Heavy Welded Structures up to 50 t – DIN EN 1090-2 EXC3
Large-format, highly stressed welded structures up to 50 t – manufactured as a certified welding contractor to DIN EN 1090-2 EXC3 with heavy-load handling in Lorch.
Crane capacity 50 t
2×25 t crane system in tandem lift – turning and positioning even with an unfavourable centre of gravity.
SAW longitudinal seams, boom up to 7 m
Fully automated ESAB systems for deep, high-strength seams on large-format structures.
Distortion control in-house
Flame straightening and vibratory stress relieving directly after welding – no furnace size limit, no external logistics.
Final machining in one piece
Portal milling up to 26,000 mm and vertical turning up to Ø 4,800 mm – without splitting the structure.
DIN EN 1090-2 EXC3
The highest execution class for load-bearing structures, including weld verification and documentation.
Heavy-load handling throughout the plant
Over 50 crane installations, 37 wall-mounted jib cranes and heavy-duty forklifts up to 16 t.
Welded Structures to Drawing – Focus on Dimensions and Load Capacity
Heavy welded structures at Bock are large-format, load-bearing steel components – from solid single-piece structures to complex welded assemblies with demanding requirements for dimensions, weight and geometric accuracy.
Unlike welded assemblies, the focus is not on the number of individual parts but on structural size, component weight and handling effort. Normative requirements, close tolerances at large dimensions and high-strength materials define the component profile.
Production is carried out to customer drawings or specifications. CNC machining, shot blasting, painting and assembly operations can be integrated into the project workflow as required.
Heavy-Parts Handling up to 50 t – 2×25 t Crane System
The production facility is equipped with a 2×25 t crane system providing a total lifting capacity of 50 t. This allows large-format welded structures to be handled, turned and positioned safely – even with awkward dimensions or unfavourable centres of gravity.
This crane capacity is a structural prerequisite for components that cannot be moved or fabricated in standard workshops. It is not an optional feature but an integral part of the production infrastructure.
What matters is not just the lifting itself, but turning the component during welding: a structure that can be welded in the flat position achieves better weld quality than in constrained positions. The crane equipment therefore directly determines what weld quality is achievable on a heavy component at all.
Cranes & heavy-load handling
Over 50 crane installations in the plant – bridge cranes up to 50 t in tandem lift, 37 wall-mounted jib cranes at the workstations and heavy-duty forklifts up to 16 t move heavy components safely through the entire production.
MAG, TIG and Submerged Arc Welding for Heavy Structures
Depending on component geometry, material and seam requirements, Bock applies different welding processes:
- MAG Welding
- is the standard process for structural steel components and complex structures. Suitable for a wide range of materials, including high-strength structural steels.
- TIG Welding
- is used where particularly high seam quality and close tolerances are required – for example on stainless steel structures or quality-critical weld joints.
- Submerged Arc Welding (SAW)
- is the process for deep, high-strength seams on heavy components. Fully automated ESAB systems with booms up to 7 m reach allow high-strength longitudinal seams on large-format structures.
Process selection is based on the requirements of the component. Where necessary, multiple welding processes may be combined within a single structure.
European Quality Steels – from Structural Steel to Fine-Grain Steel
Bock uses predominantly European quality steels with traceable origin. Materials are selected according to drawing and requirements:
- Structural steel (S235, S355)
- Fine-grain and high-strength structural steel
- Hardox (wear-resistant steel for abrasively loaded structures)
- Stainless steel / corrosion-resistant steel
- Further materials to drawing or specification
Material quality and origin are documented through material certificates where required by project or customer specifications. Components can extend up to 50 t unit weight; specific limits for special materials or unusual dimensions are agreed on a project basis.
Certified Welding Contractor – DIN EN 1090-2 EXC3, EN ISO 3834-2 and NDT
Bock Maschinenbau is a certified welding contractor to DIN EN 1090-2 EXC3 and EN ISO 3834-2. Complemented by a certified quality management system to DIN EN ISO 9001:2015, these standards form a binding quality framework for the fabrication of welded structures: welding process qualifications, inspection requirements and documentation obligations are an integral part of production. Current certificates are available as PDF for clients with verification requirements.
Quality Assurance and Non-Destructive Testing
For welded structures, quality depends not only on the finished weld but also on traceable verification of the required standard. Welding operations are therefore accompanied by appropriate quality assurance measures. Depending on component, material, weld requirements and customer specifications, visual inspection and non-destructive testing (NDT) methods may be applied.
- Visual Testing (VT), Liquid Penetrant Testing (PT) and Magnetic Particle Testing (MT) are available in-house with Level 2 qualification to DIN EN ISO 9712.
- Ultrasonic Testing (UT) is available on a project basis in-house through certified testing personnel.
This covers surface indications, cracks, near-surface irregularities and internal irregularities in suitable components and weld joints.
Inspection and documentation requirements are agreed on a project basis according to drawing, normative requirements and customer specifications – ensuring that quality assurance is tailored to the individual structure rather than applied as a blanket measure.
Heavy steel fabrication
Welded, tested and fully machined — with no stop in between.
CNC Machining, Shot Blasting, Painting and Assembly Where Required
Heavy welded structures frequently require further production steps. The following operations can be integrated into the project workflow as required:
- CNC Heavy Machining
- CNC heavy-part machining up to 50 t, portal milling up to 26,000 mm, vertical turning up to Ø 4,800 mm.
- Surface Preparation
- Shot blasting to Sa 2.5 in a large-format blast chamber.
- Corrosion Protection and Painting
- Industrial painting to EN ISO 12944 in a 25 × 7 × 6 m large-format spray booth.
- Assembly
- Project-specific pre-assembly or partial assembly of components.
Heavy welded structures can therefore be not only welded but also machined, surface-prepared, coated or pre-assembled within the same production facility – subject to agreement and project requirements.
Suitable for Large-Format and Normatively Demanding Structures
Heavy welded structures from Bock are produced for technically demanding applications where dimensions, weight and certification are critical:
- Load-bearing and highly stressed structures with normative documentation requirements
- Large-format individual components and structures above 10 t unit weight
- Structures with close dimensional and geometric tolerances at large dimensions
- Wear-loaded structures with Hardox content
- Structures for demanding projects in crane, plant and special vehicle engineering
For projects where complexity and structural requirements exceed the scope of welded assemblies, the specialised production of heavy welded structures provides the appropriate framework.
Heavy Welded Structures – Why Bock
Bock Maschinenbau has been producing heavy welded structures at its Lorch site for over six decades:
- Crane Capacity
- 2×25 t crane system – 50 t total lifting capacity for safe handling of large-format structures
- Certification
- DIN EN 1090-2 EXC3, EN ISO 3834-2 and DIN EN ISO 9001:2015 – a binding quality framework for demanding clients
- Material Expertise
- Predominantly European quality steels – structural steel, Hardox, stainless steel and fine-grain structural steel
- Process Range
- MAG, TIG and SAW welding to specification
- Quality Assurance
- VT, PT and MT in-house Level 2 to DIN EN ISO 9712; UT available on a project basis
- Downstream Operations
- CNC machining, shot blasting, painting and assembly integrable within the same production facility
- Heavy-duty for the region
- Crane, plant and special-machine builders from the Stuttgart area and the DACH region source load-bearing heavy-duty welded structures up to 50 t from our EXC3 facility in Lorch.
Contact
Your project — right from the region
Send us your enquiry for contract manufacturing, structural steel or custom machinery — we'll get back to you promptly.
Request Heavy Welded Structures
For an initial assessment, please provide your drawing or technical specification, material, required quantity and any quality, inspection and documentation requirements. We will review production feasibility and prepare a project-specific quotation.