Specification and material
Before fabrication we establish the medium, pressure and temperature, material grades, joint geometry, dimensions, installation location and required quality.
Technology / Fabrication, installation and overhaul
Metal and plastic welding
We offer comprehensive metal and plastic welding, from joint design and process preparation through fabrication, installation, repairs and inspection. The process, material and documentation scope are tailored to the product and its service conditions.
Operating context
The whole application matters.
We address structural and process piping, welded assemblies, corrosion-resistant components and plastic process equipment. Alongside conventional arc and plastic-welding methods, we develop individual solutions for special materials and processes. A required welding procedure can be added and qualified for the project.
Scope of the solution
- Arc welding of steels
- Stainless, duplex and special metal materials
- Mechanised welding and multi-run joints
- Laser welding
- Thermoplastic pipe welding
- Extrusion and hot-gas welding of plastics
- Electrofusion joints and installation interfaces
- Custom process development and qualification
- Coordination of weld examinations and subsequent equipment testing to project requirements.
- Process and mechanical interfaces between robotic welding, fixtures, positioning and handling
Engineering priorities
From operating need to design.
Procedure and qualification selection
Each joint type is assigned a suitable welding procedure and personnel qualification. Assessment covers material groups, process, thickness, diameter, position, filler and the other conditions of the applicable record.
Preparation and traceability
We prepare joint surfaces, fit-up and component identification; weld maps and material-record traceability are maintained as specified. Plastics work addresses cleanliness, system compatibility and fusion-cycle conditions.
Inspection before equipment closure
Access to joints may change after assembly. The inspection plan therefore links visual and other non-destructive examinations to fabrication or repair stages and final verification.
Robotic welding-station integration
For automated welding, we coordinate joint location, clamping, reach and access for the torch or spot-welding gun. Path design and weld sequence are checked against fixture geometry and part transfers. Sample trials follow the specified welding procedure and inspection plan.
Before engineering
Inputs that matter.
- Drawing or component description, material grade and available certificates.
- Thicknesses, diameters, joint types and required quantities.
- Medium, operating pressure and temperature, environment and installation location.
- Inspection requirements, test conditions and handover documentation.
- Weld map, material combinations, selected process, tooling and joint-quality criteria
Agreed with the proposal
Outputs and acceptance.
- Visual examination – VT: Weld condition and geometry, accessible surface imperfections and compliance with the drawing and specified criteria.
- Penetrant testing – PT: Examination for surface-breaking discontinuities in suitable non-porous materials, with surface preparation and procedure defined for the task.
- Additional product-specific methods: RT, UT or MT and the corresponding examination-personnel qualification can be selected for the material, geometry and required inspection scope.
- Dimensional inspection and assembly testing: Dimensions, nozzle positions and installation interfaces are assessed separately from weld quality. Leak or pressure tests are defined for the product and its specific test conditions.
- Inspected-joint map and reports within the agreed scope.
- Welding-station interface specification and an agreed sample-joint test plan
The actual scope and acceptance criteria depend on the application and contract.
Metal and thermoplastic joining
Fabrication, installation and repairs
The required product defines the scope of supply. The specific procedure, equipment and qualifications are established during project preparation.
Arc welding of steels
Carbon and low-alloy steels for structures, piping and process assemblies. MMA, MAG or TIG is selected for the joint, access and production scope.
- Frames and supports
- Pipe components and connections
- Fabrication and repair of welded assemblies
Stainless, duplex and special metal materials
Joining of austenitic stainless steels, duplex steels, selected nickel alloys and aluminium materials. Preparation covers suitable filler, shielding and thermal conditions.
- Corrosion-resistant piping and components
- Dissimilar-material interfaces to the design
- Workshop and site joints
Mechanised welding and multi-run joints
For repeat production or larger sections, we develop the mechanisation approach, run sequence and joint preparation. Submerged-arc or plasma processes can also be addressed for a specific project.
- Butt and fillet joints
- Distortion control and welding sequence
- Product-specific procedure preparation and qualification
Laser welding
Laser welding is assessed for suitable materials and component geometry. Preparation reviews fit-up accuracy, access and required weld quality, with a trial joint where needed.
- Sheet components and assemblies
- Local joints and assessed repair applications
- Sampling and procedure verification
Thermoplastic pipe welding
PE, PP and PVDF piping systems are specified for the medium, temperature and pressure. The scope includes butt fusion and socket fusion, with other suitable jointing methods selected for the system.
- Fabrication of piping components
- Tank, pump and valve connections
- Modifications to existing systems
Extrusion and hot-gas welding of plastics
Extrusion or hot-gas procedures are developed for sheet fabrications, vessels, troughs, ducts and repairs. Preparation distinguishes PE, PP, PVC and PVDF, filler material, surface condition and weld geometry.
- Sheet components and process assemblies
- Nozzle and local interface joints
- Repairs following material and loading assessment
Electrofusion joints and installation interfaces
Electrofusion fittings are selected for compatibility with the particular piping system. Work covers surface preparation, restraint, execution of the fitting-specific cycle and inspection of the completed joint.
- PE pipes and fittings
- Piping repairs and extensions
- Fusion-cycle records as specified
Custom process development and qualification
For atypical products, we can assess resistance, stud, friction, ultrasonic, beam or specialised plastic joining. The proposal addresses process suitability, required equipment, a test specimen and how the result will be verified.
- Joint feasibility assessment
- Application-specific samples and tests
- Preparation of a new WPS and qualification coordination
Engineering the joint
Process preparation and WPS
We prepare the procedure specification, its technical variables, links to qualification and handover documentation. Required approval and any tests are determined by the product and contract.
01
Materials and geometry
Preparation distinguishes both joint materials, thicknesses, diameters and weld-preparation geometry. Butt, fillet, lap, socket and custom joints can be addressed.
02
Run schedule and parameters
The root, fill and cap sequence, process, filler, shielding gas and required parameters are specified. Plastic joints use the appropriate welding or fusion cycle.
03
Consumables and production planning
Process preparation can include weld length and volume take-offs and estimates of filler, gas and working time for project costing.
04
Qualification, review and issue
Documentation connects the procedure with the applicable qualification record, inspection plan and responsible approval. The draft is completed following technical review or a qualification test.
05
Documentation in the project language
Welding specifications can be prepared in Czech, English or German. A common input set helps keep technical information consistent across language versions.
A new material or joint outside an existing procedure?
We include procedure development, a trial assembly, testing and qualification coordination in the proposal. The required scope is defined for the application before production begins.
Discuss the welding scope ↗Supporting qualification resources
Existing records as a starting point.
A WPQR records procedure qualification, a WPS specifies the production procedure, and an individual certificate defines the welder’s qualification. Preparation brings these records together for the particular joint. These examples describe existing records; the offered scope can be extended through technical preparation and qualification for the new work.
01MAG welding of carbon steels
+
WPQR 533/01/2023
Fabrication of welded assemblies, supports, frames and pipework within the material and joint-design scope.
- Method
- 135 – MAG, partly mechanised
- Material
- Group 1.1; tested material S235JRH
- Joint
- Multi-run butt and fillet welds in plate and pipe
- Thickness
- Parent material thickness 3–12 mm; butt-weld thickness up to 12 mm
- Diameter
- Pipe butt joints: outside diameter from 28.5 mm
- Position
- Record range: all positions except PG and J-L045
The procedure is selected for joint geometry, thickness, required mechanical properties and inspection conditions.
02TIG welding of austenitic stainless steels
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WPQR 05.653.478 / WPS F47
Stainless-steel piping and process components with requirements for root quality and the post-weld surface condition.
- Method
- 141 – TIG
- Material
- Group 8.1; example grade 1.4571 / 316Ti
- Joint
- Pipe butt welds
- Thickness
- Documented thickness range 3.0–10.4 mm
- Diameter
- Outside diameter from 44.2 mm
- Position
- The record states position H-L045
Root shielding, filler material, cleaning requirements and weld examination are specified before fabrication.
03TIG welding of duplex steels
+
WPQR 401/02/2018
Duplex-steel piping and process components, using a procedure selected for the specific material and thermal conditions.
- Method
- 141 – manual TIG
- Material
- Tested material grade 1.4410, group 10.2
- Joint
- Butt joints; the record also contains a separate fillet-joint range
- Thickness
- Butt joints: 1.4–5.5 mm
- Diameter
- Outside diameter from 30.2 mm
- Position
- PA
Butt-joint applicability depends on more than the material grade: filler, heat input, position and joint configuration are also considered.
04TIG welding of nickel alloys
+
WPQR 401/1/2018
Special corrosion-resistant components, with the procedure selected for the alloy, service medium and joint.
- Method
- 141 – manual TIG
- Material
- Alloy 2.4360, group 42
- Joint
- Plate-to-pipe fillet welds
- Thickness
- Joint member 1: 3–10 mm; member 2: 3–20 mm; fillet-weld throat a = 1.9–3.8 mm
- Diameter
- Pipe member from 10 mm outside diameter, subject to the recorded joint geometry
- Position
- Record range: all positions except PG and J-L045
The dimensions apply to the two members of the specified fillet joint; the manufacturing drawing defines the quotation scope.
05PE pipe butt fusion
+
Individual basic-course certificate ZK 11 P 3
Workshop and site joining of PE piping, including end preparation, alignment and a system-specific welding cycle.
- Method
- Butt fusion
- Material
- PE – polyethylene
- Joint
- Pipes and fittings
- Thickness
- Wall thickness and SDR are selected for the piping system
- Diameter
- Supporting qualification record: diameter up to 315 mm
- Position
- According to joint and installation arrangement
Where an advanced qualification is required, the corresponding qualification record and procedure conditions are established in advance.
06PE electrofusion jointing
+
Individual basic-course certificate ZK 16 P 3
PE pipe connections and repairs using electrofusion fittings, including surface preparation, joint restraint and recording of the fusion cycle as specified.
- Method
- Electrofusion welding
- Material
- PE – polyethylene
- Joint
- Pipe-to-electrofusion-fitting joints
- Thickness
- According to the selected piping system and fitting
- Diameter
- The basic-course record has no diameter restriction; the actual size is selected for the system and equipment
- Position
- According to the pipe arrangement
Material compatibility and dimensions are checked against the system manufacturer information; an advanced qualification is documented where required.
07PP socket fusion
+
Individual basic-course certificate ZK 15 P 2
Fabrication and modification of PP piping, connections to valves and process equipment, and agreed tests of the completed assembly.
- Method
- Socket fusion
- Material
- PP – polypropylene
- Joint
- Pipes and fittings
- Thickness
- According to the piping system and operating conditions
- Diameter
- The basic-course record has no diameter restriction; installation scope is defined for the particular system
- Position
- According to the pipe arrangement
Procedure, joint preparation and welding conditions are selected for the material and system; advanced qualification is arranged where required by the application.
08PE extrusion welding
+
Individual thermoplastics welder qualification under EN 13067
Welding of PE plate components and process assemblies, including groove preparation and control of preheating and extrusion.
- Method
- 3.2 – manual extrusion welding
- Material
- Group 3 – PE
- Joint
- Plate components
- Thickness
- Supporting individual qualification: nominal thickness eₙ ≥ 3 mm
- Diameter
- Diameter is not the determining parameter for this scope
- Position
- According to joint type and access
Joint geometry, product design conditions and required procedure verification are established before fabrication.
Relevant experience
From the project portfolio.
Project photograph.
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Automated battery storage project
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Project 667 · Process plant upgrades
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Project 741 · Process plant upgrades
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Broader project portfolioPartial engineering and installation stages
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Connected disciplines
Expertise for this application.
Related technologies
Connect the whole solution.
Your next project
A clear brief.
A practical next step.
Send your drawings, operating parameters or a short description of the change you need. We will review the technical interfaces and propose the next steps towards a quotation, clarifying any missing information with you.
Discuss your requirements ↗Prepare a technical brief →+420 731 771 147info@emkoproject.cz