Manufacturing – Heavy Fabrication

Characterized by some of the largest machine tools in private industry.

Intercon offers a full range of heavy fabrication services. Welding expertise extends from mild steels to alloys, stainless steels, aluminum and structural materials. Procedures and personnel meet various welding codes, including AWS D1.1, ASME Section IX, and NAVSEA Technical Publications 248/278.

Welding methods include robotic, semi-automatic and fully automatic MIG, TIG, Submerged Arc and Pulsed Arc. Four D.C. sub-arc stations, using 30 ft. aerial manipulators, provide unique cladding and circumferential weld capability. Heavy positioners, turning rolls, and custom fixturing permit in-position welding of fabrications. As required by customers weld mapping and material heat lot tracking can be provided.

Intercon’s main gantry crane can lift loads up to 100 tons. A series of smaller cranes and hoists provide additional lifting capacity for sub-assemblies and smaller parts.

Thermal stress relieving of large fabrications is provided by two furnaces, each instrumented and controlled for exact heating cycles. Temperature measurements can be made using either air temperature readings or calibrated thermocouples. Intercon performs stress relieving as a standalone service as well as part of larger fabrication and machining activities. Fabrications 44 ft. long, 16 ft. wide, and 18 ft. high can be accommodated in Intercon’s car bottom stress relieving furnace.

Cleaning and surface preparation of raw materials and weldments are accomplished with state-of-the-art grit blasting facilities. The interior blast booth, featuring rail entry and media recycling equipment, measures 45 feet by 75 feet. Cleaning media ranges from heavy steel grit to aluminum oxide for delicate cleaning of machined surfaces.

Intercon’s rail entry painting facilities are equipped for a wide range of commercial, marine, and military paint requirements.