Category Archive SKELLERNS Metal & Concretework Casting Services

SAND MOULDINGS & INVESTMENT CASTINGS

Skellerns is one of the top foundry’s in New Zealand for Green Sand Moulding, Hard Sand Moulding and Investment Castings using the lost wax process for detailed precision work.

This scope of expertise enables us to be more versatile and flexible when selecting the most appropriate methodology to achieve your desired metal casting outcomes.  

We take great pride in our attention to detail and our customer service.  

Working with Patterns

Castings from Existing Patterns

For bronze, aluminium and other metal castings, when you provide us with your existing patterns the Skellerns team will use their metal casting expertise and skills to ensure the highest quality and economical resulting products. 

Design & Process Guidance for New Patterns

Our experienced Sales & Support team will collaborate with you to ensure they understand all your requirements completely. With their wealth of industry knowledge they provide you technical guidance throughout the entire pattern design process and ensure it is prepared and ready to meet your timeframes.

Metal Casting Processes

Green Sand castings process is performed by using sand moulds formed from “wet” sand which contains water and organic bonding compounds, typically referred to as clay.  The “Green” of Green Sand Moulding is not in reference to the colour of sand but relates the sands state.  The name relates to the fact that the sand mould is not “set”, it is still in the “green” or uncured state even when the metal is poured in the mould.

Advantages of Green Sand Moulding:

  • This is the least expensive process when producing small quantities (normally less than 100) and also boasts with the least expensive tooling.
  • Range of casting sizes – ability to cast very large parts.
  • Flexibility in metal choice – Both ferrous and non-ferrous metals can be casted using this process.
  • Economical – A low production cost due to materials used and little post-casting tooling required.

Disadvantages of Green Sand Moulding:

  • Lower degree of accuracy – dimensional accuracy is less than that delivered by other processes.
  • Tolerances limitations – This process requires large tolerances. Surface roughness – The surface finish for ferrous casts delivered usually requires additional work.
  • Weight excess – Castings produced with this proceed usually exceeds the calculated weight.

The Hard Sand moulding process can have specific advantages over other manufacturing processes, which often lead to major cost savings, not only in the part price itself but also in the overall cost of production. Some of the benefits are in the processes flexibility:

  • Variety of metals able to be cast – ability to use both ferrous or non-ferrous metals.
  • Automated or hand crafted for accuracy – Mould replicates the component with high level of accuracy and consistency.
  • Jobbing or low volume production – ability to produce from 1 to 1000 units per run.
  • Complex shapes – undercuts and hollow centres can be formed and the process is capable of producing very large pieces.
  • Minimal wastage – Scrap and moulds can be and are often recycled

STREETWARE

Skellerns manufacture and import a wide range of standard and bespoke cast iron and aluminium Streetware products.

Our Streetware components have proven to be robust and durable over many years.  They have been approved by major utility companies for use on their networks and in areas with extreme load applications such as port and airport pavements.  For example the new Skellerns oversized 610 mm diameter manhole access cover and frame has been independently tested and approved by Watercare, Auckland for use on its waste water network. 

Access Covers & Frames 

Skellerns range of manhole access covers are tested to strict standards, as well the ability to meet a wide range of functions.,

Stormwater Products

Skellerns provides a wide selection of frames, grates and related ancillary products to meet your storm water requirements.

Grates

Skellersn provide a range of Cast Iron and Aluminuim Alloy Grates. Our grates are a strong proven product and are profiled for a variety of solutions.

Watermain Products 

Skellerns Metal Castings reticulation fittings, meter boxes and sump lids are durable and versatile. They are designed to meet a range of practical and robust working conditions.

Loading, Size & Weight Guidelines

These loading guidelines are to be used with caution and if in doubt we recommend consultation with our technical team.

A.  Extreme Light

Not intended to take traffic of any kind but may be used in areas accessible by pedestrians only.

B.  Light

Foot Pathways that may be mounted on occasions by light vehicles or livestock.

C.  Medium

Pedestrian areas and plazas that may take light slow moving commercial vehicles.

D.  Heavy

Road ways and pathways intended for light vehicles and light commercial.

E.  Super Heavy

Highways and roadways that are intended for all legal weight heavy goods vehicles

S.  Special

Enquire for special duty requirements products for docks and aircraft pavements subject to very high wheel loads.

Details for the size and weight provided for products on this website are as follows:

Sizes

Sizes are actual grate sizes / Clear access size,

OD = Outside/External Diameter.   ID = Inside/Internal Diameter

Weight

All weights are shipping wgt. for complete unit.

CONCRETEWORK

Skellerns produces a range of concretework products including: Septic Tanks, Cesspits and Concrete Risers and supporting Streetware and drainage components. 

Contact our Hamilton foundry office to discuss your specific Concretework product requirements.

Septic Tanks

Skellerns offers a range of Septic Tank sizes and chamber variations, along with other components and accessories.

Concrete Cesspits

Skellerns offer a variety of concrete Cesspits.

Concrete Risers 

Skellerns offers a range of Concrete Risers that can be used with a variety of cast iron Streetware and watermain products.

PLAQUES

Plaques that dedicate, commemorate, acknowledge or brand with distinction and timeless elegance.

Skellerns high quality custom designed metal plaques have been used to commemorate a wide range of special occasions.  Whether it be on a headstone, as a memorial plaque, a monument marker or for business branding purposes, a personal tribute or as part of a display to commemorate a significant event, a bronze, aluminium or stainless steel plaque will always be a timeless point of remembrance.  No other product matches the permanence and long-lasting elegance of an individually designed metal plaque. 

We also have extensive experience with repairing, restoring, conserving and preserving all types of plaques to make them look like new again, or if that is not possible anymore, then we can produce a replica plaque using new materials and fixings.

All of our plaques comply with the materials and fixings specified in the New Zealand Standard 4242:2018 – Headstones and Cemetery Monuments

Skellerns Plaque Design & Casting Process

At Skellerns, we can cast almost any size of plaque in Bronze or Aluminium and offer 5 general styles for you to choose from to easily meet your plaque design requirements. 

We ensure the highest casting quality and to achieve this we do have a limitation on how small text can be, however the amount of text is only limited by the size of your plaque. 

Any graphics you provide must adhere to copyright laws and/or restrictions and will need to be checked by our designers to ensure they are suitable for casting.

Once your plaque has been designed and your order has been confirmed, then you will be provided with a computer generated layout of the plaque for your prior approval, before the casting work begins.  Then it is over to our experienced manufacturing department to cast and finish the plaque to the required high standards of craftmanship and then arrange for its delivery, or alternatively complete the plaque mounting work if required.

Following are the 5 styles of plaques we offer for you to start creating elegant and long lasting memorial tributes or check out our Plaque gallery to get some inspiration.

Standard Flat Plaque

This plaque is suitable for any occasion or purpose.

Our Standard Flat Plaque is either rectangular or square in shape and can have either a single or double lined border with a choice of background colour of Black or Brown.

Bevelled Edge Plaque

This plaque is suitable of any purpose and best suited for horizontal placement.

Our Bevelled Edge plaque has sloping edges that gives it an elevated appearance with a single border containing small gaps that enable water to run off the face to preserve it.

Flat Book Plaque

This plaque portrays the appearance of a book and a story being told.

Our Flat Book styled plaque is a flat rectangular plaque that has an outlined border in the shape of a book.  

The plaque is approximately 8mm in depth.

Raised Book Plaque

This plaque portrays the appearance of a book and a story being told.

Skellerns Raised Book or Loose Leaf plaque is cast to have its edges shaped with book pages layering up to the face of the plaque.  It can be cast with front face format to have either 1 full page or 2 half pages.

This style of plaque has substantial depth of approximately 30mm.

Non Standard Plaque

This plaque is any shape variation and is suitable for any purpose. It is often used as a decorative tribute. 

Our Non Standard Plaques are all other plaques in a variety of different shapes.

Call our expert plaque designers to discuss your specific requirements.

Plaque Design Guidance

1. Bronze

Bronze plaques are the popular choice for interior as well as exterior plaque applications.  Although the finish of a bronze plaque will naturally patina over time, the material itself will never deteriorate.

Objects made from bronze have been submerged in seawater for over 3000 years and are still in excellent condition when discovered.

2. Aluminium

Aluminium plaques are more suited to indoor applications or where regular maintenance is possible and where budget or weight is a factor.

Aluminium plaques are cheaper due the lower cost per kg of the aluminium alloy and the aluminium alloy is also lighter than either bronze or steel.

However, aluminium is not as corrosion resistant or physically resilient as bronze.

An aluminium plaque makes a great alternative when you can’t afford a bronze plaque, but still want a large plaque that is both lightweight and durable.

3. Stainless Steel

Stainless steel plaques are generally at the upper end of the quality and cost range due to the cost of the raw materials used in the casting and the time required to prepare, cast and finish a stainless steel plaque.

Once you have chosen the wording, you will need to choose the font, size, format and layout for the plaques design.

Consider what font styles and sizes will enhance the comprehension of the reader. They can include:

  • LARGE and small text;
  • Bold text for prominence; 
  • Font styles such as an elaborate wedding script style text for an elegant title line; 
  • Clear and spaced readable body text;
  • italics to distinguish “comments or quotes”.

All of our memorial and tribute plaques are custom made and we can accommodate virtually any content you may desire.

Take a look at some of our plaque designs to get inspired with what you can create and contact our design team to help you achieve.

Personalise and embellish a plaque by including graphics that have meaning and purpose, whether it be a logo, a favourite flower, an animal or object, or maybe it is an elegant and personally drawn art design.

If your graphic can be drawn with pen or within a computer application, it will almost always be able to be included in your plaque design.

Our plaques include a single line border which is available at no extra cost on all ‘average’ sized plaques.

Some plaque border designs are not practical on small namestrips that are under 5cm in height.

If your graphic can be drawn with pen or within a computer application, it will almost always be able to be included in your plaque design.

Prior to highlighting the letters the background is painted with a colour which assists in providing a contrast with the highlighted letters to make them stand out more.

As a standard, we offer you an option of two colours, however, you are able to choose any colour you like for the background for a customer price. 

  • Brown– The standard and most popular colour for bronze plaques.
  • Black– Can be used for both bronze and aluminium plaques. Black will provide the best contrast for aluminium plaques.
  • * Custom – Painted any colour of your choice

* We require you to provide us a physical example of the custom colour in order for us to match. 

Our creative bronze memorial plaques and headstones have been developed with alternative background textures or floors.  

To give your plaque an enhanced or distinctive look, choose from:  Sand, Stipple or Leatherette.

Once the background of the bronze plaque has been painted, the surface areas (these are the raised letters or lines of artwork) are highlighted by sanding (flat areas) or buffing (sculpted areas) to create the elegant contrast of forms.

* Clear lacquer is our standard clear, protective coating. Unless otherwise specified, all plaques will receive clear lacquer protective coating.

Finishing & Polishing styles we offer:

Satin Bronze — The Natural metal colour with subtle horizontal grain lines.

Polished Bronze — The natural metal colour buffed to a high gloss, obtained by polishing with successively finer abrasives, then buffing with fine buffing compound.

Chrome Plated Bronze — The raised surface of the bronze plaque is polished to meet the polished bronze specifications. The background of the plaque remains in its “natural sandblast” state, providing contrast with the polished raised surface. The entire plaque is then electro-plated using a standard commercial copper/nickel/chrome plating process.

Protective Finish — In order to protect the natural, highlighted finish of a cast bronze plaque a Clear Protective Lacquer is added providing a low gloss appearance, this clear coating was developed to help ensure many years of carefree maintenance.

Lugs & Screws

These are used for a concealed mount where drilled lugs are added on the back of the plaque and screws used to hold in place for mounting to brick, stone or cement.

Flat backed plaques have no lugs or screw holes unless otherwise requested.

Counter Sink Screws

Countersink screws are the smallest plaque mounting option.

This method of mounting is typical for mounting on a park bench or memorial wall. Plaque is mounted to surface using construction adhesive or by bolting from the rear. This option can be used on almost any surface. Wood screws can be used to fasten directly into timber or machine screws selected for mounting when fastening to a solid wall such as concrete.

ARTWORK & SCULPTURES

Skellerns foundry is proud to have produced a wide range of elegantly designed and cast Artwork and Sculptures, for parks, streets, homes, gardens and businesses.

We enjoy and have worked with a number of local and internaltional renowned and upcoming artists and designers by providing high quality support and services to ensure their artwork designs and ideas on paper and as preliminary moulds are truely recreated in an elegant form.

Following are some of our recent sculptures and artworks which have included the Marlin in Paihia designed by Axia Designs and the Statue of Sir Colin Meads in Te Kuiti beautifully designed by artist Natalie Stamilla.

Air New Zealand Suppliers Awards

In 2019 Skellerns were commissioned by Air New Zealand Suppliers Division to cast the sculptured Tuhono Supplier Award to be presented to the winners of the various supplier divisions at their inaugural Annual Awards evening. 

Not only did each division winner gain the well deserved recognition of both Air New Zealand and their peers, but they also got to take home a bespoke engraved bronze sculpture cast by Skellerns especially for the presentations.

The following press release backgrounds the Awards and the Suppliers achievements:  https://www.airnewzealand.co.nz/press-release-2019-airnz-celebrates-its-suppliers .

Battle of Passchendaele Memorial

This project was completed for the Passchendaele Society in Auckland with funding from the New Zealand Lotteries Commission.

It comprised the manufacture of three large 600 mm x 600 mm bronze plaques (one was curved) and 846 bronze disks at 50 mm diameter each.

Skellerns liaised with both the Society and their project management team in Belgium throughout the preliminary design and detailing phases of the project, during the manufacturing process, and the time critical overseas transportation, as well as the final installation phases. 

The memorial was opened on 12 October 2017.

The following article at http://passchendaelesociety.org/memorial-garden backgrounds the project and the following photographs show the curved memorial narrative panel plus a photograph of one of the disks fixed to a headstone.

Statue of Sir Colin Meads

Location: Te Kuiti
Artist/Designer: Natalie Stamilla

We are proud to have worked with Natalie Stamilla to cast her sculptured design of Sir Colin Meads in full flight, into its larger than life form.

The Colin Meads statue stands 2.87 metres high and weighs approximately 650 kg. The project was commissioned and funded by a huge effort from Te Kuiti’s local fundraising community.

Skellerns found innovative ways to cast the artists very detailed sculpture and devised an innovative way to hold the statue upright, whilst also satisfying the local Structural Engineers and the local Building Inspector’s requirements. 

Time was of the essence, as once the unveiling date was committed and dignitaries invited from around the world, the statue had to be finished and erected on time. 

The following articles show Sir Colin Meads with his look-a-like at the unveiling ceremony on 17 June 2017.

In the news: NZ Herald, Fox SportsStuff.co.nz
Read some reviews: TripAdvisor

Statue of Marlin

Location: Paihia
Artist/Designer: Fullers & AXIA Designs

Skellerns were honoured to be requested by Fuller family and AXIA Designs to cast and erect of the Leaping Marlin that now represents the area of Paihia in the Bay of Islands so elegantly.

The Marlin statue is almost 4 metres high and weighs 600kg. A prize catch in anyone’s book, but also a great sight on the waterfront at Paihia. The Leaping Marlin statue project was generously funded by the Fuller family as a donation to the local community.

The moulding of the Marlin required an innovative solution, in that a 3D digital model was created of a real marlin, and then that model was used to create the moulds which formed the basis of the casting process. 

The following articles confirm the Fuller Family were very pleased with the final result.

In the news: NZ Herald, Stuff.co.nz

Location: Paihia Artist: AXIA Design & Fullers

Albany Pool Sculpture

Location: Albany Stadium Pool
Artist/Designer: Seung Yul Oh

Skellerns worked with Seung Yul Oh to  bring this creative design to form for the Albany Stadium Pool.

In the news: Stuff.co.nzmetromag.co.nzaucklandcouncil.govt.nz

Location: Albany, NZ Artist: Seung Yul Oh