Soundproofing for Foundries
For facilities operating 24/7
Soundproofing for Foundries Directly from the Full-Service Manufacturer
Soundproofing for foundries is among the most demanding tasks in industrial noise control because heat, dust, vibrations and high sound levels act on equipment and personnel at the same time. Since 1986, sta Group has been planning, manufacturing and installing complete solutions for melting halls, moulding shops, core-making areas and fettling shops, taking responsibility for every project step from the first sound measurement to the documented handover.
In-house acoustics planners identify the dominant noise sources directly on site, evaluate frequency spectra and define insulation values according to DIN EN ISO 11690. On this basis, concepts are developed that effectively reduce levels at melting furnaces, pneumatic knock-outs and shot blasting lines while accommodating maintenance, charging and heat dissipation. The soundproofing consultation forms the binding first building block of every project.
As a full-service manufacturer, sta Group coordinates design, production, logistics and installation from a single source. The TOP 100 Innovator 2024 award confirms this integrated approach. Customers such as Audi, BMW, ThyssenKrupp and Schuler have relied on this breadth of expertise for years and receive reliable sound levels without the typical interface risks between individual trades within a soundproofing project.
Tailored Acoustic Concepts for Melting Halls and Fettling Shops
Every foundry has its own acoustic signature. Melting hall, moulding shop, core making and fettling shop produce different levels, frequencies and structure-borne sound transmission, each demanding its own measures. Our acoustics planners record these areas with a state-of-the-art 3D scanner and create millimetre-accurate digital surveys as a robust basis for design, material selection and detailed planning.
In the melting hall, low-frequency components from burners and pneumatics dominate; in the fettling shop, high-frequency noise from blasting lines, grinders and cutting wheels prevail. Our designers therefore combine heat-resistant machine enclosures with absorbing wall claddings, vibration-isolated operator cabins and sound-insulating partition systems. Material and construction follow the temperature and fire protection classes of the respective areas.
The transition between loud and quiet zones is also taken into account consistently. Strategically placed industrial sound absorbers noticeably reduce reverberation time in large hall volumes. Soundproofing for foundries thus becomes a concept that meets the requirements of the German Noise and Vibration Occupational Health and Safety Ordinance and at the same time improves concentration and speech intelligibility at operator workstations.
Industrial Foundry Soundproofing Custom-Made and from a Single Source
Industrial foundry soundproofing is only effective if all services are precisely coordinated with each other. sta Group covers the entire value chain and works with a dedicated project manager per order. This person guides you from the first sound measurement through design and production to a clean handover in your foundry.
The planning phase uses 3D CAD and provides full visualisation of the future solution before production starts. On request, collision checks, escape routes, maintenance clearances and lifting equipment corridors can be verified directly in the model. Connections for ventilation, media supply and control systems are also defined bindingly in this phase, so that nothing has to be reworked on site.
After handover, sta Group also handles adjustments, expansions and maintenance work on installed systems on request. Operators in combination with neighbouring areas such as soundproofing for metalworking or stamping production particularly value this continuity, because standards and contacts remain stable over the years and new lines speak the same acoustic language.
Effectively Reducing Noise at Melting Furnaces and Blasting Lines
Melting furnaces, ladle transport, sand preparation and fettling areas are among the loudest stations in a foundry. Sound levels of 95 to 110 dB(A) are not unusual here, particularly when several systems run in parallel. Effective reduction is achieved through a combination of source enclosure, vibration isolation and hall acoustics, matched to the respective process step and the local space conditions.
Heat-resistant enclosures, ventilation silencers and encapsulated drives address the noise directly at the source. At blasting lines, double-shell wall constructions with absorbing inner sides reduce levels by 15 to 25 dB. Pneumatic knock-outs and vibrating shake-out grates receive elastic mountings that reliably separate structure-borne sound from the hall floor. Complementary measures within the industrial hall reduce transmission to neighbouring work areas.
For operators, vibration-isolated soundproof control cabins and control rooms are created with their own ventilation and insulated viewing windows. These protective spaces allow continuous work in the immediate vicinity of the equipment and significantly reduce personal noise exposure below the upper action value of 85 dB(A). Soundproofing for foundries works here as a tiered system of technical, organisational and personal protection measures following the STOP principle.
Automotive industry. Equipment manufacturers. End customers.
A brief selection of references
In-House Production of Elements up to Six Metres in Length
In-house manufacturing in Hamm an der Sieg enables components up to 6 m in length and precisely fitting custom parts for complex hall geometries. An automated plasma cutting system cuts every desired contour, while in-house welding and painting ensure consistent quality across all batches. This depth of value creation accelerates lead times and reduces interfaces with external partners.
Special foundry requirements also feed directly into production. Heat classes, fire protection requirements according to DIN EN 13501 and stresses caused by molten metal splashes are taken into account during material selection and connection technology. In-house fitters handle the installation, often in parallel to ongoing melting operation, with clearly coordinated access windows and a clean handover of the work areas.
Soundproofing for foundries is therefore the responsibility of a single partner, from planning to maintenance. Anyone investing long term in quiet and safe casting operations benefits from this vertical integration in the form of predictable costs, shorter downtimes and reliably achieved sound levels over the entire service life of the installed systems. The result is durable protection for people and machines that grows with every plant expansion.
Successful Customer Relationships
A Selection of Our Clients
Contact us now—we’re here for you!
Soundproofing Systems
Soundproofing Systems
We’ll take the time to ensure that the right representative answers all your questions about your specific project. We look forward to hearing from you. Guaranteed!