- Surface Plates, T-slotted plates, counterweights
- 40 T CNC Beds, slide tables, taper slides
India's largest 150-MT load-capacity gantry mill — entire casting set supplied by this foundry. Reference and engineering note under NDA.
Machine bed · 40 T CNC bed
Beyond the core six categories
Forging-press equipment, ingot moulds, anvil blocks.
Forging Press Rams & Anvil Blocks
Single-piece castings for forging press and hammer equipment, including columns and rams up to 120 MT per piece.
Ingot Moulds & Plates
Forging ingot moulds and plates up to 80 MT per piece. Bottom-pouring configuration available.
Alloy-Steel Base Plates
Heavy base plates for steel-plant machinery, cast and machined to drawing.
Not sure where to start?
Tell us your component. We'll tell you what to ask next.
Mill housing / chock / slag pot
Send the drawing or current OEM print. Within five working days we return feasibility, indicative lead time, and the two or three specification questions that change the casting.
Kiln tyre / mill head / girth gear
Share the kiln capacity, kiln age and current service-life pattern. We'll match metallurgy to operating regime.
Machine bed / cross rail / VTL casting
Include load specification, dimensional tolerance class and finish-machining requirement.
The first move is a conversation
Not a quotation.
Upload your drawing and operating conditions. You'll get an engineering response from the foundry — not a sales reply.