Deep, high-strength longitudinal and circumferential seams on heavy parts up to 50 t – fully mechanized submerged arc welding to DIN EN 1090-2 EXC3 in Lorch.
ESAB systems with high deposition rate for large seam volumes.
High-strength longitudinal and circumferential seams even on large-format structures.
2×25 t crane system for safe handling of heavy components.
Certified welding contractor to EXC3, EN ISO 3834-2 and DIN EN ISO 9001:2015.
VT, PT and MT to DIN EN ISO 9712 in-house, UT on a project basis via our cooperation partner.
CNC machining, shot blasting, painting and assembly within the same facility.
Submerged arc welding (SAW) is a fully mechanized arc welding process in which the arc burns beneath a layer of granulated flux. The process enables deep penetration, low spatter losses and a consistent weld surface – combined with high deposition rates and stable process control.
At Bock, SAW is used for long, straight seams on heavy components and large-format structures – where MAG or TIG welding reach their capacity or process limits. Typical applications include load-bearing longitudinal seams on tubular sections, beams, vessels and welded structures with high strength requirements.
Production is embedded within the certified quality framework to DIN EN 1090-2 EXC3 and EN ISO 3834-2. Welding process qualifications, inspection requirements and documentation obligations are an integral part of the production processes.
The SAW installation at Bock is based on ESAB components with welding columns and booms providing a reach of up to 7 m. Welding current extends to 1,250 A – the prerequisite for deep penetration and high-strength seams on solid components.
Heavy components up to 50 t can be safely positioned and handled during welding via the 2×25 t crane system in the production facility. Large-format pipes, beams and welded structures with long seam segments can therefore be welded in a fully mechanized process.
Pipe and vessel components are set up on welding rotators for submerged arc welding. Long longitudinal and circumferential seams on large-format parts can therefore be produced fully mechanised, with the seam position kept under control throughout the process.
The process is particularly suited to recurring load-bearing seam runs on pipes, cylinders and vessels — wherever deep penetration, consistent weld quality and a high deposition rate are called for.
| Machine | Reach | Working height | Welding current | Wire diameter |
|---|---|---|---|---|
| ESAB ROMAR RM7070 SAR 400 · Submerged-arc welding column & boom | 7 m | 7 m | 1,250 A | up to 4 mm |
| ESAB CAB 300M · Submerged-arc welding column & boom | 4 m | 5 m | 800 A | up to 4 mm |
| ESAB MKP · Submerged-arc welding column & boom | 5 m | 5 m | 800 A | up to 4 mm |
SAW is not the optimal process for every seam – it delivers its strengths where the following conditions apply:
For short seams, complex geometries or fillet welds, SAW is complemented by MAG or TIG welding. Process selection is based on component requirements – within a single structure, multiple processes can be combined.
Bock uses predominantly European quality steels with traceable origin for SAW welding:
Material quality and origin are documented through inspection certificates and material records where required by project or customer specifications.
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 all welding operations: 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.
Weld seams are 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.
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.
Certified welding contractor for load-bearing steel structures – qualified up to Execution Class EXC3.
DVS ZERT · Zertifizierungsstelle des DVS download as PDFComprehensive quality requirements for fusion welding of metallic materials.
DVS ZERT · Zertifizierungsstelle des DVS download as PDFCertified quality management system – full process traceability and audit-ready documentation.
TÜO · Technische Überwachungsorganisation für Sicherheit, Qualität und Umweltschutz GmbH download as PDF1 / 3
Components produced by SAW welding frequently require further production steps. The following operations can be integrated into the project workflow as required:
Components 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.
SAW at Bock is applied where high seam quality, deep penetration and fully mechanized process control are required:
SAW complements the process range for welded assemblies and heavy welded structures – not as a replacement for MAG or TIG, but as a specialised process for defined seam types and component classes.
Bock Maschinenbau operates fully mechanized SAW welding in Lorch as part of a certified welding operation:
Long, load-bearing SAW seams for vessel and apparatus builders from the Stuttgart area and the entire DACH region – at our certified welding company in Lorch.
Submerged arc welding (SAW) is a fully mechanized arc welding process in which the arc burns beneath a layer of granulated flux. The process enables deep penetration and a high deposition rate with low spatter losses and a uniform weld surface. Bock uses SAW for long, straight seams on heavy components and large-format structures.
Up to 7 m reach and up to 1,250 A on the largest of the three ESAB SAW masts, the ESAB ROMAR RM7070 SAR 400 with 7 m working height. The other two masts, the ESAB CAB 300M (4 m reach, 5 m working height) and the ESAB MKP (5 m reach, 5 m working height), operate at 800 A; all three process wire up to 4 mm in diameter. Heavy parts up to 50 t are positioned via the 2×25 t crane system.
Process selection is based on component requirements: SAW is used for long, straight longitudinal and circumferential seams, high requirements for penetration depth and weld strength, large weld volumes and heavy components where manual welding is insufficient in capacity. Short seams, complex geometries and connection seams are complemented by MAG or TIG welding; within a single structure, several processes are combined.
Yes. For submerged arc welding, pipe and vessel components are positioned on welding rotators, so that long longitudinal and circumferential seams on large-format components are produced fully mechanized and the seam position is kept under control throughout the process. Typical components are pipes, hollow sections, cylinders and vessels with recurring, load-bearing seam runs.
In submerged arc welding, Bock processes structural steel S235 and S355, fine-grain structural steel up to S1100, Hardox 400 / 500 and special steels to drawing and customer specification. Where required by project or customer specifications, material quality and material origin are documented through records and inspection certificates.
Send us your drawing, material, seam lengths and seam geometry. We decide which seams are submerged-arc welded – on request we supply the complete structure including machining and painting.
