Foundry work comprises:
To make a mould of something you need a 'pattern' to start with. This is a model of the shape you want to eventually cast in iron. This model or pattern had to be EXACTLY the correct shape and size you needed, so pattern makers were very skilled craftsmen - usually making the patterns from wood, but sometimes also in wax. A wooden pattern could be used over and over again.
This scene is typical of the area's foundries, with its open plan floor and a skylight roof supported on iron columns. The floor is covered with sand used in the moulding process. The sand had to be 'riddled' (put through the round sieves on the floor) to get rid of any lumps which would have caused flaws in the surface of the casting. It is then placed in the iron mould on the floor (where the worker is kneeling), which has the pattern inside it. A second box is then placed on this and filed with sand, surrounding the pattern completely. After tamping down the sand, the two halves are separated and the pattern taken out, leaving an empty space in the shape of the pattern. Afterwards the two halves are put together again, channels are made for pouring in the molten metal, and the mould is ready for casting. Notice the young boys in the centre of the photograph - apprentice moulders.
Small items are poured by hand from small ladles as in this picture - but larger items are poured from much larger ladles. In both cases it is hard, heavy work - and all the molten iron splashing up can be very dangerous. That is why the men are wearing face masks and leg protectors.
An animation of wax casting can be seen HERE
This was the work of the 'Dressing Shop' - see the men in the picture on the previous page. This photograph was taken during the war years in another foundry. It shows that 'dressing' a casting to get rid of rough edges etc was hard work, often using hammers and chisels. The women are working here because many men were off to War in the army.
