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Innovative Connections
Cast Connections
Cast connections are actually about simplicity. Cast connections are being used increasingly in projects. The
castings have nothing to do with its earlier cousin: cast iron. Casting was formerly used to create highly ornate, rep
possible by rolling or extruding the steel. Cast iron was not able to be welded as it had a high carbon content and w

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The Paris Metro entrances by Hector Guimard took advantage The Biblioteque Ste. Genevieve by H
of the casting process to create highly ornate design. steel to economically replicate identical,

Steel castings today are higher strength, weldable and more ductile. You generally see castings in conjunction with
complex tubular joints for buildings or bridges. While they bring with them the added advantage of handling comple
difficulties found using multiple combinations of tubes and plates, they do require a different level of engineering an

Economy is still found in the mass production of the elements. One-off castings or small runs can be very expensive
need a reason.

• Do you have repetition (so the cost of making the mould is partly amortized)? (A must) Are there many elements
• Do you want to use castings in a high-stress zone?
• Do you have a foundry in your area that has the expertise?
• Would castings provide aesthetic advantages?

If you answer yes to at least 3 of these questions, then maybe these are appropriate for your project. A rough `rule
starts to cost four times as much as the material it is made of, then steel castings start to be economical.
 Smaller castings are generally die cast and can be produced
in larger runs. There is better economy. This solid steel pin
connector, technically called a clevis, is part of the Reichstag in
Berlin by Foster+Partners. You can see an identifiable
connection between the rod and the casting. There has been no
extra effort/expense to conceal the meeting of the two elements.
This type of pin connector will normally use a specialty connector
rather than a simple bolt.
This casting at the Caisse du Depots e
Montreal, Quebec is and example of a
cast, hollow cast connector. There w
elements within the large atrium space,
these large elements normally involves l
Smaller hollow castings have been used
connectors for the upper web members o
the connection between the HSS membe
concealed.

A cast member has a different finish. This is due to their manufacturing process and a function of the materia
casting. For example if a sand casting is used the surface texture of the finished steel will have a rough sand like ap
required if a seamless final appearance is sought between the casting and the adjacent tubular member. For higher
mean significant grinding and filling to smooth out the rougher finish of the casting, or remove casting mill marks.

Castings can be formed hollow or solid. Solid castings are usually to be found in smaller connectors like the o
terminus of tension rod type structures. Hollow castings are used for larger members as solid castings would have d
cooling and would be more expensive. Non uniform cooling can create internal stresses. Non-destructive evaluation
ultrasonic testing should be considered as a minimum. When selecting a caster be sure that they will perform appro

Larger castings are made from expendible moulds. The base shape The casting must be cleaned up after it i
is translated from the CAD file, into 3D. A resin cast is made from mould. You can see the granular surface
this full sized 3D element. the sand cast method. If this is not accep
extra to have the fabricator grind and fill

Large specialty castings require specific testing to ensure that they are properly designed and capable
exhibits isotropic properties, making it quite suitable for transferring forces through the connections in a reliable ma
shear, moment, and torsional stresses. It accomplishes this by working the geometry as a function of variations in
the finished form of the exterior. Unlike fabrications made from tubes or plates, the interior dimensions of the void
the exterior form of the object.
CAST CONNECTIONS CAN BE SMALL AND FAIRLY REPETITIVE...
Castings are used to connect parts of the Reichstag walkway
system as they can give a very clean appearance and there is also
much repetition to warrant making special die casts. A custom
fabricated steel element would have been clunky in appearance.
CAST CONNECTIONS CAN BE LARGE AND FAIRLY UNIQUE....
The Caise du Depots et Placement in Montreal makes use of a
variety of large hollow castings to create its architectural connection
language. Each is a slight variation of the other. These are designed
to accept hollow structural sections. The connection points are
welded. Where other members are to be connected on site, pin type
connections allow for easier on site bolting.
CASTINGS CAN BE CONNECTED WITH A SEAMLESS APPEARANCE...
The designers have modified the typical
the attachement of two rods. This begins
connections" to work with the overall des
triangular plate is used to attach the con
The base connecton for the vertical truss
to bring the three vertical HSS members
base more cleanly allows for the three ro
at one point. The texture of the base cas
process.
The mechanical pipe that is connected to this cast node at the
University of Guelph Science Building is precisely the same
diameter as the node portion. The members will be welded together
and the welds ground and filled as to be invisible. This was done to
attach the node to the trunk of the tree in the shop where such
work is easier to do.
The weld seam that joins the branch to the casting requires multiple
passes and subsequent grinding and filling in order to create the
seamless appearance desired by the architect.
A closer view of one of the smaller nodes
tube that is set inside the node to backst
has been held back from the portion to b
will be removed prior to welding. The wh
used to align and hold the upper branche
be welded and fixed into place.
It was extremely important to take into c
paint finish as it would be completely unf
minute imperfection in the fabrication.
 The node elements for the Queen Richmond Centre in Toronto
will be formed by these large castings. You can see the scale of the
incoming round tubular column elements. Castings by
CastConnex ® .
A view of the casting when it is still
red hot. The cooling must be
carefully controlled as not to result in
internal stresses that could cause a
failure.

Seismic uses for castings. Solid castings are being effectively used in seismic installations.

These high strength cast seismic connectors, developed by
CastConnex ® , can be used as the diagonal bracing in seismic
resistant concentrically framed steel buildings. The casting is
welded to a hollow structural member.
The diagonal braces are able to absorb t
simpler to erect than some alternate sys
These castings were donated to Haiti for
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Terri Meyer Boake - University of Waterloo | Vincent Hui - Ryerson University | © Copyright 2018 Canadian Institute of Steel C