wire cage welding machine
Operation Mode: PLC-controlled fully automatic system
Welding Method: Gas shielded welding process
Rebar Diameter Range: 6–40 mm (customizable range)
Cage Diameter Range: 500–2500 mm optional sizes
Cage Length Range: Up to 12 m depending on requirements
Power Supply: 380V / 50Hz / 3-phase (custom configurations)
Control System: PLC with HMI touchscreen
Production Efficiency: 1–3 cages/hour depending on model
Main Materials: High-strength welded steel frame
Application: Used in pile foundation and bridge construction works
Product Description
Wire Cage Welding Machine – Advanced Automated Rebar Processing Solution
The industrial demand for precision-engineered reinforcement structures has driven the evolution of automated fabrication technology. Shandong Zhongji Luyuan Machinery Co., Ltd., established in 2016 with a registered capital of RMB 50 million, delivers enterprise-grade wire cage welding machine systems designed for high-volume infrastructure applications. Our LYZD-GJL2500 model achieves a production output of 13 cages per 10-hour shift, processing cage diameters from φ700–φ2500 mm and lengths up to 12 meters. With fully automatic PLC control and dual spiral bar configurations, this system reduces labor requirements to just 1 operator while maintaining welding pitch accuracy within ±1mm—critical for bridge foundations, deep pile works, and precast concrete manufacturing where structural integrity cannot be compromised.
Why Choose Our Rebar Cage Welding System
You need equipment that delivers consistent results under demanding project schedules. Traditional manual binding methods introduce variance in weld quality and consume excessive labor hours.
Our automated solution addresses these pain points directly. The gas-shielded welding process ensures uniform penetration across all joints. You eliminate the risk of missed welds or inconsistent spacing that can compromise structural load distribution.
The system handles main bar diameters from φ18–φ40 mm and spiral bars from φ8–φ16 mm. This flexibility means you can serve multiple project specifications without investing in separate machines.
Technical Specifications
| Parameter | Value | Notes |
|---|---|---|
| Model | LYZD-GJL2500 | — |
| Cage Diameter Range | φ700–φ2500 mm | Adjustable welding disc |
| Cage Length Capacity | Up to 12 m | Single-section output |
| Main Bar Diameter | φ18–φ40 mm | High-tensile rebar compatible |
| Spiral Bar Diameter | φ8–φ16 mm | Single/double spiral options |
| Spiral Bar Spacing | ≤300 mm | Precision pitch control |
| Hydraulic Pressure | ≤16 MPa | Stable clamping force |
| Air Supply Pressure | ≤0.8 MPa | Standard compressor compatible |
| Total System Power | 30 kW | Welding power: 100 kW |
| Operating Personnel | 1 person | Minimal training required |
| Production Efficiency | 13 cages / 10 hrs | 12-meter sections |
| Footprint | 30 m × 8.5 m | Compact layout design |
| Power Supply | 380V / 50Hz / 3-phase | Custom configurations available |
| Control System | PLC + HMI touchscreen | Intuitive interface |
Core Performance Advantages
300% Efficiency Gain Over Manual Methods
Your team completes more cages per shift without increasing headcount. The automated feeding and welding cycle runs continuously once parameters are set.
Consistent Weld Quality Across All Units
Every cage meets the same structural specifications. The servo-controlled welding head maintains uniform pressure and current delivery, eliminating the human error factor that causes rejected batches.
Reduced Operational Costs
You cut labor expenses significantly. One operator monitors the entire process through the touchscreen interface while the machine handles material positioning, rotation, and welding sequences.
Quick Specification Changeover
Switching between project requirements takes minutes, not hours. The modular design allows fast mechanical adjustments, and HMI presets store common configurations for instant recall.
Heavy-Duty Construction for Continuous Operation
The reinforced steel frame withstands the stresses of high-volume production environments. You experience fewer breakdowns and lower maintenance intervals compared to lighter-duty alternatives.
Enhanced Workplace Safety
The enclosed welding zone and automated material handling reduce operator exposure to hazards. Your site meets stricter safety compliance standards with minimal manual intervention in the welding process.
Application Scenarios
High-Speed Rail and Bridge Infrastructure
Large-scale projects demand thousands of identical cages with zero tolerance for dimensional deviation. Our system maintains precise pitch spacing across 12-meter lengths, essential for bridge pier foundations that must withstand seismic loads.
Urban Metro and Tunneling Projects
TBM tunnel lining segments require perfect circularity and weld integrity. You achieve the structural consistency needed for high-pressure underground environments where moisture and soil stress test every joint.
Precast Concrete Production Facilities
Maximizing yard throughput depends on cycle time reduction. The wire cage welding machine integrates into your production line, feeding completed cages directly to concrete pouring stations without bottlenecks.
Marine and Port Engineering
Underwater piling applications require extra-long cages with exceptional corrosion-resistant welds. The gas-shielded process creates clean joints that perform reliably in saltwater exposure conditions.
How It Works
You begin by loading main bars and spiral wire onto the feeding system. The PLC reads your input specifications from the touchscreen: cage diameter, length, spiral pitch, and bar quantities.
The machine automatically positions the main bars in the welding disc arrangement. Spiral wire feeds from the motorized spool as the cage rotates. Welding heads move along the frame, applying precise heat and pressure at each intersection point.
The completed cage exits the production zone once the final weld cools. Your operator performs a visual quality check before the next cycle begins. The entire sequence runs with minimal manual touchpoints.
Frequently Asked Questions
Q: How does the machine adjust for different cage diameters?
A: The system uses adjustable welding discs and HMI-programmed presets. You can reposition components mechanically for major changes or select stored diameter settings for rapid automated adjustments via the PLC.
Q: Can the machine weld both ribbed and smooth rebar?
A: Yes. Welding pressure and current are adjustable through the inverter controls. This accommodates various surface profiles while maintaining weld integrity across different rebar grades.
Q: What is the typical maintenance cycle for welding electrodes?
A: You should dress electrodes every shift to maintain optimal contact. Full replacement occurs every 500-1000 cages depending on wire gauge and current settings used during production runs.
Q: How does the machine handle voltage fluctuations on-site?
A: The LYZD-GJL2500 incorporates automatic voltage stabilization and power filters. These protect the PLC and ensure welding consistency even in environments with unstable electrical supply.
Q: Is specialized training required for operators?
A: While the HMI interface is intuitive, operators need training on electrode alignment and safety protocols. We provide basic certification during commissioning to verify competency on these critical procedures.
Q: What quality standards does the equipment meet?
A: Our production adheres to ISO9001 quality management systems. The welding processes align with structural reinforcement standards, ensuring your output meets project specifications and regulatory requirements.
Why Partner with Shandong Zhongji Luyuan
You work with a manufacturer trusted by China Railway Group, China State Construction Engineering Corporation, and China Communications Construction Company. Our equipment supports projects across nearly 100 countries.
We provide complete intelligent rebar processing solutions—not just standalone machines. Our engineering team assists with production planning, workflow optimization, and integration into your existing operations.
Your investment is protected by our nationwide service network. Technical support responds quickly to minimize downtime, and our modular design simplifies field repairs when components require replacement.
Contact Us
Ready to increase your reinforcement cage production capacity? Our engineering team will assess your wire cage welding machine requirements and recommend the optimal configuration for your application.
Reach us at sales2@shandongluyuan.com to discuss specifications, request technical documentation, or schedule an on-site evaluation. Let's build your competitive advantage together.
