Hyperbaric Welding

UESI’s welding program encompasses welding procedure specification (WPS) development, procedure qualification (PQR) and Welder Qualification (WQTR), in accordance with AWS and/or ASME codes. Our 10 CFR 50 Appendix B QA program supports safety-related welding in the nuclear industry. Divers/Welders are qualified at our facility in UESI’s hyperbaric welding chamber. This allows us to develop and qualify the WPS, and then train the divers on the procedures required at the specific depth at which our team will perform the work.

Understanding Hyperbaric Welding

Hyperbaric welding is a specialized underwater welding process that plays a crucial role in repairing and maintaining offshore structures, including oil rigs, pipelines and ships. Unlike traditional welding performed on land, this method requires highly skilled divers and advanced equipment to manage the extreme underwater conditions, such as high pressure, poor visibility, and rapid cooling.

At UESI, we combine decades of experience with innovative underwater engineering solutions to deliver safe, reliable, and efficient results for our clients across multiple industries.

Wet-dry Welding Techniques

One of the most important aspects of hyperbaric welding is the choice between wet and dry welding techniques. Wet welding is performed directly in underwater, allowing for fast and cost-effective repairs, especially in emergencies. However, water exposure leads to rapid cooling, reduced weld strength, and a higher risk of defects.

On the other hand, dry welding is performed inside a pressurized chamber or habitat filled with a controlled gas mixture, also known as a hyperbaric chamber. This environment enables superior precision, better visibility and higher weld quality. Dry welding is especially practical for thicker materials and long-term structural repairs.

By combining both methods strategically, we ensure our clients receive the most effective solution for each project’s unique challenges. Learn more about our approach in our hyperbaric welding solutions across the U.S.

How Hyperbaric Welding Works

The process relies on adapted welding methods, including SMAW (stick welding), GTAW (TIG welding), and FCAW (flux-cored arc welding). These techniques are modified to handle the effects of pressure and water interference. During dry welding, divers enter a sealed hyperbaric habitat, where they work under carefully monitored atmospheric conditions.

Wet welding, while less controlled, is invaluable when immediate action is required, such as repairing a leaking pipeline or reinforcing damaged subsea structures. Both methods demand highly trained professionals capable of managing technical precision and safety risks simultaneously.

Hyperbaric Welding Solutions

Key Challenges and Hazards in Underwater Welding Services

Working underwater introduces hazards not seen in surface welding. Electrical risks are heightened by water conductivity, requiring specialized insulation and safety protocols. Divers must also contend with pressure-related health issues, including decompression sickness.

Likewise, gas buildup from hydrogen and oxygen during hyperbaric welding increases the potential for explosions, making ventilation critical to avoid accidents.

Additionally, poor visibility and rapid cooling pose significant challenges to weld quality. UESI addresses these challenges through rigorous safety protocols and standards, advanced equipment, and a culture of innovation that ensures every project is completed with precision and reliability. Learn more about our approach to safety in our diving operations.

Applications of Our Underwater Welding Services

Hyperbaric welding has broad applications across industries that rely on offshore and underwater infrastructure.

In the oil and gas sector, it is essential for the construction and maintenance of rigs and subsea pipelines. In shipbuilding, it supports both construction and emergency repairs. It is also vital in underwater infrastructure projects, where pipelines, bridges, and other submerged assets must be kept in serviceable condition. Defense organizations also utilize these methods for submarine repair and decommissioning.

UESI’s underwater welding services are trusted worldwide by commercial marine contractors, nuclear power operators and government agencies. By offering turnkey solutions that integrate engineering, diving and project management, we provide unmatched value and long-term reliability for all marine and underwater projects.

Advanced Welding Technology at UESI

At the heart of our operations is a commitment to advanced welding technology. From state-of-the-art hyperbaric welding chambers to robotic inspection tools, UESI invests in innovations that enhance precision, reduce downtime and improve safety. Our specialized engineering teams continuously refine welding procedures to meet the highest industry standards and regulatory requirements.

By integrating technology with decades of field experience, we provide clients with solutions that not only solve immediate repair needs but also extend the lifespan of their critical underwater infrastructure. Discover how we leverage innovation in our underwater inspection and repair services.

Underwater Welding Solutions

Why Choose UESI for Hyperbaric Welding?

As a global leader in commercial diving and marine construction, UESI combines expertise, safety, and customer service to deliver results that exceed expectations. Our commitment to quality and innovation guarantees that every hyperbaric welding project is handled with unmatched professionalism. Whether you need emergency pipeline repairs, ship maintenance, or large-scale offshore construction, we have the skills and resources needed to complete your project safely and efficiently.