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  • On 2002, UCF had modified its existing management system to comply with requirements of ISO 9002 : 94.
  • On 2003, UCF had modified its management system to comply with requirements of ISO 9001 : 2000.
  • On 2005, UCF had, once again, modified its management system to adopt and declare its environmental commitment, thus complying with requirements of ISO 14001 : 2004.
  • On 2009, UCF management system was modified as per ISO 9001 : 2008 requirements.
  • On 2010, UCF management has adopted new specific policies and values that enable UCF to satisfy international market requirements.

UCF is awarded ISO 9001 : 2015 and ISO 14001 : 2015 applicable to :

  • Plain carbon and alloy steel castings
  • Wear, corrosion and heat resistant steel casting
  • Chromium iron castings
  • Fabricated wrought steel products
  • Foundry patterns.in all its work sites and locations.

In all it's work sites and locations

  • As per UCF Quality plans of products , there are process control activities implemented by production dept. and an in –process inspection activities implemented by quality dept.

The process control and the in – process inspection plans of a definite production process shows :
- Aspects need to be measured or tested
- Frequency of testing or measuring
- Means of testing or measuring
- Responsible body of carrying out this testing
- The quality form used for recording testing results
- Specification or criterion of evaluating the testing results.

  • UCF is committed to continual improvement of all its processes and its integrated management system. This commitment is the only way for realizing its customer satisfaction and expectations.
  • QUALITY is one of the main features of the processes, products and services that UCF offers its customers all over the world.
  • Each stage in the process, from the design, material purchasing manufacturing, inspection & testing, and dispatch to the customer is supervised and controlled according to UCF internal procedures and specifications of its Quality Management System, in compliance with the ISO 9001 standard.
  • The industrial and quality management processes are continually reviewed and improved through conducting internal and external audits by customers or other monitoring bodies.
  • UCF laboratories testing the finished products are spectrometer laboratory, sand testing laboratory, mechanical laboratory, and metallographic laboratory.
  • UCF Consider the customer expectations as the most valuable opportunity for improvement.

Upon Customer request, UCF can offer its valued Customers with one or more of the following services:

  • Wear type assessment and optimum alloy selection.
  • Upgrade of cement and raw mills to increase their output & decrease their power consumption.
  • Grinding process evaluation and optimization.
  • Reproduction of the existing customer's liners by reverse engineering or offering a new design.
  • Equipment follow up and monitoring (mill liners, hammers, drag chains, grizzly bears, crusher wear plates ...).

In addition to the above, UCF conducts frequent free of charge training programs at its premises for cement plant engineers which include:

  • Lectures on: Metallurgical fundamentals of cast alloys applied for cement industry (wear resistant alloys mainly high Criron and steel, austenitic Mn steel, and heat resistant alloys).
  • Assessment of wear rate, breakage and deformation of grinding media.

Production capacity :

60% Complete
20 000 tons of grinding media / Year
10% Complete
2000 tons of wear resistant and heat resistant castings / year
80% Complete
Thus, UCF overall production capacity is 22 000 tons / year.

Production facilities :

Foundry :

  • Melting shop:Nine induction melting furnaces of various capacities
  • Molding lines:Four moulding lines,One line of jolt squeeze machines,Two lines of DISAMATIC machines,One flour molding line
  • Three shot blast machines
  • Two breaker drums
  • Technical office for design activities and Pattern making workshop for manufacturing araldite patterns.The success of grinding media patterns had been proved through more than 20 years of grinding media production.

Heat treatment Plant :

  • Four continuous heat treatment furnaces
  • Seven tempering furnaces
  • One device for quantitative analysis of retained austenite. Retained austenite, being one of these undesirable phases, is quantitatively measured after heat treatment to assure that it is lower than a definite limit.

Laboratories :

UCF has a group of laboratories that satisfy the needs of :
  • process control plans implemented during production running
  • The needs of inspection and testing activities of finished products
UCF laboratory facilities include :
  • Two spectrometers for chemical analysis
  • Complete set of devices for testing new sands and moulding sand mixtures, carrying out tests as:Green compression strength, shear strength, permeability,compactibility, moisture content, grain size.
  • Stationary and portable hardness testing devices ( HB, HV, HRC )
  • Metallographic laboratory with optical microscopes of magnification X 1200 attached with the necessary devices of grinding and polishing for samples preparation for the metallographic examination
  • Non destructive testing for invisible crack detection.

Machining workshop :

  • It is equipped with all the necessary machines and tools for conducting machining operations as per customer requirements.
  • The machining workshop has a forging line for producing bolts necessary for fixing mill liners. Bolt threads are made by thread rolling machine
  • UCF in order to achieve continual product development, mainly depends upon R & D facilities of CMRDI which is the Egyptian national Metallurgical institute .
  • Due to the strong collaboration of UCF & CMRDI, and the highly active R & D staff of UCF, new product development had been reached Extensive research work was conducted in order to satisfy the difficult demands of many customers. This work was carried out using R & D facilities of CMRDI.
  • Material properties play a central role in controlling efficiencies of almost all industrial processes.Materials cause many planned and unplanned process interruptions in which productivity and energy are lost. Operating efficiency is also lost as materials corrode, wear or otherwise degrade.
  • For such environmental poivd & view, improving lifetimes of the supplies to cement and mining industries has become an imperative duty of the suppliers.
  • Use of improved supplies could be a part of the solution to the problem of energy waste minimization. Such improvement would be through R & D activities.
  • UCF had strongly activated its research & development role for meeting the mines and cement plant demands of more efficient energy consumption.
  • R & D activities had resulted in developing new alloys for definite applications with the aim of submitting higher wear resistant alloys, thus improving process economics at customer premises. Also UCF succeeded to replace the cast alloys used in some applications by other alloys proposed by its R & D team. In mining applications, UCF succeeded to replace some forged grinding media by cast ones of lower wear rates and developed new alloys for liners of their chutes.
  • UCF believes that R & D is the only way to achieve the customer expectations, his difficult demands, and also to approach the most cost solution of a process.

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