Floating structure welding solution

The development of the energy, oil, and petrochemical industries has led to an increasing demand for large-sized steel structures with high thickness and harsh working conditions. From wind power towers, power plant structures; equipment support frames, pipe racks, skids, and technology modules; to steel structures serving oil and petrochemical projects, each product group sets strict requirements on manufacturing precision, load-bearing capacity, welding joint quality, and stability during operation.

In particular, many components in this field use thick steel plates, large sizes, long welding lengths, and a high proportion of load-bearing welds. Therefore, manufacturing quality depends not only on individual equipment but also on the ability to control the entire process from material preparation, cutting and edge preparation, assembly, welding, surface treatment to production data management.

Weldcom provides an ecosystem of solutions serving the production of steel structures in the energy and oil sectors in that direction, combining processing equipment, high-productivity welding technology, robots, and automation to simultaneously meet quality, output, and project schedule requirements.

Diverse structure production for various energy sub-sectors

Unlike production lines specializing in a highly repetitive group of components, the energy and oil sector includes many different types of structures in terms of size, cross-section, and manufacturing methods: heavy beams and columns, box structures, equipment support frames, pipe racks, skids, structural modules, tubular structures, and auxiliary steel components.

Specifically, in the wind power sector, large-diameter tubular components require specialized welding equipment, adaptability to the workpiece diameter, and stable control of long welds. Bruco has developed specialized welding gantries for handling tubular workpieces with diameters from 4,000 to 14,000 mm.

Therefore, Weldcom's solution is built with flexibility in workpiece size, material thickness, component profile, and welding technology, helping businesses organize the production of multiple product groups on the same technology platform.

Accurate processing of thick steel plates and standardized connections from the start

For energy and oil structures, the quality of the weld depends greatly on the accuracy of the workpiece and the connection preparation process. Dimensional deviations, bevel angles, or assembly gaps from the cutting stage will increase setup time, filler metal volume, welding distortion, and processing workload in subsequent stages.

Weldcom provides steel plate processing solutions from CNC cutting to high-power laser cutting, serving thick and ultra-thick materials. Bevel cutting head configurations support various edge types V, I, X, Y, K, with bevel angles up to 45°, combined with machine vision alignment and automatic deviation compensation.

Precisely controlling the geometry and joint edges from the start helps stabilize the assembly process, control weld gaps, and lay the foundation for subsequent automated welding technologies.

High-productivity welding technology for large structures and thick steel

Welding is one of the stages that determine the productivity of energy and oil structure manufacturing plants. Heavy beams, box structures, and thick components often concentrate a large amount of filler metal, while requirements for penetration, weld shape, and input heat control are increasingly high.

Weldcom deploys automatic SAW solutions, Tandem SAW, Triple Arc, and Tandem ICE suitable for each structural group. Tandem ICE combines a current-carrying welding wire with a cold feed wire to increase speed and deposition productivity while maintaining low line energy.

This technological direction is particularly suitable for components with long welds, large cross-sections, and high thickness, where the challenge is not only to "weld faster" but also to balance deposition productivity, penetration, input heat, and structural distortion.

Production flow control for projects with high schedule requirements

Energy and oil projects often involve large manufacturing volumes, heavy components, multiple stages, and delivery requirements by module or erection stage. As scale increases, overall productivity no longer depends solely on the speed of cutting or welding machines but on the coordination between processing, assembly, workpiece transport, welding, and finishing.

Weldcom develops solutions by integrating equipment with transport, flipping, and workpiece transfer systems, while connecting production data with SCADA/MES on suitable devices. Bruco's welding systems have integrated Ethernet/IP to serve data monitoring and connect production management systems.

This approach helps businesses better control equipment status, progress of each stage, and operational efficiency, while reducing waiting time between steps in the production line.

A technology platform for the energy and oil sector

From wind power structures; power plant structures; industrial frames, beams, and modules; to structures serving oil and petrochemicals, the manufacturing challenge converges on four main requirements: precise processing of large-sized materials and thick steel – controlling welding joint quality – enhancing manufacturing productivity – organizing efficient production flow.

Instead of focusing on a single device, Weldcom approaches the problem through the entire technology chain from material preparation → processing → joint edge creation → assembly → automated/robotic welding → surface treatment → production management.

Through this, steel structure manufacturing enterprises build a technology platform that meets increasingly high technical requirements of projects, while enhancing their ability to participate more deeply in the supply chain of the energy, wind power, oil, and petrochemical industries.