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Manufacturers of High Performance Cast Wear Parts, helping to drive Global Mining cost reductions.

Company Vision Statement

FSF designs and engineers quality cast steel wear parts as well as a variety of martensitic high chrome white iron products for the mining industry on a global scale. Our aim is to offer the market alternative and more reliable solutions to OEM parts and to ensure that any forced downtime experienced by our clients is minimised through the creation of quality parts that not only last longer and are supplied on time, but also at a reduced cost. Proprietary Alloys, linear delivery solutions and our global supply chain helps us to achieve this.

Company Overview

Established in the Foothills of the Rocky Mountains outside of Calgary, Alberta in 1947, Foothills has evolved over the years. From our beginnings supplying simple castings and small forgings, we have evolved into a large scale producer of high performance castings and fabrications, large scale machine turned steel componentry and professional engineering services. With over 70 years of history in supplying quality solutions into the mining, quarrying and petrochemical industries and having a global presence throughout the world, Foothills Steel Foundry is a leader in our field and a renowned supplier of parts that last.

Business Units

  • Design & Engineering
  • Pattern making
  • Metallurgical and material engineering and selection
  • Material Testing (NDT)
  • Full Scale Casting Operations
  • Fabrication and Assembly
  • Precision Machining
  • Freight and Dispatch
  • Customer Service Team


We manufacture customized cast parts for almost any industry. 

Our ability to cast steel alloy parts for almost these markets means that we are versatile and adaptable. Our main focus has been cast wear parts for the crushing industry, but with the globalisation of our company we have garnered an ability to pivot and stretch into other industries such as Rail, Ports and Oilsands Mining.

Our products include:

  • 12%-24% Hadfields Manganese Wear Parts

  • Martensitic High Chrome White Iron (HCWI)

  • Chrome Carbide Plate Overlays

  • Ground Engaging Teeth (GET)

  • Crawler Shoes

  • Electric Rope Shovel Racking

  • Rubber Matting

  • Custom Castings

  • Nickel/Chrome/Moly alloys for general use


At FSF we help our customers with unique problems. Often we are asked to evaluate a component, and develop a part that isn’t on the market; we are designers, engineers, thinkers and leaders in our space through a collaborative approach with our clients. 

Because we can design our own solutions, we have a full complement of Design and engineering staff who work with our clients delivering custom solutions to challenging problems. 

Our capabilities are vast and our experience extensive. At Foothills we design, engineer and manufacture parts to solve your specific problem on site. Our services include: 

  • DESIGN + ENGINEERING –  FSF design engineers are highly trained professionals that specialize in steel casting theory, while applying that knowledge to practical solutions to everyday problems. Quite often our engineering and redesign will result in a steel casting that exceeds the original design, reducing downtime and providing significant up front cost savings. 
  • CASTING – Utilizing (4) 3 tonne induction furnaces, FSF Can cast up to 8 tonnes clean weight, and up to 130 tonne per day of raw castings. 
  • REVERSE ENGINEERINGTrained in the latest 3D technology, FSF Engineers utilize Creaform scanners for reverse engineering projects, wear rate analysis reports, and any CMM verifications our clients may require
  • MATERIAL TESTING FSF Material testing is either handled in house or through an accredited third party. This can include (but not limited to) Impact testing, Tensile testing, UT, MPI, WPI, dimensional testing as well as chemical testing. 

Customer Service

Customer Service is important to us at Foothills, with over 70 years of experience, we understand our clientele and respect the fact that they continue to choose us time and time again. We have an intrinsic understanding of our craft, knowledge of the application and the industry and the people to drive progress.

You can contact our customer service team on: 

TEL: 403-255-0125
FAX: 403-252-8994

Facilities & Equipment

Foothills manufacture world-class wear solutions with a reputation for providing some of the best wear life in the Industry.

Foothills Steel Foundry has a casting capacity ranging from 50 grams to 9,000kg, and volume capable of producing well over 100 000lbs  per month. Our other in-house facilities include metallurgy, heat treatment, machining, welding and assembly.

We offer a full range of foundry services, including:


    Faro and Creaform laser digital profiling


    Solidworks CAD modelling and drawing


    Sand and investment casting pattern making
    Mold design and construction


    Chemical and Physical Metallurgy

    • Gas Spectrometer and Digital chemical analysis
    • Hardness testing
    • MPI, WPI, UT and Visual

    Full casting facility – 50 grams to 9,000kg


    Heat treatment capabilities for all castings produced.

    • Digitally controlled Heat treatment ovens
    • Water (constant flow) and Oil quench
    • Rapid air cooling

    Machining capabilities for all sizes and alloys

    • (3) 84″ manual vertical boring mills
    • (3) open axis large capacity manual table planers
    • (2) 5 axis CNC end mills, 3’x5′ table size
    • (1)  3 axis end mill 4’x10′ table size, oversize travel capacity
    • (1) 36″ max diameter CNC lathe 
    • (1) 6’x10’ Plasma Table, 5 axis
    • (1) 8 x 10 Plasma Table 5 axis
    • (1) 60” width capacity plate roller
    • (1) 10’x10’ stress relief oven
    • (1) 100 ton vertical press
    • (1) 100 ton horizontal press
    • (2) 10 ton overhead cranes
    • Misc forklifts, lift capacity up to 20 ton
    • 20 acres of usable land for storage
    • (2) 10 000 sq ft workshops, 20’x20’ door clearance
    • (1) welding rollover
    • 3 wire feed welding stations with multiple hand held mig welders
    • Paint shop

Safety, Quality, Accreditations and Risk Management practices

Safety Management and track record 

Employees at every level, including management, are responsible and accountable for the company’s overall safety initiatives. FSF recognizes this as job #1. Complete and active participation by everyone, every day, in every job is necessary for the safety among all workers on the job site. Management supports participation in the program by all employees and provides proper equipment, training and procedures. Employees are responsible for following all procedures, working safely, and, wherever possible, improving safety measures

With a newly recognized COR Certificate, FSF has shown that through the 3 pillars of business (commitment to the environment, employees and financial bottom line) that success is not measured strictly by the wealth of the balance sheet; rather a success in its employees and a push to reduce our own carbon footprint wherever possible.

Quality Management System

We are certified to ISO9001 which means we consistently provide products and services that meet customer and regulatory requirements. Our processes are well defined and we take safety and customer service seriously.

Our COR / SECOR shows that Foothills Health and Safety Management System (HSMS) has been evaluated by a certified auditor and meets provincial standards established by Partnerships in Injury Reduction (PIR).

Being ABSA certified means that as a manufacturer of all components in the manufacturing process, we have complete control over the quality, delivery and maintenance of our pressure vessels. 

Environmental Management Policy

We understand the importance of managing our emissions. As a steel casting supplier we are conscious of the GHGs that our facility emits. Our way of combating these GHG emissions is by not only “reducing, reusing and recycling”, but also by creating carbon and energy offsets from our wind power development project.  

FSF has taken an active position owning and developing approx 300 acres of space just outside of Fort Macleod, Alberta where we are in the process of developing a 30MW wind farm. After compiling wind data for over a decade, and bringing to market one of the most efficient sites in Canada, we are set to create not only carbon offsets, but bring to market a commercially viable project that is a model of sustainability. 

We believe it is imperative to play a part in climate control and be a leader in the global movement to adhere to the UN’s 17 key Sustainable Development Goals. 

We are working towards creating affordable and clean energy for industry to utilize (Goal 7) and by being active in this space we adhere to goal 13 which aims to manage Climate action.

  • How do you manage your waste products?

    Lean Manufacturing

    We believe in being efficient at FOOTHILLS. Using the same principles of lean manufacturing, our professionals drive cost efficiencies through identifying value, mapping the value chain streams, and seeking continuous cost and longevity improvements.  


We are members of APEGA and hold a permit to practise

APEGA members

Our capability increases your productivity

Over 70 years we have had the honour of working with some major league projects. 

We take pride in coming up with innovative solutions to solve what sometimes are referred to as unsolvable issues that seriously effect output and create unplanned downtime.

Our team of experts have amassed hundreds of years of knowledge which is all used to aid our clients to find solutions to increase productivity and profit margins. 

P&H Rope Shovel
Gear Rack Assembly