INFRASTRUCTURE
CONNECTED CAPABILITY FROM FOUNDRY TO FINISH
Across five manufacturing plants, Cal Group brings foundry, machining, fabrication, heat treatment, pattern development and testing capabilities together to support standard and customised components with greater process control.
FOUNDRY AND MANUFACTURING
DEVELOPED WITH UK SPECIALISTS. BUILT FOR CONTROLLED PRODUCTION.
Cal Group’s foundry and process systems were developed with UK specialists, combining globally informed practices with integrated downstream capability. The result is a connected route from pattern and mould development through casting, machining, treatment, testing and dispatch.
01 — Integrated Pattern Shop
Control begins with the pattern.
In-house Aluminium and Wooden pattern development gives us direct control over casting geometry, wall thickness, machining and shrinkage allowances, core positioning and dimensional accuracy. Rapid modifications shorten development timelines while helping optimise casting strength, weight, repeatability and metal yield.
BENEFITS
- Shorter development and delivery timelines
- Greater dimensional control and repeatability
- Improved strength-to-weight optimisation
- Reduced excess material and machining
- Improved casting yield
02 — Alpha-Set No-Bake Moulding
Superior moulds. Cleaner castings.
Our mechanised Alpha-Set no-bake system is designed to handle large and complex moulds with greater strength and dimensional stability. Controlled sand, resin and hardener mixing delivers accurate geometry and a clean, high-integrity surface finish—reducing casting defects, weld repair, fettling and downstream machining.
BENEFITS
- Large and complex moulding capability
- Superior as-cast surface finish
- Reduced weld repair and fettling
- Repeatable mould Greater dimensional accuracy
- High mould strength and stability
- Consistent repeatability
03 — Electric Arc Furnace
Every heat controlled. Every composition repeatable.
Two 5-tonne Electric Arc Furnaces support steel castings ranging from 500 kg to 8 tonnes. Each heat is developed around the required chemical composition, verified through spectrometer analysis and corrected through controlled alloy additions before pouring. Recorded heat data and established metallurgical recipes allow approved compositions to be reproduced consistently across repeat orders.
BENEFITS
- Precise heat-by-heat chemical control
- Spectrometer verification before pouring
- Corrective alloy additions to achieve specified composition
- Reproduction of approved chemistry across repeat orders
- Complete heat history linked to every casting
- Consistent metallurgical properties between production batches
- Flexibility across manganese, carbon and low-alloy steels
- Steel castings from 500 kg to 8 tonnes
04 — Controlled Heat Treatment
Properties engineered through every degree.
An eight-zone heat-treatment furnace operating at temperatures up to 1,300°C provides uniform heating with reduced thermal variation across large castings. Normalising, tempering and water-quenching cycles are developed around the steel grade, section thickness and application requirements—achieving the required balance of strength, hardness, toughness and dimensional stability.
FACILITIES
Normalising
Tempering
Application-specific treatment routes
BENEFITS
- Uniform heating across eight controlled zones
- Application-specific treatment cycles
- Refined and consistent grain structure
- Controlled strength, hardness and toughness
- Repeatable properties across production batches
05 — CNC Precision Machining
Precision within a fraction of a millimetre.
CNC machining capability across 3 to 13 metres of X-axis travel supports fully machined long, heavy and complex components. Multiple 3-axis and 5-axis machines, double-head CNC systems and custom tooling enable multi-face and simultaneous machining in fewer setups—delivering tight, drawing-specific tolerances, precise mating interfaces and surface roughness down to Ra 3 µm.
BENEFITS
- CNC machining across 3 to 13 metres
- 3-axis, 5-axis and double-head capability
- Multi-face machining in fewer setups
- Tight tolerances for precise component fitment
- Surface roughness down to Ra 3 µm
06 — Fabrication and Flash-Butt Welding
Joining technologies for advanced trackwork.
Precision fabrication is supported by specialised flash-butt welding technology that joins CMS crossings directly to adjoining rails through controlled heat and pressure. The process creates a high-integrity, continuous connection with fewer mechanical interfaces—supporting smoother wheel transition and track systems designed for higher speeds and heavier axle loads.
BENEFITS
- Direct welding of CMS crossings to rail
- High-integrity joints using filler metal
- Fewer mechanical joints and discontinuities
- Reduced impact and dynamic loading
- Support for higher speeds and heavier axle loads
CORE STRENGTHS
ADVANCED CAPABILITY. REPEATABLE OUTCOMES.
GLOBALLY BENCHMARKED
International machinery, specialist technology and global process expertise—delivered through a cost-efficient Indian manufacturing base.
FASTER TO PRODUCTION
Integrated precision and process control reduce dependencies, rework and lead times from development through delivery.
BUILT FOR VOLUME
Five manufacturing plants and 22,000 MT of annual capacity support bulk production and recurring requirements at scale.
PERFECTED ONCE. REPEATED CONSISTENTLY.
Validated process parameters allow the approved product to be reproduced accurately across every production batch.
Let’s Build What Comes Next
Explore integrated casting, machining, fabrication, treatment and testing capability built around scale, precision and process control.