Shipbuilding
NAVAL
Shipyard & Heavy Industry · Flux-Cored · ESAB Aristo 500ix
Where humans cannot enter
robot resources.
Shipbuilding resource automation, It is ideal for structural applications requiring long seams. Shipyards are the world's toughest environment for welding equipment — salty air, high humidity, enclosed tank interiors, overhead positions. With ESAB Aristo 500ix + ROKAE CR12 IP67, 24/7 repetitive plate and rib seam welding under these conditions is of a quality ready for classification society approval.
IP67
Robot Protection Class
Salty air, humidity, water splashes
500A
Heavy Industry Power
Thick plate, full penetration.
7/24
Shift-free production
Meet the delivery schedule.
— The reality of the shipyard —
Welder in shipbuilding
Both the most critical and the most fragile link.
The shipyard environment presents one of the most challenging working conditions for a welder. This situation leads to both quality inconsistencies and serious staffing and productivity problems.
Harsh field conditions affect the equipment.
Salt air, high humidity, water splashes — the shipyard environment dramatically shortens the lifespan of standard welding equipment. Failures occur at the most critical production moments.
Risk of enclosed tank and confined space.
Internal and tank welding exposes the welder to welding fumes, oxygen deficiency, and restricted movement. Workplace safety risks give rise to both human and legal responsibilities.
Thousands of repeating plate stitches
Ship hull plate joints, rib and rib seams — the same process is repeated thousands of times. A tired welder makes mistakes, and the final quality of the batch differs from the initial quality.
Gas shield disintegrates in open field.
Wind disperses standard MIG gas, increasing the risk of porosity. Flux-cored is essential for open field welding, however. Management and consistency are difficult in manual sourcing.
Class organization control pressure
Lloyd's Register, DNV GL, Bureau Veritas, Turkish Lloyd — every seam must be traceable and documentable. A source that fails the audit requires re-approval of the entire department.
I can't find a shipyard welder.
Due to harsh conditions and physical demands, the shortage of shipbuilding welders is increasing every year. Those who are found demand high fees and stop the line when you leave.
From these problems at least 3 of them Does this also apply at your shipyard?
All these problems can be solved with an IP67 robot and a multi-process power unit.
- Solution -
For shipyard conditions
manufactured system.
IP67. Flux-Cored. 500A.
The ESAB Aristo 500ix is an industrial multi-process power unit specifically positioned for shipbuilding and heavy industry applications. MIG, Pulse MIG, Flux-Cored and Gouging With its support, it meets both indoor and outdoor field power needs with a single system. QSet™ It automatically optimizes the arc parameter even with variable torch-workpiece distances — a critical advantage in irregular geometries such as ship surfaces. ROKAE CR12's IP67 certification, This guarantees equipment reliability even in salty air and high humidity conditions. Every stitch is recorded, every parameter is trackable — ready for class organization audit.
The welder gets tired, takes a leave of absence, and leaves.
The robot doesn't work shifts.
The robot doesn't work shifts.
FCAW
Flux-Cored
QSet™
Arc Adaptation
IP67
Robot Protection
ESAB Aristo 500ix + ROKAE CR12 IP67
System Specifications
- Welding MachineESAB Aristo 500ix
- Supported ProcessesMIG · Flux-Cored · Gouging
- Parameter SystemQSet™ Automatic Adaptation
- Maximum Output500A / %60 Duty Cycle
- Continuous Output400A / %100 Duty Cycle
- Robot ModelROKAE CR12 · IP67
- Repeatability Accuracy±0.03 mm
- Power Unit ClassIP23 · Field Conditions
- Put in to use5 Business Days
— Operational Process —
To the shipyard line
Integration in 3 steps.
No lengthy integration project is required. It is added to the existing production line in 5 days and managed at the operator level.
01
Select Process & Material
For the open field Flux-Cored (FCAW), for the closed section MIG/Pulse Select. The Aristo 500ix's more than 250 synergy lines automatically adjust the parameter according to plate thickness and material type. QSet™ optimizes the arc in real time as the torch distance changes.
02
Record Stitch Route
Hold the ROKAE CR12 and run it along the plate joint or rib line. Ghost Teaching technology It records long, straight seams and repeating rib points in 15 minutes. Separate programs are saved for different ship sections, and switching is done in minutes.
03
Produce — Every Stitch is Recorded
The robot welds each plate joint continuously using the same parameters. Each stitch parameter is digitally archived. — Under the supervision of the classroom organization, the source history can be presented immediately. The delivery schedule is not affected by welder absences.
IP67 — Reliable for Shipyard Conditions
The ROKAE CR12's IP67 certification provides complete protection against salt air, high humidity, and water splashes. With the IP23 rated power supply, the system operates flawlessly in field conditions.
Flux-Cored — Works even in windy conditions.
In open field welding, the gas shield is dispersed by the wind. The Aristo 500ix's Flux-Cored support eliminates this problem. A single system, a single program approach for both indoor and outdoor settings.
QSet™ — Stable Arc in Variable Geometry
The torch distance varies depending on the slope and irregular geometries of the ship's surfaces. QSet™ detects this in real time and adapts the arc accordingly. Result: equal penetration at every point.
Audit Ready Record
The parameters of each resource session are stored in a digital archive. Source traceability certificates can be generated instantly during audits by Lloyd's, DNV, and Turkish Lloyd.
— Target Audience —
For whom?
the right choice?
It involves repetitive structural stitching, operates in harsh field conditions, requires class organization approval, and Every shipyard and heavy industry company that wants to reduce its dependence on welders.
01
Shipyards & Shipbuilding Companies
Plate joints, ribs, ribs, section seams — thousands of repetitive welding points. The robot is ideal for this workload. Classroom organization is ready for audits with digital record keeping.
02
Offshore Platforms & Marine Structures
Offshore platforms, pipe bridges, and pier structures. Requiring long seams and high penetration in harsh environmental conditions. The Aristo 500ix+ IP67 robot is a perfect fit.
03
Tank & Pressure Vessel Manufacturers
Storage tanks, pressure vessels, process equipment. Documentation and certification of every seam are mandatory. Full traceability with recorded parameters, zero audit surprises.
04
Heavy Machinery & Construction Equipment Manufacturers
Excavator, crane, and transport machine bodies. In structures carrying high tonnage loads, welding quality is directly related to safety certification and warranty costs.
- To compare -
Is it manual in the shipyard?,
Registered system?
In shipyard conditions, human performance is directly affected by the environment. The robot is unaffected by humidity, salty air, and fatigue — every stitch remains the same.
Manual Source
Aristo 500ix + CR12
Harsh environment resistancePerformance decreases.IP67 · Unaffected
Flux-cored (open field)InconsistentAutomatic control
Indoor securityThere is a risk.No risk.
Class establishment documentManually kept recordDigital archive
Daily capacity7.5 hours24 hours
Quality consistencyHe falls from exhaustion.Constant throughout the series
Rework rate%5–15<%1
Risk of workplace accidentsHigh (indoor)Minimal
— Cost Analysis —
Classified welder
as the deficit grows,
Sled costs are skyrocketing.
The demanding physical conditions of shipbuilding increase the turnover rate of skilled welders, directly threatening project timelines. Classification Society (IACS) rejections due to faulty welds, extra repair labor, and extended dry dock/slipway occupancy costs rapidly erode your profit margin. Eliminate personnel dependency in long-length seams with Astoryas welding automation — achieve flawless penetration to Lloyd's standards the first time, and launch the vessel on time.
Open the ROI Calculator →Annual cost of shipyard welder~ ₺2,200,000
Reprocessing & class establishment error~ ₺350,000
Project delay & audit cost~ ₺200,000
Total annual apparent cost~ ₺2,750,000
System investmentOne-Time Payment
— Turnkey Package —
Specifically for the shipyard line,
Installation in 5 days.
We're not selling a long integration project, we're selling a working system. This includes installation and commissioning tailored to on-site conditions.
✓ System Content
All Inclusive Package
No extra costs, no surprises.
- ROKAE CR12 Cobot — 12kg load, IP67, 1327mm reach
- ESAB Aristo 500ix — MIG, Flux-Cored, Gouging, QSet™
- TBI 82W Robotic Torch — High amperage, long lifespan
- Shipyard synergy lines — Ready-made programs based on plates and profiles.
- Mobile platform — It has wheels and can be transported within the shipyard.
- Turkish HMI interface — Process and material-based selection
- On-site installation — Astorian engineers
- 1 year warranty — The entire system
✓ Service & Support
You Produce, We Support
We don't leave you alone after the sale.
- Remote support — 24/7 technical support line
- Istanbul center — Nationwide field support in Türkiye
- Spare parts stock — TBI consumables & ESAB consumables
- Periodic maintenance — Scheduled service visits
- New department teaching — With remote support
- Parameter archive — All registered sewing programs
- ROKAE official distributor — Turkish official
- ESAB authorized dealer — Guaranteed original product
— The next step —
Welder at your shipyard
Let it no longer be the most vulnerable link.
System in stock, ready for delivery. You start production within 5 days. Synergy programs tailored to shipyard and heavy industry pipelines, including Flux-Cored installation and on-site commissioning. Contact us today for a free technical analysis.
