--- title: "Welded Assemblies up to 50 t" description: "Welded assemblies up to 50 t to DIN EN 1090-2 EXC3 and EN ISO 3834-2: MAG and submerged arc certified, TIG by qualified welders. Lorch, Germany." url: "https://bock-gmbh.com/en/services/welded-assemblies/" language: "en" index: "https://bock-gmbh.com/en/llms.txt" --- # 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. Certified welding contractor to EXC3, EN ISO 3834-2 and DIN EN ISO 9001:2015. 2×25 t crane system for safe handling of heavy welded assemblies. Three welding processes selected by component requirement and required seam quality. Steel, fine-grain structural steel, Hardox and stainless – exclusively certified materials. 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. ## Welded assemblies for mechanical engineering ### Three processes on one assembly MAG for the structure, TIG for quality-critical seams, SAW for deep weld volume – combinable within a single component. ### NDT by our own staff VT, PT and MT to DIN EN ISO 9712 in-house, Level 2 – testing happens where the welding happens. ### EXC3 with documentation Welding procedure specifications (WPS) and procedure qualification records (WPQR) to DIN EN 1090-2 are in place; project-specific records such as 3.1 inspection certificates, dimensional reports and NDT test reports are documented with the assembly. ## Welded Assemblies to Drawing and Welding Plan 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. All Services Overview ## MAG, TIG and Submerged Arc Welding to Specification 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 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. Submerged Arc Welding DIN 1090 ## Welding technology and equipment The welding operation at Bock is extensively equipped for heavy and large-format assemblies: - Around 100 shielding-gas welding stations, mainly MAG, plus 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 – Standard structural steel - Fine-grained structural steel up to S1100 – high-strength, weldable - Hardox 400 / 500 – wear-resistant steel for high-stress components - Stainless steel 1.4301, 1.4571 – corrosion-resistant - Special steels to drawing and customer 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 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 – ensuring that quality assurance is tailored to the individual assembly rather than applied as a blanket measure. Certifications and NDT Qualifications ## Certificates for welded assemblies ### 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 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. ## Typical welded assemblies Welded assemblies from Bock are produced for technically demanding applications where material quality, certification, joining sequence and weld geometry are critical: - Structural and highly stressed assemblies with normative documentation requirements - Wear-loaded fabrications with Hardox content - Multi-part assemblies with a high number of joints and connection dimensions - Assemblies with close dimensional and geometric tolerances across several connections If, on the other hand, the number of joints is not the focus, but rather the size of the individual component and its handling, the production of heavy welded structures provides the appropriate framework. ## Impressions from our welding shop Real shots from our shop floor in Lorch – from the flame-cut bevel that prepares the joint, through welding on the part and the hand-welded MAG fillet weld beside the machined mating face, to a large welded assembly taking shape. More from our production: Welding · 21 images ## 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 - MAG, TIG and SAW welding to specification - Quality Assurance - VT, PT and MT in-house Level 2 to DIN EN ISO 9712; UT on a project basis via our cooperation partner - Downstream Operations - CNC machining, shot blasting, painting and assembly integrable within the same production facility 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. Steel Construction & Contract Manufacturing ## Industries: who we manufacture for ### Machinery & special machine building Special machinery assemblies, gearbox housings, ring gears and flywheels — manufactured complete to drawing. ### Crane & lifting technology Crane bridges, crane girders, lifting beams and rope drums — load-bearing heavy-duty steel components up to 50 t to DIN EN 1090-2 EXC3. ### Plant, apparatus & vessel construction Vessels, heat exchangers, rotary kilns and pressure vessels to AD 2000 — welded, turned, coated. ### Conveying & recycling technology Screw conveyors, crusher plant components, screening plants and wear plates in wear-resistant steel. 1/4 ## Frequently asked questions about welded assemblies ### Which records are provided for welded assemblies? URL: https://bock-gmbh.com/en/services/welded-assemblies/#faq-nachweise-schweissbaugruppen Which records are supplied is agreed on a project basis, for example material certificates with inspection certificate 3.1 to EN 10204, dimensional reports and non-destructive testing reports. The basis is certification to DIN EN 1090-2 EXC3 and EN ISO 3834-2 with quality management to DIN EN ISO 9001:2015; the current certificates are available as PDF. Certifications ### On what basis is the welding process for a welded assembly determined? URL: https://bock-gmbh.com/en/services/welded-assemblies/#faq-schweissverfahren-schweissbaugruppe-festgelegt Bock determines the process and joining sequence from the component and the weld cross-section; what is specified is the result – seam quality, tolerance and execution class. MAG welding is the standard process for structural steel components, TIG welding is used for stainless steel assemblies and SAW welding for deep weld volume – the processes can be combined within a single component. SAW welding ### Are headed and threaded studs welded onto welded assemblies? URL: https://bock-gmbh.com/en/services/welded-assemblies/#faq-kopfbolzen-gewindebolzen-aufgeschweisst Yes. In stud welding, headed and threaded studs up to Ø 22 mm are joined directly to the component – for fastening points, anchors and brackets without a through-hole. ### Is weld seam preparation for welded assemblies carried out in-house? URL: https://bock-gmbh.com/en/services/welded-assemblies/#faq-schweissnahtvorbereitung-fasen Yes. The bevels for weld seam preparation are produced in production in Lorch, either on the edge milling machine (Alme) up to 12 × 45° or as a flame-cut bevel. Oxy-fuel cutting ### What welding capacity is available for the production of welded assemblies? URL: https://bock-gmbh.com/en/services/welded-assemblies/#faq-schweissplaetze-kapazitaet Around 100 shielding-gas welding stations, mainly MAG, plus TIG (Oerlikon, ESAB, Lorch, ESS), as well as three ESAB submerged-arc systems with column and boom masts. Welded assemblies are produced up to 50 t unit weight. ## 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 Welded Assemblies Send us your drawing, material, quantity and your inspection and documentation requirements. We weld the assembly to EXC3 – on request including machining, blasting, painting and assembly in the same plant. ### Alexander Schulz For new enquiries, quotations and technical questions on the feasibility of your project. ### Jochen Hack