A foundational shift is occurring within the structural DNA of heavy equipment manufacturing. Charter Casting, the leading provider of innovative cast metal solutions and cast iron bar stock (DuraBar), today released new industry insights revealing a "silent shift" of manufacturers abandoning traditional steel weldments and fabrications in favor of complex iron castings.

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The study of more than 300 purchasers of iron and steel products reports 56% of companies have successfully converted steel weldments with complex iron castings on multiple projects, and 99% cite benefits in the conversion.

“Heavy equipment OEMs are beginning the transition from steel fabrications to modern and advanced ductile iron castings saving time, money, and delivering increased performance,” said Shane Bonner, President of Charter Casting. "Manufacturers are discovering that the labor-intensive process of cutting and welding dozens of steel parts together is a legacy bottleneck. This latest data tells a story of a massive, successful undercurrent of manufacturers replacing fabrications and weldments with iron castings to solve for labor challenges and simplifying designs that resolve the engineering challenges ahead.”

‘Silent Shift’ driven by benefits and depleted workforce

According to the data, this transition is no longer a theoretical or academic conversation. Almost all manufacturers (99%) report they are likely to use advanced ductile iron castings in the next two years.

Among companies that have replaced steel weldments with iron castings, 99% reported significant benefits, confirming it is a proven method with a high success rate.

This shift is driven by the physical demands of the modern job site:

• Durability and Strength: 78% of respondents identified durability as the most important factor when evaluating complex castings, where available Austempered Ductile Iron (ADI) outperforms traditional steel in high-stress environments.
• Vibration Damping: 40% of manufacturers cited superior vibration-damping, a critical factor for operator comfort and machine longevity.
• Consistency: 44% of industry leaders noted that iron castings provide easier quality control and improved part consistency (42%) compared to the variability of manual welds.

Another driving factor driving change is the welding labor shortage across the industry. According to projections from the American Welding Society, more than 320,000 new welding professionals are needed by 2029 due to the aging workforce. A third (33%) of manufacturers point to that trend that may move them to iron castings in the near future.

Navigating the transition

Despite nearly all manufacturers planning to incorporate complex iron castings into their process, they express concern over making the transition:

• 50% cite high upfront tooling costs
• 49% are concerned about risking quality in the transition
• 47% are uncertain about the performance of complex iron compared to welded steel

“Change can create uncertainty, yet manufacturers tell us they know it’s coming,” said Bonner. “They want to turn a 10-piece steel assembly into one single iron part. That’s where our engineering-led conversion support becomes a business imperative. We don't just pour metal; we partner with, and work alongside our customers to de-risk the evolution."

The Resurgence of Domestic Reliability

In an era of unpredictable global logistics, the move to iron is also a move toward supply chain security. Charter Casting’s data shows that 70% of manufacturers rank "Made in the U.S.A." as the most appealing characteristic when selecting a partner. By offering high-tech ADI solutions domestically, Charter Casting ensures that the transition from steel to iron is not derailed by international shipping delays or quality inconsistencies.

About the research

Charter Casting conducted a survey of 335 decision makers at companies purchasing iron and steel products. The survey was completed in August 2025.

About Charter Casting

Charter Casting is the premier U.S. partner for precision-engineered iron solutions, offering the industry’s leading continuous cast iron bar through DuraBar, along with large, complex iron castings. With operations in Wisconsin and Illinois, Charter Casting provides end-to-end support from collaborative design and engineering to manufacturing and finishing. Our solutions help customers reduce total cost, improve performance, and strengthen supply chain reliability. Backed by Charter Manufacturing, a fourth-generation, family-owned metals manufacturer, Charter Casting combines deep material science expertise, scalable capacity, and American-made quality to support the industries that feed, defend, and build America. For more information, visit CharterCasting.com.

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56% of companies have successfully converted steel weldments with complex iron castings on multiple projects, and 99% cite benefits in the conversion.