Casting for Caroflow and Caro Flood Defence

The Challenge

As part of the Caro Group of Companies, Maybrey Precision Castings manufactures aluminium castings for two of Caro's flagship product ranges: Caroflow Flat Roof Drainage and Caro Flood Defence.

Manufacturing these components in-house gives complete control over quality, lead times and product development, enabling Caro to respond quickly to customer requirements while maintaining a resilient UK supply chain.

For the Caro Flood Defence range, component quality is particularly critical. Every casting forms part of a flood barrier system independently certified to BS 851188-1:2019+A1:2021, the only demountable flood defence barrier in the UK approved for the Environment Agency Property Flood Resilience (PFR) Framework. Consistency, dimensional accuracy and manufacturing quality are therefore essential to maintaining the integrity and performance of the finished product.

Whilst most of the drainage and flood barrier components are straightforward to manufacture, the cast aluminium dome and flat grates presented a significant foundry challenge. Their long, thin-walled sections made them particularly susceptible to incomplete mould filling and inconsistent casting quality.

Our Solution

Drawing on many decades of foundry experience, our engineers undertook extensive development work to optimise the casting process for these challenging components.

Rather than accepting conventional casting parameters, we carefully refined every aspect of production, including:

Pouring temperature
Silicon content within the aluminium alloy
Core design and positioning
Die pre-heating temperature

By balancing these variables, we achieved consistent mould fill across the intricate thin-walled sections while maintaining the dimensional accuracy and surface quality required for production.

Once the optimum manufacturing process had been established, the remaining cast components for both the Caroflow Flat Roof Drainage and Caro Flood Defence product ranges were produced efficiently and consistently within our UK foundry.

Collaboration and Delivery

As part of the Caro Group, Maybrey Precision Castings works closely with the product design, engineering and manufacturing teams throughout the development process.

Having our foundry integrated within the wider business allows new products to move rapidly from concept through prototyping and into production. Design improvements can be evaluated quickly, tooling modifications implemented without delay, and manufacturing processes continually refined to improve both quality and efficiency.

Manufacturing entirely within the UK also provides customers with dependable lead times, removes overseas supply chain delays, and supports Caro's commitment to sustainable British manufacturing.

The Result: Designed, Cast and Manufactured in Britain

Today, Maybrey Precision Castings manufactures the aluminium cast components that form part of Caro's Caroflow Flat Roof Drainage and Caro Flood Defence systems.

Our castings contribute to products installed on commercial, industrial and residential projects throughout the UK, combining reliable performance with the quality expected from British manufacturing.

By manufacturing in our Future Net Zero Platinum Award foundry, Caro benefits from reduced transport emissions, shorter supply chains and complete control over quality, while maintaining the agility to respond quickly to changing customer requirements and bespoke product developments.

For the Caro Flood Defence range, every casting contributes to a product independently certified to BS 851188-1:2019+A1:2021, the only demountable flood defence barrier in the UK approved for the Environment Agency Property Flood Resilience (PFR) Framework, giving customers confidence that the finished system has been manufactured to the exacting standards required for certified property flood resilience products.

Whether manufacturing components for our own market-leading product ranges or supporting customers with bespoke casting solutions, Maybrey Precision Castings combines traditional foundry craftsmanship with modern engineering expertise to deliver exceptional castings where quality, precision and performance matter most.