How shipyards are using Terac to correct weld distortion
Shipyards are rapidly shifting toward induction-based deck and bulkhead straightening to improve safety, efficiency, and precision. Terac, developed by ENRX, is increasingly becoming the preferred solution for correcting steel distortion in modern shipbuilding and offshore fabrication.
So far this year, ENRX has sold four Terac systems, three of them in Spain. This strong uptake reflects a broader industry trend: once shipyards adopt induction straightening technology, it quickly becomes embedded in daily production.
Once a shipyard adopts Terac, it becomes a trusted part of their long-term production setup
Adrian Assie
Managing Director at ENRX Spain
In shipbuilding, where downtime is costly and schedules are tight, equipment is not evaluated in theory, but in day‑to‑day reality – under pressure, in production, and across shifting project demands. Tools earn their place not because they look good on paper, but because operators trust them, supervisors rely on them, and projects move faster and safer as a result.
“This is exactly the environment in which Terac continues to prove its value,” says Adrian Assie, Managing Director at ENRX Spain.
Across shipyards, the challenges are familiar: distortion during welding, tight tolerances on decks and bulkheads, restricted access, and an uncompromising focus on safety. Straightening must be fast, repeatable and predictable without disrupting the wider production flow. In this context, induction‑based straightening is increasingly recognised not as an alternative, but as the preferred approach.
The recent sales reflect this shift.
“These are not pilot projects or trial installations,” Adrian explains, “They are full production systems, purchased by experienced shipbuilders and offshore fabricators who know exactly what they need – and why.”
Where Terac meets world class shipbuilding
One of the customers is among Europe’s leading shipbuilders, producing highly complex, mission‑critical naval vessels designed to operate in some of the most demanding maritime environments.
From advanced frigates and submarines to large offshore and support vessels, production is built around precision engineering at scale. Large steel structures, tight tolerances, and demanding schedules make consistency and quality essential at every stage. In this environment, Terac has become an established part of production.
“This is not a new customer. They are long‑term users, with Terac systems operating across multiple sites,” Adrian says. “And this is particularly significant given the nature of their work. Each vessel is engineered for a specific purpose, with unique structural requirements, which means that straightening operations must be both reliable and adaptable.”
Here, Terac’s controlled, induction‑based approach continues to demonstrate its value, delivering consistent results across complex and variable steelwork conditions.
Scaling proven solutions across expanding operations
Another customer operates in the offshore energy sector, delivering large‑scale and highly complex structures where precision, safety and efficiency are essential.
Again, Terac is already well established in their operations.
“At one of their sites, they actually have five Terac systems in daily use for straightening work on large steel structures,” Adrian says. “I think that reflects their long‑term confidence in the technology.”
The latest order extends this approach to a newly established facility – not as a trial, but as a direct replication of an existing, proven production setup. Rather than introducing a new solution, the customer is scaling a method that is already fully integrated and trusted.
This reinforces a wider trend seen across key shipbuilding and offshore customers: once a solution proves reliable in demanding production environments, it is not only retained – it is replicated.
Proximity, trust and proven performance
The most recent Terac order is notable not only commercially, but in context. It comes from a well-established shipyard located close to the ENRX Spain office. The yard specialises in construction and repair, where flexibility and efficiency are critical.
This shipyard already operates a Terac system and therefore has direct production experience with the technology. At the same time, they were evaluating a competing solution for another facility, creating a real-world, side-by-side decision scenario.
“Once again, Terac was selected,” Adrian smiles.
Two factors proved decisive. First, proven performance in daily operation had already built strong confidence among operators and supervisors. Second, the proximity and responsiveness of the ENRX service centre in Portugalete reinforced trust in long‑term support and uptime.
“Their decision represents a continuation of a working relationship built on performance, reliability and proximity,” Adrian says. “It also reflects a broader pattern we see across the segment: once Terac is embedded in production, it becomes the preferred standard for future investment.”
Terac continues to prove its value,” says Adrian Assie, Managing Director at ENRX Spain.
Executive summary
Induction deck and bulkhead straightening is becoming the preferred method for correcting weld distortion in shipbuilding and offshore fabrication. Compared with traditional flame straightening, induction systems provide faster distortion correction, improved safety, and more consistent results across large steel structures.
This case study explores how major European shipbuilders utilize ENRX Terac systems to eliminate welding distortion, reduce production cycles by up to 80%, and scale reliable production setups across multiple international facilities.
Terac is an induction-based straightening system that helps shipyards correct steel distortion faster, safer, and more consistently than traditional flame methods.
Terac induction system in operation on a ship deck, enabling precise, flame-free correction of weld distortion in shipyard production.
Steel distortion in shipbuilding
In shipbuilding and offshore construction, distortion caused by welding remains a critical challenge. Shipyards must correct deformation in:
- Deck structures
- Bulkheads
- Large steel assemblies
At the same time, they face:
- Tight production schedules and strict engineering tolerances
- Limited, high-risk physical accessibility
- Uncompromising workforce safety requirements
Straightening solutions must therefore be fast, repeatable, and production friendly.
Induction straightening
Induction provides controlled, localized heating that improves performance, safety and usability.
Terac is an induction-based system designed specifically for shipyard environments. It is used for deck and bulkhead straightening, weld distortion correction, and thermal straightening of large steel structures in shipbuilding and offshore fabrication.
Terac is highly suitable for high-volume, high-precision production environments. It replaces traditional flame‑based methods with controlled, localized heating using electromagnetic induction. Customers value Terac for its combination of performance, safety, and usability.
|
Performance metric |
Terac Induction System Capability |
|
Efficiency & speed |
Up to 80% time savings compared to traditional flame methods |
|
Quality control |
Precise, repeatable heating for consistent quality across steel structures |
|
Working conditions |
Vastly improved environment—no open flames, fumes, gas, or excessive noise |
|
Operational radius |
High flexibility, with a working radius of up to 45 meters (extendable to 60 meters) |
|
Workforce integration |
Fast training and ease of use, with operators typically trained within hours |
How induction deck and bulkhead straightening works
- Distortion is identified after welding.
- The Terac induction coil is positioned over the affected area.
- Controlled electromagnetic induction generates localised heat.
- The steel contracts predictably during cooling.
- Distortion is corrected without open flames or gas.
Frequently asked questions about induction straightening
Terac addresses distortion in welded steel structures such as decks and bulkheads. It enables controlled correction of deformation using induction heating, reducing reliance on flame-based methods and improving safety, repeatability and process control.
Shipyards are moving towards induction-based straightening because it offers more precise heat control, improved working conditions, and consistent results. Unlike flame methods, induction heating is localised, repeatable and easier to integrate into modern production workflows.
Terac is used in full-scale production environments. The systems described in this case are installed at experienced shipbuilders and offshore fabricators, where they form part of daily operations rather than trial installations.
Operators can typically be trained within hours. The system is designed for ease of use, allowing shipyards to integrate it quickly into existing production without long training cycles.
Once integrated, Terac becomes a proven production standard. Customers replicate installations because the system delivers predictable performance, reduces operational risk, and aligns with established production workflows.
Induction straightening uses electromagnetic induction to generate controlled localised heat, while flame straightening relies on open gas flames. Induction offers more precise temperature control, improved working conditions, reduced operator exposure to fumes and gases, and can reduce straightening time by up to 80% compared with traditional flame-based methods.