Repair, refurbishment & overhaul - steel assemblies up to 50 t
Weld repair, build-up and hardfacing, machining, blasting and coating - we repair and refurbish heavy steel components and assemblies up to 50 t, including products from other manufacturers. Contract manufacturing in Lorch, Ostalbkreis, Stuttgart area, Southern Germany and DACH.
EXC3 weld repair
Cracks, fractures and damage to large steel and welded structures repaired professionally - MAG/WIG/UP according to EN 1090-2 EXC3.
Build-up & hardfacing
Worn surfaces rebuilt and permanently protected against wear with hardfacing overlays.
Machined to size
Bearing seats, fits, bores and threads re-bored, re-cut, bushed or restored to dimension.
Complete overhaul
Dismantling, blasting, replacing wear parts, coating and assembly - assemblies handed over like new.
Heavy assemblies up to 50 t
2×25-t crane system and large machines for components up to 26,000 mm long and 50 t.
Third-party makes too
We also repair components from other manufacturers - with documented material and inspection control.
Repair, refurbishment and overhaul - all from one source
When a heavy steel assembly is worn, cracked or damaged, it does not necessarily have to be replaced. Bock repairs and refurbishes steel components and assemblies so they regain full function - often faster and more economically than new production.
Because weld repair, machining and surface technology are under one roof, logistics between steps are eliminated: a cracked frame is welded, stress-relieved, machined, blasted and coated as one continuous repair process without external suppliers.
We repair and refurbish not only our own manufactured parts, but explicitly also products from other manufacturers. Based on CAD data, drawings or measurements on the existing component, we provide dimensional reports, non-destructive testing and material documentation project-specifically according to DIN EN ISO 9001:2015.
In-house refurbishment - the three core competences
Three production areas turn a damaged component back into an operational one - each with its own machine and process profile:
Weld & build-up repair
Prepare and weld cracks and fractures, rebuild worn surfaces by build-up and hardfacing - MAG/WIG/UP according to EN 1090-2 EXC3 and DIN EN ISO 3834-2.
EXC3 · MAG/WIG/UP
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Machining repair
Re-bore and bush bearing seats and bores, re-cut or newly produce damaged threads, restore shafts, fits and sealing faces to dimension - on portal milling machines, horizontal boring mills and vertical lathes.
up to 26,000 mm · Ø 4,800 mm
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Overhaul - blasting & coating
Dismantle assemblies, blast in large spaces up to Sa 2,5, renew wear parts and liners, coat and reassemble - handed over like new.
blast booth up to 25,000 mm
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Which repairs and refurbishments we perform
From a single weld seam to a fully refurbished assembly - the scope covers all wear and damage patterns on heavy steel components:
- Weld repair of cracks, fractures and damage on large steel and welded structures
- Build-up welding to restore worn and eroded surfaces
- Hardfacing as wear protection on highly stressed components
- Renewal of wear liners and wear plates
- Machining repair - re-boring and bushing bearing seats, fits and bores, shafts and faces to dimension
- Thread repair - re-cut damaged threads, weld up worn bore areas, re-drill and restore threads up to M60
- Straightening distorted components by flame straightening - manufacturing know-how from 63 years
- Mechanical conversion, reinforcement and modernization of existing steel assemblies
Whether our own manufactured part or a product from another manufacturer - we assess the condition, coordinate the repair scope with you and document the result.
How refurbishment works - step by step
Every repair follows a clear chain - from assessment to documented handover, all steps in our own plant:
- Assessment & measurement
- Record condition, assess damage and wear, measure the component and define the repair scope.
- Blasting & cleaning
- Remove old coating, rust and deposits in large spaces up to Sa 2,5 so weld seams and inspections are reliable.
- Weld & build-up repair
- Prepare and weld cracks, rebuild worn surfaces by build-up and hardfacing.
- Machining rework
- Restore bearing seats, bores, threads and fitting faces to dimension on portal milling machines, boring mills, radial drilling machines and vertical lathes.
- Straightening & stress relief
- Correct distortion by flame straightening and reduce residual stresses by vibration stress relief.
- Coating & assembly
- Prime and coat the component, renew wear parts and liners and complete the assembly again.
- Inspection & documentation
- Non-destructive testing (MT, PT, VT), dimensional inspection and material documentation - documented project-specifically.
Not every repair passes through all steps - we configure the chain to match the damage pattern.
Materials and wear protection
Components from the full range of structural steels are repaired and refurbished - filler materials and overlay layers are selected to match the base material:
- Structural steel S235, S355 - standard construction steel
- Fine-grain structural steel up to S1100 - high-strength, weldable
- Wear-resistant steels such as Hardox 400/500 - for stressed components and liners
- Stainless steel 1.4301, 1.4571 - corrosion-resistant
- Special steels according to drawing and customer specification
We build up overlay and hardfacing layers to match the load; material certificates and inspection documents are provided project-specifically.
Typical components and assemblies
Heavy steel components of all kinds come in for repair and refurbishment - as individual parts or complete assemblies:
- Machine frames, base plates and support structures
- Shafts, axles and pins with worn bearing and fitting seats
- Large bores and bearing housings for re-boring and bushing
- Hoppers, vessels and troughs with renewable wear lining
- Frames and brackets with cracks or fractures
- Welded structures and steel assemblies from plant engineering and special machine building
Because products from other manufacturers are also repaired, the origin of the component is secondary - what matters are material, dimensions and damage pattern.
Repair and refurbishment at Bock - your advantages
Bock repairs components as part of a complete manufacturing operation - not as a pure welding shop:
- All processes under one roof
- Welding, machining, straightening, blasting and coating interlock in the same plant - without logistics between steps.
- Heavy assemblies up to 50 t
- 2×25-t crane system and travel paths up to 26,000 mm for the largest components.
- Welding according to EN 1090-2 EXC3
- Certified welding specialist with MAG/WIG/UP as well as DIN EN ISO 3834-2.
- Build-up & hardfacing
- Rebuild worn surfaces and protect them permanently against wear.
- Third-party makes too
- We repair components from any manufacturer - not only our own production.
- Documented quality
- Non-destructive testing (MT, PT, VT), dimensional reports and material documentation according to DIN EN ISO 9001:2015.
- More economical than buying new
- Professional refurbishment is often available faster and at lower cost than new production.
- Tool inventory built over decades
- 63 years of accumulated special and custom tools - the right in-house tool for almost every geometry.
Frequently asked questions about repair and refurbishment
Do you also repair components not manufactured by Bock?
Yes. We repair and refurbish heavy steel components and assemblies from any manufacturer. Material, dimensions and damage pattern are decisive, not the origin of the component.
Can worn surfaces be rebuilt?
Yes. We rebuild worn and eroded surfaces by build-up welding and then machine them to dimension. Highly stressed components are additionally protected by hardfacing.
Can damaged threads be repaired or newly cut?
Yes. We can re-cut damaged threads or, if the area is too heavily worn, weld it up, re-drill and then cut the thread again, project-specifically up to M60.
Do you also repair cracked or broken welded structures?
Yes. We prepare and weld cracks and fractures according to EN 1090-2 EXC3 (MAG, WIG, UP). If required, the components are then straightened, stress-relieved and non-destructively tested (MT, PT, VT).
Do you renew wear liners?
Yes. We remove worn wear plates and liners and replace them - including adaptation of the mounting and new coating if required.
Do you also carry out repairs on site at the customer?
No. Repair and refurbishment take place at our plant in Lorch, where all processes, machines and inspection equipment are available. The component is delivered to us; handling is done by our 2×25-t crane system.
Is refurbishment worthwhile compared with new production?
In many cases, yes. Professional repair is often available faster and is more economical than new production - especially for large, extensively machined assemblies. We assess the condition and recommend the most suitable solution.
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 component refurbishment
Send us photos, a drawing or measurements and a brief damage description. We assess feasibility and prepare a project-specific offer for repair, refurbishment or overhaul.