Sheffield Forgemasters is a heavy engineering firm located in

Sheffield Sheffield is a city status in the United Kingdom, city in South Yorkshire, England, whose name derives from the River Sheaf which runs through it. The city serves as the administrative centre of the City of Sheffield. It is Historic counties o ...

South Yorkshire South Yorkshire is a ceremonial and metropolitan county in the Yorkshire and Humber Region of England. The county has four council areas which are the cities of Doncaster and Sheffield as well as the boroughs of Barnsley and Rotherham. In N ...

, England. The company specialises in the production of large bespoke

steel Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...

casting Casting is a manufacturing process in which a liquid material is usually poured into a mold, which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified part is also known as a ''casting'', which is ejected ...

s and

forging Forging is a manufacturing process involving the shaping of metal using localized compressive forces. The blows are delivered with a hammer (often a power hammer) or a die. Forging is often classified according to the temperature at which i ...

s, as well as standard

rolls Roll or Rolls may refer to: Movement about the longitudinal axis * Roll angle (or roll rotation), one of the 3 angular degrees of freedom of any stiff body (for example a vehicle), describing motion about the longitudinal axis ** Roll (aviation), ...

ingot An ingot is a piece of relatively pure material, usually metal, that is cast into a shape suitable for further processing. In steelmaking, it is the first step among semi-finished casting products. Ingots usually require a second procedure of sh ...

s and bars. The company was

nationalised Nationalization (nationalisation in British English) is the process of transforming privately-owned assets into public assets by bringing them under the public ownership of a national government or state. Nationalization usually refers to pri ...

in July 2021, becoming wholly owned by the UK's

Ministry of Defence {{unsourced, date=February 2021 A ministry of defence or defense (see spelling differences), also known as a department of defence or defense, is an often-used name for the part of a government responsible for matters of defence, found in states ...

History

Origins

Sheffield Forgemasters traces its origins to a 1750s blacksmith forge, and then Naylor Vickers and Co. founded by George Naylor and

Edward Vickers Edward Vickers (1804-1897) was the founder of Naylor Vickers & Co. which became Vickers Limited. Career Vickers was a successful miller who invested his money in the railway industry. In 1828 he gained control of his father-in-law's steel foundry ...

, the predecessor of

Vickers Limited Vickers Limited was a British engineering conglomerate. The business began in Sheffield in 1828 as a steel foundry and became known for its church bells, going on to make shafts and propellers for ships, armour plate and then artillery. Entir ...

. Vickers built the River Don Works in 1865. In 1983, the River Don Works, then part of state-owned British Steel, merged with

Firth Brown Steels Firth Brown Steels was initially formed in 1902, when Sheffield steelmakers John Brown & Company exchanged shares and came to a working agreement with neighbouring company Thomas Firth & Sons. In 1908 the two companies came together and establish ...

to create Sheffield Forgemasters.

Early years

In the 1980s, Forgemasters manufactured components for the

Iraq Iraq,; ku, عێراق, translit=Êraq officially the Republic of Iraq, '; ku, کۆماری عێراق, translit=Komarî Êraq is a country in Western Asia. It is bordered by Turkey to Iraq–Turkey border, the north, Iran to Iran–Iraq ...

Project Babylon Project Babylon was a space gun project commissioned by then Iraqi president Saddam Hussein. It involved building a series of "superguns". The design was based on research from the 1960s Project HARP led by the Canadian artillery expert Gerald ...

"supergun", which it had believed were for a petrochemical refinery. The British investigation exonerated the company's directors, and the incident became known as the

Supergun affair The "Supergun" affair was a 1990 political scandal in the United Kingdom that involved two businesses, Sheffield Forgemasters and Walter Somers, Gerald Bull, (then) members of parliament Hal Miller and Nicholas Ridley, the UK's Secret Intellige ...

. In 1998, the company was divided and sold to American companies. Allegheny Teledyne bought the aerospace business. Atchison Casting Corp bought the River Don and Rolls businesses, which retained the Sheffield Forgemasters name. Forgemasters was threatened with liquidation in 2002. Atchison went bankrupt in 2003 and was acquired by KPS. In 2005, Graham Honeyman led a successful effort to buy Forgemasters; Honeyman became the company's chief executive and majority shareholder. Forgemasters experienced a work stoppage from severe flooding in the summer of 2007 when the works were inundated by the River Don. Three weeks after the event, repairs were ahead of schedule and the works were approaching full production.

Civil nuclear market

In the late-2000s, Forgemasters made a failed attempt to acquire a 15,000 tonne forging press for manufacturing ultra-large civil nuclear components. In March 2010, the company had secured £140 million in funding over two years, including an £80 million loan from the

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. Plans to acquire the press were ultimately suspended. The government loan was cancelled in June 2010 with a change of government. Forgemasters declined to apply for a new loan in 2011 as foreign competitors were building such presses, and the

Fukushima Daiichi nuclear disaster The was a nuclear accident in 2011 at the Fukushima Daiichi Nuclear Power Plant in Ōkuma, Fukushima, Japan. The proximate cause of the disaster was the 2011 Tōhoku earthquake and tsunami, which occurred on the afternoon of 11 March 2011 and ...

had caused uncertainty in the civil nuclear market.

Financial difficulties

Forgemasters suffered as the British steel industry declined in the early 2010s. It reported its first operating loss, of £9.4 million, since separating from Atchison in the 14 months leading to December 2014. In January 2016, the company announced plans to reduce its workforce from 800 to 700. The company's financial health attracted attention due to its involvement in Britain's nuclear submarine programme. In 2016, Forgemasters obtained a £30 million loan from US bank

Wells Fargo Wells Fargo & Company is an American multinational financial services company with corporate headquarters in San Francisco, California; operational headquarters in Manhattan; and managerial offices throughout the United States and intern ...

. The loan was underwritten by nuclear submarine contractors

BAE Systems BAE Systems plc (BAE) is a British multinational arms, security, and aerospace company based in London, England. It is the largest defence contractor in Europe, and ranked the seventh-largest in the world based on applicable 2021 revenues. ...

Babcock International Babcock International Group plc is a British aerospace, defence and nuclear engineering services company based in London, England. It specialises in managing complex assets and infrastructure. Although the company has civil contracts, its main b ...

and Rolls-Royce Marine Power, in an arrangement negotiated by the British

(MoD); the intervention forestalled Chinese investment and control in the company. In March 2018, the arrangement was due to expire in July 2019; Sky News reported that the underwriters were seeking a replacement to Honeyman, possibly as a precondition for renewal. In July 2018, Honeyman was replaced as chief executive by David Bond from BAE Systems.

Nationalisaton

In December 2020, the Ministry of Defence (MoD) and Forgemasters were in preliminary talks for the nationalisation of the company. In July 2021, the UK government announced that the MoD had launched an offer to take over the company for £2.56 million, and intended to invest a further £400 million over the next decade to support defence outputs. Investment will include a new heavy forge line and flood alleviation measures. The current senior management will run the company with two new non-executive directors.

Capabilities

The company specialises in forged and cast steel components for the defence, engineering, nuclear, offshore, petrochemical and steel processing industries worldwide. The company has the

American Society of Mechanical Engineers The American Society of Mechanical Engineers (ASME) is an American professional association that, in its own words, "promotes the art, science, and practice of multidisciplinary engineering and allied sciences around the globe" via "continuing ...

N-stamp accreditation for critical nuclear components, having produced major components for the s and the civil nuclear industry, including Sizewell B, the UK's only

pressurised water reactor A pressurized water reactor (PWR) is a type of light-water nuclear reactor. PWRs constitute the large majority of the world's nuclear power plants (with notable exceptions being the UK, Japan and Canada). In a PWR, the primary coolant (water) is ...

. Sheffield Forgemasters currently has the capacity for pouring the largest single casting (570 tonnes) in

Europe Europe is a large peninsula conventionally considered a continent in its own right because of its great physical size and the weight of its history and traditions. Europe is also considered a Continent#Subcontinents, subcontinent of Eurasia ...

. The two forging presses in use can exert a pressure of 4,500 tonnes and 10,000 tonnes on a billet of steel. The 4,500 tonne press was installed in 2010 to replace a 1,500 tonne press which dated back to 1897 and was originally steam powered, and after several upgrades became hydraulically operated.

References

External links

* {{Sheffield companies, state=collapsed Manufacturing companies established in 1805 Engineering companies of the United Kingdom Manufacturing companies based in Sheffield Steel companies of the United Kingdom 1805 establishments in England British companies established in 1805 Government-owned companies of England