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SHIPBUILDER SOLVES STEEL BACK GOUGING CHALLENGE 

A U.S. shipbuilder expanding from aluminum vessel production into steel ship construction needed a reliable abrasive solution for back gouging structural welds. The operation had to meet Navy shipbuilding requirements, stay on schedule, and create a repeatable process the welding team could use on future steel vessel programs.

Back gouging testing on a steel plate.4.5 x 1/8" Tiger Ceramic Combo Wheel  / Item #58315

We helped the shipbuilder evaluate abrasive options through on-site testing and documented performance data. The result was a validated back gouging solution that helped the welding team support contract requirements, standardize the process, and reduce abrasive-related costs.

Annual-Savings

$20,000 Annual Savings

Reduced abrasive-related costs compared to other wheels tested.

Documented-SOP

Documented SOP

Created a repeatable process for future abrasive evaluations.

weld-requirement-support

Weld Requirement Support

Helped align the back gouging process with structural weld preparation requirements.

Validated-Solution

Validated Solution

Tiger Ceramic 1/8-inch combination wheel tested on site.

“Nobody captures and optimizes grinding costs in shipyard welding like Weiler.”
— Welding Engineer

The Challenge: Meeting Steel Shipbuilding Weld Requirements

A U.S. shipbuilder expanding from aluminum vessel production into steel ship construction needed a reliable way to back gouge structural welds.

For certain double-sided welds, the weld root must be opened from the back side to sound metal before the second-side weld is completed. This helps support full weld penetration and compliance with applicable Navy shipbuilding weld requirements, including requirements tied to MIL-STD-1689A.

The shipbuilder’s existing aluminum back gouging process did not translate effectively to steel. To keep production moving, the welding engineer needed a tested abrasive solution, documented performance data, and a repeatable process the team could use for future abrasive evaluations.

Three-part illustration showing how back gouging opens an unfused weld root before completing the finished structural weld.

What Was at Stake

Weiler team and the welding engineer discussing the testing process.

Stay on Schedule: Avoid weld preparation delays that could create production bottlenecks.

Meet Weld Requirements: Support back gouging requirements for structural welds.

Protect Future Work: Reduce execution risk on current government contract work.

Standardize the Process: Create a documented SOP for future steel shipbuilding applications.

 

The Solution: On-Site Testing Through Weiler Consumable Productivity

We brought in a team that included the local District Sales Manager, an Abrasive Specialist, and a Product Category Manager to review the application on site.

Rather than relying on assumptions, we tested multiple abrasive options under real production conditions. Using the Weiler Consumable Productivity (WCP) process, we measured the factors that mattered most to the shipbuilder, including cut rate, wheel life, labor impact, and total cost.

The testing gave the welding engineer objective data to compare options and select the abrasive that delivered the best combination of performance, consistency, and cost.

 

As the welding engineer put it:

“I don’t want to base any of this on my opinion.”

The Result: Tiger Ceramic Validated for Steel Back Gouging

Through the WCP evaluation, we identified the Tiger Ceramic 1/8-inch combination wheel as the best solution for the shipbuilder’s steel back gouging application.

The wheel helped the team solve an urgent production challenge, support structural weld requirements, and establish a repeatable SOP for future steel ship work. The documented evaluation also showed $20,000 in annual savings compared to the other wheels tested.

 



A Global Abrasives Partner Focused on Mutual Success

At Weiler Abrasives, our experience dates back to 1898 when Joseph E. Weiler began manufacturing brushes for the jewelry industry in Pforzheim, Germany. Since then, we’ve grown and evolved into a global manufacturer serving customers in over 80 countries with nearly 1,500 employees around the world.

“While the company has grown and expanded significantly since those humble beginnings, our commitment to developing long-term partnerships with customers, co-workers, and community hasn’t changed. We like to call that our 3C’s.” Chris Weiler, Executive Chairman.

Whether you are looking to improve your surface conditioning processes, optimize your consumable spend, or train your team on the safe and proper use of abrasives and brushes, Weiler has the people and expertise to help you achieve your goals.

Weiler: Your Competitive Edge

For those who want a competitive edge and value productivity-enhancing solutions for cleaning, grinding, cutting, deburring, and finishing, Weiler is a premier abrasives supplier who forges collaborative, problem-solving relationships with our customers. We work with you to solve your challenges, enabling your business to get more done and, ultimately, improve your top and bottom line. It’s not just about what we do; it’s about how we do it, we call it The Weiler Way. That’s the Weiler difference.

Product Innovations

weiler abrasives

Optimum Use Line

Patent pending Optimum Use Line provides a visual reference to help get the most out of the wheel. Using the wheel to its full life reduces change-overs, which helps users be more productive while reducing waste and abrasive spend.

weiler abrasives

Cut Back

PTiger Type 27 grinding wheels are designed with fiberglass cut back from the edge for aggressive grinding right out of the box.

weiler abrasives

Longer Life

Patent pending Optimum Use Line provides a visual reference to help get the most out of the wheel. Using the wheel to its full life reduces change-overs, which helps users be more productive while reducing waste and abrasive spend.

weiler abrasives

Optimum Use Line

Patent pending Optimum Use Line provides a visual reference to help get the most out of the wheel. Using the wheel to its full life reduces change-overs, which helps users be more productive while reducing waste and abrasive spend.

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NEW Tiger 2.0

Our new metal grinding and cut off wheels are designed to be more than just a better product. They were created to help you do your best work.

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NEW Foundry Products

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NEW Flap Discs for Aluminum

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Need help solving a shipbuilding abrasive challenge?

Whether you are working to improve weld preparation, reduce rework, validate abrasive performance, or standardize a process across your operation, we can help.