The steel cage roller welding machine is a core fully automatic steel bar processing equipment precisely controlled by a PLC numerical control system. It is specially designed for infrastructure scenarios such as bridge pile foundations, expressways, high-speed railways, and building construction. It can realize the full-process automatic operation of steel cage from main reinforcement positioning, stirrup winding to welding forming. This equipment completely replaces the inefficient traditional processes of manual binding and segmented welding. Through the collaborative cooperation of the intelligent control system and mechanical structure, it greatly improves the processing efficiency and quality stability of steel cages, and is an indispensable key equipment in the process of modern construction industrialization. At present, the mainstream models of steel cage roller welding machines include GL1500, GL2000, GL2500 and other series, which can adapt to the processing needs of steel cages with different pile diameters and lengths. The processing range covers various steel cage products with a pile diameter of Φ300-Φ2500mm and a length of 9-27m.
![steel cage roller welding machine]( "steel cage roller welding machine")
Core Advantages of Steel Cage Roller Welding Machine
1. High Efficiency & Labor Saving, Doubled Production Capacity
Traditional steel cage processing requires 5-8 skilled workers to operate collaboratively, and only 2-3 standard steel cages can be completed per day on average. However, the fully automatic steel cage roller welding machine only needs 1-2 operators to realize continuous production, with a daily output of 15-25 12-meter-long steel cages. The processing efficiency is 4-6 times higher than that of the traditional mode. The equipment adopts a one-time forming process, which eliminates intermediate links such as manual handling and segmented welding, and saves 3/4 of the labor cost at the same time. Calculated based on the average monthly salary of 8,000 yuan for workers in the construction industry, a single equipment can save more than 400,000 yuan in labor costs per year, and the equipment investment recovery period is as short as 6-8 months.
2. Precise & Stable, Qualified Quality
The steel cage roller welding machine realizes millimeter-level precision control through the numerical control system. The main reinforcement positioning error is ≤±2mm, the stirrup spacing adjustment range is 50-500mm, and the error is controlled within ±5mm, which is much higher than the precision standard of manual processing. The automatic welding mechanism equipped with the equipment can ensure uniform and full welds, and the welding qualification rate is over 99.8%, which effectively avoids quality problems such as missing welding, insufficient welding and undercut common in manual welding, and fully meets the supervision and acceptance requirements of high-standard infrastructure projects such as expressways and high-speed railways. In addition, the steel cages processed by the equipment have extremely strong dimensional consistency, which can be directly adapted to subsequent processes such as concrete pouring, reducing rework losses.
3. Intelligent & Convenient, Simple Operation
The steel cage roller welding machine is equipped with a 7-inch high-definition touch operation screen, with a variety of standardized steel cage processing parameter templates built-in. Operators only need to input key parameters such as pile diameter, steel cage length, main reinforcement diameter and stirrup spacing, and the system can automatically generate processing programs. No professional programming skills are required, and new employees can work independently after 1-2 days of training. The equipment supports the parameter memory function. For the steel cage models that need repeated processing, historical parameters can be directly retrieved, reducing the time for repeated settings. Some high-end models are also equipped with remote monitoring functions, which can view the equipment operation status in real time, facilitating centralized workshop management.
4. Durable & Strong Adaptability
The body of the steel cage roller welding machine is made of integral welded steel structure, and the key load-bearing components are quenched and tempered. The equipment weight can reach 12.5-28.5 tons, with small vibration amplitude during operation, which can adapt to 24-hour high-intensity continuous operation, and the service life of the equipment is as long as 8-10 years. In terms of adaptability, the equipment can process various steel materials with main reinforcement diameter of Φ12-Φ40mm and coil reinforcement diameter of Φ5-Φ14mm, covering common types such as smooth round steel and deformed steel bars. At the same time, it supports the processing of steel cages with different pile diameters (Φ300-Φ2500mm) and lengths (9-27m), which can flexibly meet the needs of different scenarios such as bridges, building construction and municipal engineering.
Working Principle of Steel Cage Roller Welding Machine
Parameter Setting: The operator inputs processing parameters such as steel cage pile diameter, length, number of main reinforcements and stirrup spacing through the touch screen, and the system automatically parses and generates processing programs;
Main Reinforcement Feeding: Put the main reinforcements into the main reinforcement positioning mechanism of the steel cage roller welding machine one by one, and the equipment automatically completes the calibration and fixing of the main reinforcement spacing;
Stirrup Winding: The coil reinforcement is uniformly transported to the processing area through the wire feeding mechanism, and at the same time, the active roller of the equipment drives the main reinforcement to rotate to realize the spiral winding of the stirrup;
Automatic Welding: When the stirrup and the main reinforcement are in cross contact, the automatic welding mechanism starts synchronously and completes the welding operation according to the preset program, and the weld quality is monitored in real time during the welding process;
Finished Product Output: After the steel cage processing is completed, the equipment automatically releases the positioning mechanism, and the finished product is transported to the designated area through the discharge roller table. No manual intervention is required in the intermediate links of the whole process.
Core Technical Parameters of Steel Cage Roller Welding Machine
| Model | Processing Pile Diameter (mm) | Processing Length (m) | Main Reinforcement Diameter (mm) | Coil Reinforcement Diameter (mm) | Stirrup Spacing (mm) | Rated Total Power (kw) | Equipment Weight (kg) | Overall Dimension (m) |
|---|
| GL-1500 | 300-1500 | 9/12/18/24/27 | 12-40 | 5-14 | 50-500 | 15 | 12500/16000/18000/20000 | 28.5x5x2.5 / 38.5x5.5x2.5, etc. |
| GL-2000 | 400-2000 | 9/12/18/24/27 | 12-40 | 5-14 | 50-500 | 23 | 18000/21000/24000/28500 | 28.5x8x3.3 / 38.5x8x3.3, etc. |
| GL-2500 | 800-2500 | 9/12/18/24/27 | 12-40 | 5-14 | 50-500 | 27 | 18000/21000/24000/28500 | 28.5x8.5x3.5 / 38.5x8.5x3.5, etc. |
Application Scenarios of Steel Cage Roller Welding Machine
Bridge Infrastructure: Processing of pile foundation steel cages for expressways and railway bridges, adapting to the bridge foundation construction needs of different pile diameters, and ensuring precise matching between steel cages and pile foundation sizes;
Building Construction: Processing of foundation steel cages for construction projects such as commercial housing, indemnificatory housing and office buildings, which can produce standardized steel cages in batches and improve construction progress;
Municipal Engineering: Processing of steel structures for municipal projects such as urban utility tunnels, sewage treatment plants and subway stations, which can flexibly adjust parameters to adapt to the processing needs of special-shaped steel cages;
Prefabricated Component Factory: Processing of steel cages for prefabricated piles, pipe piles and other components in professional production, realizing large-scale and standardized production and improving the quality consistency of components.
After-Sales Service Guarantee
Installation and Commissioning: Provide free on-site installation and commissioning services. Professional technicians complete on-site equipment positioning, parameter calibration and trial production guidance to ensure the equipment is put into normal use within 3 days;
Personnel Training: Conduct one-on-one practical training covering core skills such as steel cage roller welding machine parameter setting, daily maintenance and fault diagnosis, and issue operation qualification certificates after training;
Quality Assurance Service: 1-year warranty for the whole machine, 2-year warranty for core components (PLC control system, welding mechanism, roller assembly), and free replacement of parts and maintenance within the warranty period;
Value-Added Services: Free supporting equipment such as CO₂ shielded welding machine, steel bar bending machine and processing templates will be given when purchasing the steel cage roller welding machine, reducing additional investment for customers;
Emergency Response: Establish a 24-hour service hotline. On-site service will be provided within 48 hours (within 72 hours in remote areas) after receiving a fault notification to ensure that the customer's production is not affected.
