Welded Assemblies up to 50 t to DIN EN 1090-2 EXC3
Load-bearing and technically demanding welded assemblies up to 50 t – manufactured as a certified welding contractor to DIN EN 1090-2 EXC3 in Lorch.
DIN EN 1090-2 EXC3
Certified welding contractor to EXC3, EN ISO 3834-2 and DIN EN ISO 9001:2015.
Assemblies up to 50 t
2×25 t crane system for safe handling of heavy welded assemblies.
MIG/MAG · TIG · SAW
Three welding processes selected by component requirement and required seam quality.
European quality steels
Steel, fine-grain structural steel, Hardox and stainless – exclusively certified materials.
NDT in-house Level 2
VT, PT and MT to DIN EN ISO 9712 in-house, UT available on a project basis.
Downstream operations under one roof
CNC machining, shot blasting, painting and assembly within the same facility.
Welded Assemblies to Drawing and Specification
Welded assemblies at Bock are fabricated steel structures produced to customer drawings or specifications – from straightforward components to heavy, multi-part assemblies with close tolerances, high strength requirements or demanding material properties.
The production facility is equipped for heavy parts up to 50 t. The combination of multiple welding processes and broad material expertise allows structurally complex assemblies to be manufactured reliably to your specifications.
Where required, CNC machining, shot blasting, painting and assembly operations can be integrated into the project workflow.
As a certified welding company in the Ostalbkreis, we take on contract welding and load-bearing welded assemblies to EN 1090 for customers in the Stuttgart region, the Remstal and throughout southern Germany.
MIG/MAG, TIG and Submerged Arc Welding to Specification
Depending on component geometry, material and seam requirements, Bock applies different welding processes:
- MIG/MAG Welding
- is the standard process for structural steel components and complex assemblies. 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 assemblies 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.
- Stud welding
- joins headed and threaded studs up to Ø 22 mm directly to the component in seconds – for fastening points, anchors and brackets without a through-hole.
Process selection is based on the requirements of your component. Where necessary, multiple welding processes may be combined within a single assembly.
Welding technology and equipment
The welding operation at Bock is extensively equipped for heavy and large-format assemblies:
- Around 100 shielding-gas welding stations for MAG/MIG and TIG (Oerlikon, ESAB, Lorch, Ess)
- Three ESAB submerged-arc systems (column and boom masts) — up to 1,250 A, boom and working height up to 7 m
- Stud welding up to Ø 22 mm
- Numerous turning and tilting fixtures as well as roller stands — components up to 60 t can be rotated into position
- Edge milling machine (Alme) for weld seam preparation up to 12 × 45°
This way, welds are made in the optimum position — economically, repeatably and in the inspected quality of a certified specialist welding company.
European Quality Steels up to 50 t Unit Weight
Bock uses predominantly European quality steels with traceable origin for all welded assemblies. Materials are selected according to drawing and requirements:
- Structural steel (S235, S355)
- High-strength structural steel
- Hardox (wear-resistant steel for abrasively loaded assemblies)
- 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 assemblies: 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 assemblies, 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 assembly rather than applied as a blanket measure.
CNC Machining, Shot Blasting, Painting and Assembly Where Required
Welded assemblies 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.
Welded assemblies 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 Heavy and Normatively Demanding Weld Fabrications
Welded assemblies from Bock are produced for technically demanding applications where material quality, certification and weld geometry are critical:
- Structural and highly stressed assemblies with normative documentation requirements
- Wear-loaded fabrications with Hardox content
- Heavy individual components and assemblies above 10 t unit weight
- Assemblies with close dimensional and geometric tolerances
For projects where component weight and structural complexity exceed assembly level, the specialised production of heavy welded structures provides the appropriate framework.
Welded Assemblies – Why Bock
Bock Maschinenbau has been producing welded structures and heavy assemblies at its Lorch site for over six decades:
- Certification
- DIN EN 1090-2 EXC3, EN ISO 3834-2 and DIN EN ISO 9001:2015 – a binding quality framework for demanding clients
- Heavy-Parts Capability
- Production of assemblies up to 50 t unit weight
- Material Expertise
- Predominantly European quality steels – structural steel, Hardox, stainless steel and high-strength structural steel
- Process Range
- MIG/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
- Contract welding for the region
- EXC3 contract welding of load-bearing assemblies for steel and plant builders from the Stuttgart area, the DACH region and across Europe – certified, from our 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 Welded Assemblies
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.