Departments › Mechanical Production Technician › Module V › Foundry Works

Foundry Works

Mechanical Production Technician · Level 6  ·  8 Chapters

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What Foundry Works covers

In this unit, you will be able to confidently transform job specifications into precise casting designs and detailed drawings, ensuring every step from pattern making to final approval is done with accuracy and care. You will master selecting the right materials, tools, and safety practices to carry out casting operations efficiently and safely. By the end, you’ll be ready to contribute skilled craftsmanship and professionalism to any foundry work, turning plans into quality cast products with pride.

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Careers after Foundry Works

Foundry works are at the heart of Kenya’s manufacturing and engineering sectors. By mastering these skills, you position yourself to work in industries that shape our nation—literally! From creating machine parts for factories to crafting tools used in jua kali workshops, your expertise will be in demand across many fields.

  • Jua Kali Sector: Small-scale metalworkers and artisans rely on casting to produce affordable machine parts, tools, and household items. Skilled foundry workers often run their own workshops, earning by making and repairing parts for local clients.
  • County Works & Infrastructure: Counties employ foundry technicians to produce and maintain parts for water pumps, road construction equipment, and public infrastructure projects.
  • KenGen & Energy Sector: Power plants, such as KenGen, require custom-cast components for turbines and generators. Foundry skills are vital for maintenance and production teams.
  • Construction Sites: Builders and contractors use cast metal parts for reinforcement, plumbing, and fittings. Foundry workers supply these essential components, either as employees or through their own businesses.
  • Matatu Industry: Mechanics and fabricators use cast parts for engine repairs, body fittings, and custom modifications. Foundry artisans can supply these parts and earn from matatu operators.
  • Agribusiness & KTDA: Tea factories (KTDA) and other agro-processors need cast machine parts for processing equipment. Foundry specialists maintain and produce these parts, ensuring smooth operations.
  • Hospitality & Tourism: Hotels and resorts require custom castings for décor, kitchen equipment, and maintenance. Foundry workers can tap into this niche market.

By mastering foundry works, you open doors to stable employment and entrepreneurship, helping build Kenya’s future with your own hands. Your skills will be the foundation of progress—forge your path with confidence!

Chapters

1
Prepare working drawing
8 topics
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2
Prepare casting operation plan
43 topics
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3
Produce moulding patterns
37 topics
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4
Prepare moulding sand
19 topics
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5
Make sand mould
13 topics
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6
Melt casting materials
21 topics
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7
Carry Out Casting Process
19 topics
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8
Inspect casting
26 topics
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What Foundry Works covers: 30 main topics in 8 chapters

1. Prepare working drawing

  1. 1.1 Working drawing interpretation
  2. 1.2 Free hand sketching
  3. 1.3 Detailed drawing

2. Prepare casting operation plan

  1. 2.2 Casting Operations and Sequencing
  2. 2.4 Materials
  3. 2.5 Defination of operation plan

3. Produce moulding patterns

  1. 3.1 Workshop safety
  2. 3.2 Pattern making Materials
  3. 3.4 Pattern design parameters
  4. 3.5 Pattern construction
  5. 3.6 Pattern assembly
  6. 3.7 Types of Patterns

4. Prepare moulding sand

  1. 4.2 Types of Moulding Sand
  2. 4.3 Moulding Additives
  3. 4.4 Moulding Sand Testing

5. Make sand mould

  1. 5.1 Moulding Process
  2. 5.2 Moulding Procedures

6. Melt casting materials

  1. 6.1 Types of furnaces
  2. 6.2 Furnace Setup and Charging
  3. 6.3 Furnace Parameters
  4. 6.4 Preheating and fluxing
  5. 6.5 pyrometer
  6. 6.6 Skimming

7. Carry Out Casting Process

  1. 7.2 Pouring techniques
  2. 7.3 Casting parameters
  3. 7.4 Cast removal procedure

8. Inspect casting

  1. 8.2 Casting Defects
  2. 8.3 Heat treatment processes
  3. 8.4 Finishing Process in Casting
  4. 8.5 Inspection Report

Practise this unit

The practical 113 The assessment itself: tools, materials and the marks Step-by-step guide 113 PPE, each step, what good looks like, common mistakes

Revise this unit

Exam-style questions 112 Written to CDACC standard, with answers Test yourself 320 Multiple-choice, one at a time Practise questions 189 Quick recall — check you know the facts
3 more for this unit
Oral exam preparation 73 What the assessor asks, and how to answer out loud Worked calculations 50 Step-by-step maths with the common mistakes Quick cards 1,584 Myth busters, skill tips and scenarios

Beyond the syllabus

Decision simulator 8 On site, what would you do? Workplace scenarios 140 Real site situations — what would you do? Turn this into income 72 Where this skill earns — what to charge, how to find clients

Other units in Module V