--- title: "Submerged Arc Welding (SAW)" description: "Fully mechanized submerged arc welding to DIN EN 1090-2 EXC3: ESAB systems to 7 m for deep, high-strength seams on heavy components up to 50 t. Lorch." url: "https://bock-gmbh.com/en/services/submerged-arc-welding/" language: "en" index: "https://bock-gmbh.com/en/llms.txt" --- # Submerged Arc Welding (SAW) to DIN EN 1090-2 EXC3 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 at Bock – Fully Mechanized, High-Strength, Large-Format 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. All Services Overview ## ESAB Welding Systems – Booms to 7 m, up to 1,250 A 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. CNC Machinery ## Submerged Arc Welding on Pipes and Vessels 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. Request Submerged Arc Welding ## Machine data | 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 | ## When is Submerged Arc Welding the Right Process? SAW is not the optimal process for every seam – it delivers its strengths where the following conditions apply: - Long, straight seam runs (longitudinal and circumferential seams) - High requirements for penetration depth and weld strength - Heavy components where the output of manual welding processes is insufficient - Structural steel, high-strength structural steel, fine-grain steel and Hardox - Large weld volumes with high deposition rate 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. Steel Construction & Contract Manufacturing ## Suitable Materials for Submerged Arc Welding Bock uses predominantly European quality steels with traceable origin for SAW welding: - Structural steel S235, S355 – Standard structural steel - Fine-grained structural steel up to S1100 – high-strength, weldable - Hardox 400 / 500 – wear-resistant steel for high-stress components - Special steels to drawing and customer specification Material quality and origin are documented through inspection certificates and material records where required by project or customer specifications. ## 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 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. ### Quality Assurance and Non-Destructive Testing 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. - 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 of our cooperation partner. Volumetric testing (radiographic testing RT, ultrasonic testing UT) is, insofar as commissioned, provided by qualified partners. 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. Certifications and NDT Qualifications ## Certificates for submerged arc welding ### DIN EN 1090-2 EXC3 Certified welding contractor for load-bearing steel structures – qualified up to Execution Class EXC3. ### EN ISO 3834-2 Comprehensive quality requirements for fusion welding of metallic materials. ### DIN EN ISO 9001:2015 Certified quality management system – full process traceability and audit-ready documentation. 1 / 3 ## CNC Machining, Shot Blasting, Painting and Assembly Where Required Components produced by SAW welding 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. 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. ## Typical Applications for Submerged Arc Welding SAW at Bock is applied where high seam quality, deep penetration and fully mechanized process control are required: - Longitudinal and circumferential seams on pipes, hollow sections and vessels - Load-bearing seams on heavy beams and welded structures - Large weld segments with high deposition volume - High-strength seams on Hardox and fine-grain structural steel - Components for crane, plant and special vehicle engineering 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. ## Submerged Arc Welding – Why Bock Bock Maschinenbau operates fully mechanized SAW welding in Lorch as part of a certified welding operation: - Equipment - ESAB welding system with booms up to 7 m reach and up to 1,250 A welding current - Crane Capacity - 2×25 t crane system – 50 t total lifting capacity for safe handling of large-format components - Certification - DIN EN 1090-2 EXC3, EN ISO 3834-2 and DIN EN ISO 9001:2015 - Material Expertise - European quality steels including structural steel, fine-grain steel and Hardox - Quality Assurance - VT, PT and MT in-house Level 2 to DIN EN ISO 9712; UT at our plant via our cooperation partner - Downstream Operations - CNC machining, shot blasting, painting and assembly integrable within the same production facility 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. ## Frequently asked questions about submerged arc welding ### What is submerged arc welding (SAW)? URL: https://bock-gmbh.com/en/services/submerged-arc-welding/#faq-unterpulverschweissen 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. ### What reach and what welding current are available for submerged arc welding? URL: https://bock-gmbh.com/en/services/submerged-arc-welding/#faq-up-anlagen-ausladung-schweissstrom 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. ### How is it decided whether a seam is welded by SAW? URL: https://bock-gmbh.com/en/services/submerged-arc-welding/#faq-verfahrenswahl-up-mag-wig 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. Welded assemblies ### Are longitudinal and circumferential seams on pipes and vessels welded by SAW? URL: https://bock-gmbh.com/en/services/submerged-arc-welding/#faq-rohre-behaelter-laengs-ringnaehte 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. ### Which materials are welded by SAW? URL: https://bock-gmbh.com/en/services/submerged-arc-welding/#faq-werkstoffe-up-schweissen 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. Processed materials ## Welder (m/f/d) Welder (m/f/d) — We are looking for welders (m/f/d) to join our team in 73547 Lorch, near Schwäbisch Gmünd, Baden-Württemberg. At Bock Maschinenbau, you will weld challenging steel assemblies, special machinery parts and large structures — MAG, TIG and submerged arc welding. ## Request Submerged Arc Welding 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. ### Alexander Schulz For new enquiries, quotations and technical questions on the feasibility of your project. ### Jochen Hack