Weir’s Heavy Bay Foundry (HBF) in the port city of Gqeberha, Eastern Cape is expanding to meet rising demand from the global mining sector.

The foundry produces large, high-performance cast components used in pumps, screens, and crushers. Following major infrastructure and process upgrades, the facility has doubled its production capacity and is positioning itself as a central manufacturing hub within the group’s global supply network.

Weir HBF head of operations Coenie de Jager notes that the foundry’s installed capacity for heavy castings exceeding 500 kg has increased to 600 t, with further optimisation and investment expected to push this figure to as much as 1 000 t.

“This expansion is driven by a series of targeted projects including casting pit extensions, melt shop upgrades and the integration of advanced pattern development systems,” De Jager says. “Each of these initiatives is aimed at removing bottlenecks and enabling higher production throughput.”

The company notes that the foundry is one of a few operations in South Africa capable of producing exceptionally large castings - up to 4 m by 4 m in size. The installation of new 4-t and 6-t induction furnaces is currently in progress, with commissioning scheduled for early 2026. Complementing these are new heat treatment furnaces, fettling booths, an automated grinder and paint booths nearing completion.

A major milestone has been the acquisition of Xmeco Heavy Engineering, a fully equipped machining facility that is said to extend Weir HBF’s capabilities. This addition allows the foundry to deliver a comprehensive end-to-end manufacturing solution, reveals De Jager.

“The extension of the foundry’s casting pit has created additional space for casting-cooling, enabling higher production throughput,” De Jager adds. “At the same time, the melt shop is being upgraded with advanced technologies to support faster, more efficient melting cycles and reduce material transport times, while the new pattern development systems give us the flexibility to serve a wider range of global markets.”

He adds that Weir HBF collaborates closely with the Nelson Mandela Bay Business Chamber to identify skilled tradespeople and participate in training and development programmes that uplift the local workforce.