Precision material for demanding process environments.

In a foundry, the sand is not a background input — it is a consumable component in a high-temperature metal casting process where material properties directly determine casting quality, mould performance, and finished part consistency. Getting it wrong shows up as defective castings, wasted metal, and production downtime. Hudson Aggregates produces high silica foundry sand from natural deposits, processed to the purity and consistency serious foundry operations require.

High SiO₂

Refractoriness confirmed by XRF analysis

XRF verified

Full oxide profile from independent lab

AFS GFN

Pre-ordered to your target fineness range

Iron foundry

Optimised for 1,250 to 1,400°C applications

Why Silica Content Matters in the Foundry

SiO₂ is the primary determinant of refractoriness — the sand's ability to withstand extreme thermal exposure without breakdown, fusion to the casting surface, or gas-producing volatile content that causes porosity defects. For iron foundry applications at 1,250°C to over 1,400°C, high and consistent SiO₂ is a baseline requirement.

Our SiO₂ content is confirmed through internal testing and independent external XRF analysis — verified data for your metallurgical and QA teams, not supplier assertions. XRF also characterises the full oxide profile, providing the complete chemistry picture modern foundry quality systems require.

Internal SiO₂ testing Independent | XRF verified | Data with every supply

SiO₂

Silicon Dioxide — refractoriness

Al₂O₃

Aluminium Oxide

Fe₂O₃

Iron Oxide

TiO₂

Titanium Dioxide

CaO

Calcium Oxide

MgO

Magnesium Oxide

Grain Size and AFS Fineness:
Pre-Ordered to Specification

AFS grain fineness number (GFN) is a process parameter — it determines casting surface finish, mould permeability, and sand behaviour within your binder system. The right GFN is a function of your process, your pouring metal, and your customer surface finish requirements. We adjust size fraction on a pre-ordered basis to match your target AFS GFN range.

Finer GFN

Smoother casting surface

Reduces mould permeability. Suited to precision castings where surface finish is the priority. Requires careful management of gas entrapment within your binder system.

Coarser GFN

Higher permeability and thermal stability

Better gas venting, higher thermal mass. Suited to applications where surface finish requirements are less demanding but mould integrity and thermal performance are the priority.

This is not a commodity stock item where you take what is available. It is a specification supply arrangement that begins with a conversation about what your process actually requires. Engage with us at the process planning stage — not at the point of immediate need.

Suited to the main bonded sand systems.

Our material profile — high silica, controlled GFN, low clay and fines — performs within the three primary foundry binder systems.

Green sand system

Clay-bonded moulding sand used for high-volume iron casting. Low clay content in the base sand supports controlled addition of bentonite binder without unpredictable interaction from naturally occurring clay minerals

No-bake chemical binder

Chemically bonded system where sand cleanliness and consistent grain surface are critical to binder performance. Our washed, low-fines material provides a predictable base for resin bonding

Cold-box core process

High-precision core making where gas permeability, dimensional stability, and clean shakeout are the priorities. Consistent grain fineness and low volatile content support reliable core performance batch to batch.

Iron Foundry: Our Primary Application

Our material profile — high silica, controlled grain fineness, low clay, documented chemistry — is particularly well matched to iron foundry moulding and core sand. The thermal conditions of iron casting demand a sand that holds structural integrity under repeated thermal cycling, resists fusion at the metal-sand interface, and releases cleanly during shakeout.

1,250 to 1,400°C application range Thermal cycling resistance Clean shakeout release

Other Processes: Honest Assessment

For steel foundry applications or non-ferrous casting processes with different thermal profiles and chemistry sensitivities, we discuss suitability on a case-by-case basis. XRF data and grain size analysis are available for your technical team to evaluate before any supply commitment.

We will always give you an honest assessment of whether our material is the right fit for your specific process.

Internal Testing and Independent XRF Analysis

Every supply arrangement is supported by two layers of analytical data. Documentation is provided with supply and structured to integrate with your incoming material acceptance and quality management systems.

Documentation available to support incoming material acceptance procedures, process qualification, and customer quality documentation requirements.

Internal testing

Grain size distribution, AFS fineness number, clay content, and loss on ignition. The standard suite of physical and chemical parameters for foundry sand qualification.

Independent XRF

Third-party laboratory analysis confirming the full oxide chemistry. Provides independent verification that quality-managed foundry operations increasingly require from their supply chain.

– Ready to Work Together

The only facility in DFW that closes the loop.

No broker. No middleman. We take the waste, run the plant, and produce the aggregate — all from one permitted facility in Kennedale.

– Contractors and Buyers

Get your quote.
Build with it.

Local supply, natural material, ASTM-certified. Tell us what you need and we'll have pricing back within two hours.

– Haulers and Disposers

Stop driving past us. Drop it off.