rebar cage welding workstation
Operation Mode: Full automatic PLC operation
Welding Method: Gas shield welding technology
Rebar Diameter Range: 6–40 mm adjustable
Cage Diameter Range: 500–2500 mm optional range
Cage Length Range: Maximum 12 m (customizable design)
Power Supply: 380V / 50Hz / 3-phase system (customized available)
Control System: PLC + touchscreen operator panel
Production Efficiency: 1–3 cages per hour (size dependent)
Main Materials: Heavy steel structural frame
Application: Bridge construction, pile foundation, civil engineering
Product Description
Rebar Cage Welding Workstation - Automated Steel Reinforcement Manufacturing Solution
Modern infrastructure demands precision and efficiency in reinforcement fabrication. The rebar cage welding workstation from Shandong Zhongji Luyuan Machinery delivers enterprise-grade automation for high-volume production environments. Our LYZD-GJL2500 model processes cage diameters from φ700mm to φ2500mm with longitudinal bars ranging φ18–φ40mm and spiral reinforcement φ8–φ16mm.
Maximum creation length comes to 12 meters per cycle. Generation capacity accomplishes 13 total cages per 10-hour shift—representing 300% proficiency change over manual get together. The framework works on full programmed PLC control with gas shield welding innovation, requiring as it were one administrator per workstation. Add up to introduced control is 30kW with 100kW devoted welding capacity, backed by 380V three-phase control supply.
Established in 2016 with RMB 50 million enlisted capital, our company serves China Railroad Bunch, CRCC, CSCEC, and sends out to about 100 nations over bridge development, heap establishment, and gracious building sectors.
Technical Specifications
| Parameter | Value | Remarks |
|---|---|---|
| Model | LYZD-GJL2500 | Industrial grade |
| Cage Diameter Range | φ700–φ2500 mm | Adjustable system |
| Maximum Cage Length | 12 m | Customizable design |
| Main Bar Diameter | φ18–φ40 mm | HRB400/500 compatible |
| Spiral Bar Diameter | φ8–φ16 mm | Continuous feed |
| Main Bar Configuration | Single/Double main bar | Custom options available |
| Spiral Bar Type | Single/Double spiral | Pattern flexibility |
| Spiral Pitch Range | ≤300 mm | Precision control |
| Hydraulic Pressure | ≤16 MPa | Stable clamping force |
| Air Supply Pressure | ≤0.8 MPa | Pneumatic components |
| Total Power | 30 kW | Excluding welding |
| Welding Power | 100 kW | Gas shield technology |
| Operating Personnel | 1 person | Minimal training required |
| Production Efficiency | 13 cages / 10 hours | 12m standard length |
| Equipment Footprint | 30 m × 8.5 m | Compact layout |
| Power Supply | 380V / 50Hz / 3-phase | Customizable voltage |
| Control Interface | PLC + Touchscreen | Intuitive HMI design |
Core Manufacturing Advantages
Precision Engineering
Your production quality depends on weld consistency and dimensional accuracy. Our workstation features synchronized dual-drive motors that maintain circumferential alignment within ±5mm tolerance throughout the entire fabrication cycle.
Top-mounted automatic welding heads deliver uniform penetration depth across all joint intersections. This eliminates the cold joints and missed welds common in semi-automated systems.
Operational Efficiency
The rebar cage welding workstation reduces labor requirements by 75% compared to traditional methods. Touchscreen CNC control allows specification changes in under 3 minutes—your team can switch from φ1200mm to φ2000mm cages without mechanical adjustments.
Hydraulic clamping systems self-compensate for minor variations in longitudinal bar lengths. This automatic correction maintains spiral pitch consistency even when raw material tolerances vary.
Structural Durability
Heavy steel frame construction withstands continuous operation in demanding site conditions. Reinforced roller beds support cage weights exceeding 3 tons without deflection, ensuring straightness throughout 12-meter spans.
Modular design simplifies maintenance procedures. Critical components like welding heads and feed mechanisms can be serviced without complete system shutdown, minimizing your downtime exposure.
Safety and Compliance
Enclosed welding zones protect operators from UV radiation and spatter. Integrated fume extraction systems meet international occupational health standards for enclosed workspace environments.
All weld joints conform to AWS D1.4/D1.4M structural welding code for reinforcing steel. This certification ensures your fabricated cages meet structural engineer specifications for load-bearing applications.
Applications Across Infrastructure Sectors
Bridge and Viaduct Construction
High-speed rail projects require cylindrical pile cages with extreme precision. Your foundation elements must maintain verticality tolerances under dynamic loading conditions that manual fabrication cannot guarantee.
Our workstation produces bridge pier reinforcement with consistent spiral spacing that meets strict seismic design requirements. Automated production eliminates human error in complex reinforcement patterns.
Urban Transit Systems
Subway diaphragm wall construction demands rapid cage throughput to match excavation schedules. The rebar cage welding workstation fabricates large-diameter rectangular cages with intricate bar arrangements at speeds conventional methods cannot achieve.
Underground station box construction benefits from our system's ability to handle extra-long sections. Your logistics costs decrease when fewer splices are required on-site.
Marine and Coastal Projects
Offshore platform foundations face corrosive high-salinity environments where joint integrity is critical. Robotic welding delivers penetration consistency that protects against premature failure in submerged conditions.
Extended cage lengths up to 12 meters reduce the number of field connections required in marine pile driving operations. This minimizes your risk exposure in challenging offshore installation scenarios.
Quality Control Protocols
Weld Integrity Verification
Periodic tensile testing validates shear strength across random sample joints. Macro-etching inspection reveals penetration depth and confirms complete fusion at all intersections.
Your QC team can implement ultrasonic testing on primary load-bearing joints to detect internal voids. Non-destructive testing protocols ensure structural performance without compromising production throughput.
Dimensional Accuracy Monitoring
Automated laser measurement systems verify cage circularity in real-time during fabrication. Digital logs from the PLC controller document spiral pitch consistency throughout each production run.
Total length deviation measurements confirm compliance with design specifications. This data traceability supports your ISO 9001 quality management documentation requirements.
Surface Quality Assessment
Inspection protocols evaluate weld spatter control to ensure proper concrete bonding. Excessive surface contamination compromises the mechanical interlock between rebar and surrounding concrete matrix.
Visual inspection standards reference ACI 318 and Eurocode 2 requirements for reinforcement placement tolerance and cleanliness specifications.
Installation and Training Support
Factory Acceptance Testing includes full-cycle trial production of sample cages matching your project specifications. Load-bearing tests on rotation rollers verify mechanical reliability before shipment.
On-site commissioning typically requires 5-7 days including operator training. Your personnel receive hands-on instruction covering PLC operation, welding parameter adjustment, and routine maintenance procedures.
Our technical support team provides remote diagnostics capability through the control system's data logging features. Real-time monitoring of welding current and voltage enables proactive troubleshooting before quality issues develop.
Frequently Asked Questions
Q: What production speed can I expect for standard 12-meter cages?
A: Depending on diameter and spiral pitch, completion time ranges from 15-25 minutes per cage—approximately 3-4 times faster than manual teams working with traditional fixtures.
Q: Does the system accommodate epoxy-coated rebar?
A: Yes, but welding parameters require adjustment for coated materials. Some configurations utilize mechanical tying modules instead of fusion welding for specific coating types to preserve barrier integrity.
Q: What operator skill level is necessary?
A: The HMI interface is designed for site workers without advanced programming knowledge. A 3-5 day training program covering PLC operation and basic maintenance procedures is typically sufficient for competent operation.
Q: How does the workstation handle variations in bar length?
A: Hydraulic clamping systems automatically compensate for minor length discrepancies in longitudinal bars. Pneumatic adjustment maintains proper tension without manual intervention during setup.
Q: What maintenance schedule should I plan?
A: Daily cleaning of welding nozzles and weekly calibration of wire feed tension are standard protocols. Monthly inspection of roller bearings and hydraulic seals prevents unexpected downtime.
Q: Can I customize cage specifications beyond standard parameters?
A: Extended diameter ranges and specialized bar configurations are available through custom engineering. Contact our technical team to discuss your specific project requirements.
Investment Value for Your Operations
The product delivers rapid ROI through labor cost reduction and productivity gains. Single-operator functionality eliminates the 4-6 person teams required for manual cage assembly.
Consistent weld quality reduces rejection rates and rework expenses. Your material utilization improves when dimensional accuracy minimizes field adjustments and scrap generation.
Compact 30m × 8.5m footprint fits existing fabrication facilities without major site modifications. Telescopic design elements allow multi-purpose use when project specifications change between contracts.
Contact Us
Ready to enhance your reinforcement fabrication capabilities? Our engineering team will help you configure the optimal solution for your rebar cage welding workstation requirements.
Email: sales2@shandongluyuan.com
Request detailed technical specifications, pricing information, or schedule a virtual demonstration of our workstation in operation.
