84-Inch WCB Ball Valve Casting for U.S. Dam Project: Large Steel Casting Case Study

Telida Metal has successfully completed the pouring of two 84-inch ball valve casting bodys for a major international water infrastructure project, marking another milestone in the company’s large-scale casting capabilities. The massive casting, produced recently at the company’s foundry, will ultimately become part of an advanced valve system destined for a dam project in the United States.

The project involves a German customer specializing in industrial water control systems. After machining and finishing, the cast valve body components will be assembled in Germany into fully operational active valves designed for high-capacity water regulation. The completed valve systems are expected to play a critical role in managing water flow and pressure within the American dam project.

According to Telida Metal engineers, the 84-inch ball valve body represents one of the largest and most technically demanding castings undertaken by the company in recent months. Producing a casting of this size required strict control over molten metal temperature, pouring speed, solidification timing and internal structural integrity.

The casting process involved several weeks of preparation, including mold design optimization, material analysis and simulation testing to ensure the final product would meet the demanding specifications of the customer. Engineers monitored the pouring operation continuously to guarantee stability throughout the process and minimize the risk of shrinkage, porosity, or deformation.

Company representatives stated that the successful pouring demonstrates Telida Metal’s growing expertise in manufacturing oversized valve castings for critical infrastructure applications. Large-diameter ball valves are widely used in hydropower stations, municipal water systems, dams, and energy facilities where reliable flow control is essential for operational safety.

The finished casting body weighs 22 metric tons each and was produced in material WCB selected for their strength, corrosion resistance, and long-term durability under high-pressure working conditions. Following the pouring and cooling stages, the casting will undergo heat treatment, non-destructive testing, dimensional inspection and machining before shipment to Germany.

Industry observers note that international cooperation has become increasingly important in large infrastructure projects, with manufacturing, machining, and final assembly often taking place across multiple countries. In this project, Telida Metal’s casting expertise serves as the foundation for the German customer’s final valve assembly technology, while the completed systems will support water management operations in the United States.

The successful completion of the casting also highlights rising global demand for heavy-duty water control equipment as governments invest in dam modernization, flood prevention, and sustainable water infrastructure. Large ball valves are essential components in such projects because they allow precise regulation of enormous water volumes while maintaining high operational reliability.

Telida Metal officials expressed confidence that the project will strengthen the company’s position in the international valve casting market and open additional opportunities for cooperation with global engineering and infrastructure partners in the future.