Flexible automation for the manufacture of reinforcement elements

Flexible automation for the manufacture of reinforcement elements Industrial robots have been established for years as a proven solution for the automation of welding processes. They offer high speed and precision, resulting in improved welding quality. Another advantage of industrial robots is their ability to handle heavy and unwieldy parts. However, these robots require high investment costs and extensive programming skills. They are therefore often too complex for the production of small batch sizes, for use in small and medium-sized companies or for special applications such as the welding of reinforcements. In comparison, welding cobots are much easier to programme. Their low investment costs enable rapid amortisation, which makes them particularly attractive for smaller manufacturing companies. However, one disadvantage of standard welding cobots compared to industrial robots is often their limited radius of action and working area. With the new mbk welding cobot, however, this disadvantage is a thing of the past. DSM-L (Line)The DSM-L (Line) model was specially developed for the manufacture of long reinforcement elements and is suitable for a wide target group – from small steel companies to precast concrete plants. “The DSM-L can process components up to eight metres in length, which was previously only possible with industrial robots. We thus offer a unique solution on the market,” says Mario Pfender, Managing Director of mbk. The cobot travels on an eight metre long linear axis and thus covers the entire working area. In addition to the robot, the welding power source, the wire supply, the welding fume extraction system and the torch cleaning station also move. The integrated 3D welding table has an impressive size of 8400 x 1395 mm. Very high safety at full performanceSafety is the top priority at mbk. Protective welding walls around the welding cell protect the operator from electric arcs and eye damage. Laser scanners monitor the working area and ensure that the cobot stops immediately if an operator gets too close to the working area. These safety precautions make it possible to achieve the maximum movement speeds of an industrial robot without jeopardising safety. Simple operation and flexible programmingThe mbk Cobot impresses with its user-friendly interface. The software was specially developed and optimised for the cobot and the welding process. The multifunctional handle serves as an interface between the robot and the operator. Teaching involves manually moving the welding torch to the desired welding spots. Start, end and intermediate points are saved at the touch of a button. Whether you are an experienced programmer or a beginner – professional welding programmes can be created in just a few minutes. The entire process can be simulated before the actual welding so that the operator can make adjustments if necessary. Efficient work in alternating operationAnother highlight of the mbk Cobot DSM-L is its special design, which enables efficient work in alternating operation. The workspace can be divided into two areas by a partition wall. This arrangement creates space for two working areas, so that the operator can set up or clamp workpieces on one area while the cobot is already welding on the other. This significantly increases productivity. Welding is a demanding, physically strenuous activity that requires a high level of concentration. The cobot relieves employees of tiring routine tasks and reduces physical strain at the same time. An optional single-axis manipulator with counter bearing enables the precise positioning of workpieces weighing up to 2,000 kg in the optimum welding position, eliminating the need for laborious reclamping. The manipulator and robot axes work simultaneously, resulting in greater efficiency and speed during welding. The result is precise spot welds of consistently high quality. Other models and versionsIn addition to the DSM-L, there are also the DSM-H (House) and DSM-T (Table) models, which are each tailored to smaller component dimensions and their specific requirements and applications. mbk – Partner for innovative manufacturing solutionsWith the new mbk Cobot DSM-L and other advanced technologies, mbk is setting new standards in automated production. The company stands for quality, innovation and customised solutions that sustainably increase productivity and efficiency in the manufacturing industry. mbk is not only aimed at small and medium-sized companies, but also offers user-friendly automation solutions to large companies.

Difer Impianti becomes part of the mbk group

Difer Impianti becomes part of the mbk group The mbk group is growing and integrating the Italian pile cage welding machine manufacturer Difer Impianti. Founded in 2007 by Leo Ferrari, the company specializes in the development and manufacture of its own piling machines. The machines on offer cover the entire range of sizes up to 3 m in diameter, including an extensive portfolio of accessories. mbk Maschinenbau develops and sells customized solutions for the concrete, construction and precast industries. The third-generation family-owned company has been active in the field of reinforcement welding machines for over sixty years and is one of the world’s leading companies in the industry. Machines for processing reinforcing steel as well as customer-specific special machines round off the product range. Difer Impianti and mbk are united by a very similar corporate philosophy of offering customers a high-quality, reliable and durable product. Combined with strong customer orientation and focus on after-sales service. “After decades of dedication to the design and marketing of piling machines that have improved the production of foundation piles around the world, the time has come for me to retire. It is with great pleasure that I have sold my company Difer Impianti to Mario Pfender of mbk, safe in the knowledge that he will be able to continue it with great success,” says Leo Ferrari. Mario Pfender, Managing Partner at mbk comments: “I am looking forward to the new challenge and the opportunities we have together. The Difer gas shielded arc welding machines complement mbk’s resistance welding machines perfectly. Together we are able to cover almost all requirements in the field of cage welding machines for bored pile cages. With the gas-shielded arc welding machines, the resistance welding machines and the patented Dual Weld Option (which combines both technologies in one machine), we offer a range that no other supplier can match.” Both companies benefit from their respective experience in this segment and want to utilize synergies in the future, not only in the areas of sales and service. Stefano Gabrielli, Technical Director at Difer Impianti, adds: “After 20 years of experience in the reinforced steel machinery sector, particularly with the pile cage machines, I’m thrilled to embark in this new chapter with MBK and our new CEO, Mario Pfender. This is a huge opportunity for both Difer Impianti and myself, and I can’t wait to see how we can further strengthen our company for the future. The journey continues, and I’m excited for what lies ahead!”

Buildex Syria 2025

25. – 26.04.2023
Grand Arena, Accra, Ghana

Booth 37

Big5 Egypt 2025

17.06. – 19.06.2025 Egypt International Exhibition Center (EIEC)Cairo, Egypt Booth Hall 3 / 3D18

Big5 Global 2025

24.11. – 28.11.2025 Dubai World Trade CentreDubai, VAE Booth tba.

Customised solutions for the modernisation and optimization of production facilities

Customised solutions for the modernisation and optimization of production facilities Customised solutions for the modernisation and optimization of production facilities The renowned company mbk Maschinenbau in Kisslegg is increasingly establishing itself as a preferred partner for customer-specific solutions in the modernisation and optimisation of production systems. Through dedicated collaboration with customers and continuous expansion of the product portfolio, mbk is able to precisely identify and realise individual requirements. The modernisation and optimisation of existing production facilities is one of the focal points of the corporate strategy. Supported by the company’s practice-focused development and design departments, this area is increasingly taking centre stage. Customers benefit from the many years of experience and the customer- and solution-orientated approach that is one of the company’s guiding principles. A very good example of mbk’s innovative strength is the newly developed product family of the mbk DRA wire straightening and cutting machine. The DRA family offers solutions for different requirements in various versions: DRA C features Rotor straightener with one rotor, fixed measuring stop and upright cutters. A cost-effective solution, particularly suited to jobs where the investment cost is paramount, without sacrificing quality. Image 1: Wire straightening and cutting machine DRA-C DRA E features Rotor straightener with a rotor, length measurement by a measuring wheel and optional stationary or flying cutter. This variant is particularly suitable for tasks where a high-quality solution with simultaneous flexibility is required. Image 2: Wire straightening and cutting machine DRA-E DRA M features Rotor straightener with up to six rotors, either stationary or flying cutters. This option offers very high performance and quality with great flexibility. This is an extremely worthwhile option, especially for customers who want to overcome capacity and quality bottlenecks in existing circulation systems. Image 3: Wire straightening and cutting machine DRA-20-M for wires up to 20 mm Another special feature of the DRA M series is the possibility of equipping it with a double bender, which considerably expands the range of applications and flexibility. This facilitates use in new investments and retrofits in precast plants and reinforcement bending companies. Other automation solutions include possibilities for placing the wires on a circulation pallet or picking units. Image 4: DRA-M wire straightening and cutting machine with integrated double bender mbk supports customers in all project phases – from the initial idea through project planning and technical implementation to commissioning and after-sales, directly on site in the customer’s existing infrastructure. The contemporary implementation, modernisation and optimisation of advanced transport, logistics and automation solutions, safety concepts and software connections are also part of mbk Maschinenbau’s holistic concept of customer-oriented solutions.

Mesh welding machine for precast slabs, double and solid walls

Mesh welding machine for precast slabs, double and solid walls The mesh welding machine developed by mbk Maschinenbau GmbH is a cutting-edge solution for producing precast slabs with in-situ topping, double and solid walls. This machine incorporates technical innovations such as a mesh conveyor system that allows for different depositing positions and stack formation according to the pallet layout. It offers flexibility in providing meshes based on customer requirements and ensures just-in-time placement on the pallet. mbk, headquartered in Kisslegg, Germany, specializes in efficient and reliable solutions for the construction, concrete, and precast industry. Their highly skilled team integrates customer needs and requirements into modern production environments, responding to market changes with innovative approaches and designs. Efficient and intelligent reinforcement production is crucial for highly automated precast production of walls, double walls, and precast slabs with in-situ topping. The meshes produced by mbk find applications in building construction, residential and industrial construction, particularly in precast concrete elements with recesses for window and door openings, walls, and ceiling recesses. The flexible mesh welding machine, MSM-M, directly welds reinforcing steel meshes according to individual CAD drawing specifications. It can produce mesh widths ranging from Image 1: MSM-M welding portal with 6 or 9 welding heads possible Image 2: DRA-16-M: longitudinal and transverse wire transfer to the welding portal 500 mm to a maximum of 3,500 mm and mesh lengths ranging from 1,000 mm to 8,000 mm. Smaller and larger sizes are also available. For automatic loading of longitudinal and transverse wires, mbk utilizes the DRA-M multiple rotor straightening and cutting machine. It handles standard wire diameters from 6 mm to 16 mm, adjustable up to 5 mm to 20 mm. The longitudinal reinforcement is transferred automatically from the DRA-M to the welding unit of the mesh welding machine, while the transverse reinforcement lengths are assembled by the DRA-M and transferred as required. Image 3: Mesh extraction from the welding portal Image 4: Mesh transport with mesh stacking unit on chain cross conveyor Once the mesh is completed, it is automatically labeled with text and/or barcode, and a mesh conveyor system enables further processing through a fully automated traverse. The mesh is transported for further processing to the bending beam for Z-bending or directly to the stacking position. In the subsequent circulation plant, the mesh is deposited and stacked according to the master computer specifications. The MSM-M mesh welding machine from mbk ensures everyday suitability, cost-effectiveness, and low maintenance requirements. It can be tailored to meet specific production requirements, offering different performance levels and automation accessories. The plant layout is flexible and adaptable to local conditions. Special and standard meshes can be produced for series and end stirrup production. Image 5: Plant overview: MSM-M with mesh conveyor and Z-bending unit (BF4) To produce precast slabs, the machine is equipped with a mesh bending station for frontal Z-bending of the bar overhangs. The automated traverse allows the produced slabs to be deposited on an additional stacking pallet for external use in structural precast elements and construction site additions. mbk’s strength lies in developing and implementing individual, modern, and future-oriented solutions based on customer needs. They also prioritize professional spare parts and maintenance services. These qualities have earned mbk Maschinenbau GmbH a strong reputation worldwide, as they value customer relationships and their impact on market shares.

Efficient automation solutions for the concrete pipe industry

Efficient automation solutions for the concrete pipe industry The main objective is to stay one step ahead and provide solutions as soon as the market signals new requirements. The BSM is an innovative cage welding machine made by mbk that has been continuously refined. It offers various customisable automation solutions to ensure efficient and economical day-to-day production. These customisable automation solutions are an important step towards the future, where excellence and competitiveness play an even greater role. Customers attach great importance to high quality, maximum performance and low staff costs. Easy integration into existing production environments, low maintenance requirements and fast response times in the event of service are equally important. A machine manufacturer must meet these requirements. Considerable savings in materials and manufacturing processes can be achieved due to the versatile customisation options of the machines. Customised automation solutions are an integral part of mbk Maschinenbau GmbH’s everyday business. The company develops, designs and implements modern concepts for the reinforcing steel, precast concrete, manhole and concrete pipe industries at its headquarters in Kisslegg. The BSM cage welding machine features innovative technology and modular design and offers various automation solutions. The proven BSM cage welding machine is becoming increasingly important in the manhole and concrete pipe industry. It is used to produce reinforcement cages in various designs, such as round cages (straight or with spigot end and bell/ socket), double cages (outer and inner cage) arranged alternately behind each other, oval, egg-shaped, maul-shaped or even special shapes such as round-oval-round (ROR) or oval-oval-oval (OOO). Depending on the machine type, eight different sizes are currently available. The cage diameters that can be produced range from 220 to 5,200 mm. Image 1: High speed cage welding machine BSM-190-R Image 2: BSM-190-R with automatic longitudinal wire feeder (ALZ-M) Image 3: Automatic longitudinal wire feeder (ALZ-M) with integrated wire straightening and cutting machine The fully automated BSM-190-R cage welding machine can produce cages with lengths of up to 7,000 mm. Other lengths are possible on request. This machine excels in reliability, stability and longevity. According to the manufacturer, the machine offers high productivity at low maintenance and energy costs. Due to their precise manufacturing tolerances, very accurate and straight cages are produced. The BSM also complies with various standards and is therefore particularly suitable for daily use. Companies are under constant pressure to improve their production processes. Customised automation solutions can help to optimise the value chain. mbk offers interesting automation solutions for the BSM cage welding machine. These range from simple automation accessories to fully automatic production lines with buffer solutions and transfer of the reinforcement to the downstream pipe machine. Wire straightening and cutting machine (DRA) The wire straightening and cutting machine (DRA) is used for the production of longitudinal wires. There are different versions of the DRA, from simple single straightening and cutting machines (DRA-C and DRA-E) to multiple wire straightening and cutting machines (DRA-M). These plants can straighten, cut and bend reinforcing wire with diameters from 4 to 20 mm. Optional additional features such as the automatic connection to the cage welding machines further facilitate the production process. Automatic longitudinal wire feeding An automatic longitudinal wire feeder can automatically feed the longitudinal wires for the cage. This is done either with pre-cut longitudinal wires from a magazine that can be filled with up to one tonne of material (type ALZ-B) or alternatively via an integrated wire straightening and cutting machine directly from the coil (type ALZ-C). The longitudinal bars are fed individually and one after the other, which means that these variants also permit the placement of non-round products such as ovals or egg shapes. The latest version of the automatic longitudinal wire feeder (type ALZ-M, patented) allows feeding of all required longitudinal wires in one step, fully automatically and independent of the cage diameters that can be produced. The wires are already inserted during cage removal, which reduces the machine downtimes in the production process to a minimum. Automatic winding wire changing system The automatic winding wire change system (type AWDW, patented) allows changing between up to five different wire diameters. It consists of winding wire reels for the different diameters and a wire changing unit with an automatic wire Image 4: BSM-190-R with automatic longitudinal wire feed (ALZ-M) and winding wire changing system (AWDW) cutter and feed unit. The automatic wire cutter cuts the wire during cage production, which further reduces the cycle time compared to conventional cutters. The feed unit guides the next active wire up to the welding roller to make it available for the production of the following cage. The welding carriage is further equipped with an automatic adjustment of the welding and contact roller for automatic adjustment of the welding roller stroke and compensation of different wire thicknesses and wear. With the winding wire change system, inner and outer cages can be produced alternately with optimised wire diameters. Also, cages can be serially provided in different sizes, for example for pipe machines that alternately produce different pipe diameters. Cage removal device and cage removal and joining device After the production of the cage, there are various solutions for their automated removal and handling. The cage removal device (KEG) is available in various designs for removing and depositing reinforcement. Image 5: Cage removal robot (KFG) in operation at the customer’s site Image 6: Cage removal with cage feeding function (KFG) It meets a wide range of requirements, from a single to multiple parking positions. Depending on the stage of expansion, it also offers the loading of buffer and conveyor belts. The cage removal and joining device (KFG) is also used to remove, place and join double reinforcements (outer and inner cage). Like the KEG system, it features several set-down positions and the loading of buffer and conveyor belts. With transport and buffer solutions, reinforcement can be buffered and safely transferred to the pipe machine. This compensates for different cycle times and the cage welding machine can produce continuously, even if the cages are removed

Cage welding machine for the production of reinforcement square pile

Cage welding machine for the production of reinforcement square pile C L Pile Sdn Bhd is a reputable manufacturer of Quality Reinforced Precast Concrete Square Piles. The company was incorporated in Malaysia in the 1990s and start with the aim of management commitment and term cooperation effort, in order to optimize both productivity with quality and equipment life cycle, and maximize infrastructures effectiveness with cost effective control. The piles are manufactured in various sizes ranging from 125mm x 125mm to 450mm x 450mm and with various length 3.000 mm to 12.000 mm length, customize length can be made according to requirement as well – thus providing options to suit different working loads and depth of penetration and hence with minimum resources wastage. In order to meet the market, C L Pile produces both Reinforced Concrete Square pile and Prestressed Square pile. C L Pile’s product has been cooperated in many of the major projects and used extensively in highrise buildings, commercial buildings, mall, port, bridges, reservoirs, retaining walls, schools, residences and shop lots. They are not only supplying piles in Malaysia, but also exporting to Singapore and Indonesia, such as projects at Malaysian Johor Port/PTP, the development of luxury real estate and various independent Chinese schools in Malaysia, as well as Changi Airport and the Tuas Mega Port project in Singapore. Image 1 & 2: C L Pile Sdn Bhd in Johor Bahru Image 3 & 4: Driven piles produced in different dimensions RSM cage welding machine To produce round and square reinforcements for driven and bored piles (with or without cone end), columns and beams, that is what the cage welding machine RSM stands for in the -V and -S versions. For square cages (type RSM-V), the flank length on the outside ranges from 92 to 422 mm, depending on the wire combinations. The number of longitudinal wires is four, with optional double wires in the corner. In the round version (type RSM-S), round columns and micropiles with an outer cage diameter between 130 and 596 mm can also be manufactured. Cage lengths are possible from 3 to 18 m, with other sizes also available on request. The RSM can convince with many features, such as a very high variability in the freely programmable winding wire pitch (also multiple production of short cages in a long cage programmable), the production of cages with tip (cone end) by means of pre-bent longitudinal wires or the possibility of double wires in the corner. Due to the economical resistance welding technology, the RSM also eliminates the consumption of shielding gas and electrodes. The cage welding machine also convinces many users with its simple handling, with the setting of the reinforcement cage and welding data via saved programmes, low maintenance requirements and the LAN/WLAN connection for uncomplicated remote maintenance. Image 5: mbk cage welding machine RSM-V at C L Pile’s plant for high quality and efficient reinforcement for driven piles

Cage welding machines with well-proven technology

Cage welding machines with well-proven technology Driven and bored piles form the basis of load-bearing foundations on construction sites. There is usually no way around them especially in difficult soil conditions. Precast concrete driven piles are a popular choice. mbk, as one of the leading manufacturers of welding machines and systems for the construction and precast concrete industries, also has innovative solutions for this application in its product portfolio. Reinforcements of the most varied dimensions are possible with the VSM series cage welding machines. These machines have been tried and tested over a long period of time and can thus guarantee stable production processes. This is primarily due to their high quality, reliability and durability – but also because of the numerous possibilities of customising them completely individually to relevant production requirements. mbk is passionate about its work, should special designs and dimensions outside the usual range be required, and ensures that (almost) every customer specification can be met with a high level of technical expertise, a wealth of experience and immense innovative power. Image 1: VSM-V cage welding machine Square cages – VSM-V cage welding machine The VSM-V cage welding machine is tailored to the production of square reinforcements for driven piles, and also columns and girders up to a maximum length of 24m. Flank lengths of 111 to 422 mm are possible depending on the wire diameter combination. Both single and double wires can be welded in the corner. The VSM, unlike the other types of mbk cage welding machines, works or welds on a stationary product. It means that, rather than the cage, the coil together with the winding wire and welding unit rotates around the product, resulting in more speed and stability for products with a square cross-section. The spool for the winding wire can either be wound directly in the machine or alternatively by means of a separate spool winder. This then allows very short changeover times in conjunction with additional spools when the winding wire runs out or needs to be changed to a different wire diameter. Image 2: The spool rotates around the product together with the winding wire and welding unit. The result – more speed and more stability for products with a square cross-section Image 3: Square, rectangular, round, triangular – the VSM-S cage welding machine Image 4: VSM-057-S cage welding machine from mbk The wire decoiler supplied for coils is equipped with an adjustable decoiler attachment, which allows different coil sizes to be accommodated and is designed for a max. coil weight of 3,000 kg. Square, rectangular, round, triangular – the VSM-S cage welding machine The VSM-S cage welding machine is the flexible version of the well-known VSM. In this design, adaptable interchangeable discs allow different cage geometries to be produced on one and the same machine, with flank lengths up to 450 mm or diameters/diagonals up to 636 mm depending on the wire diameter combination. The discs and thus cage geometry can be changed easily and rapidly by means of a quick-change system. This has more than proven its worth particularly in the case of frequent geometry changes, such as in steel reinforcement and precast production facilities. This flexibility makes the VSM-S interesting not only in manufacturing driven piles, but also for producing reinforcement for bored piles, precast concrete columns, beams and masts. Image 5: Automatic VSM-V with DRA-20-M Round cages can also be produced in lengths up to 24 m – with different cage diameters and also different spacings. Cage lengths of up to 14 m can be achieved when manufacturing rectangular cages. Processable wire diameters for all versions are 8 to 25 mm for the longitudinal wire and 5 to 8 mm for the winding wire. Practical add-ons – accessories and automation solutions for the VSM A comprehensive range of accessories is available for the VSM series, as well as automation solutions ranging from the simple automation of individual operations to fully automated production lines. This means that longitudinal wires can be prefabricated and automatically fed to the machine when connected to a wire straightening and cutting line, allowing different cage lengths with different wire diameters to be produced just in time. It also facilitates a high degree of flexibility in production, for example, when fulfilling structural specifications for customer orders. The fully automated changeover of all relevant systems to other product sizes is possible as is the integration of a longitudinal wire insertion device for welding cages with short longitudinal wire overhangs. After welding, cage handling equipment and stacking systems enable the automatic removal, intermediate storage, transport and positioning of finished products for further processing in downstream operations. Image 6: VSM-V with intermediate storage system including product positioning for removal Flexibility is enhanced significantly thanks to fully automated production processes. Outputs of up to 1,600 linear meters of driven pile cages are also possible in a single working shift. A bundling solution for packaging cages for shipping is also part of the extensive range of accessories for the VSM. All of these automation solutions both ensure savings on personnel in the manufacturing process and also allow staff to work ergonomically in day-to-day production operations. Specialised for over 60 years in manufacturing reinforcement welding machines mbk is a global player in the concrete, construction and precast industries with over 1,200 machines sold worldwide. Welding machines – now in the third generation – have been manufactured in Kisslegg since 1961 and are operating in more than 60 countries. Professional, technically advanced after-sales service also plays a significant role in the company’s day-to-day activities. Quality “Made in Germany”, assured by qualified personnel, a state of the art design and development department, new generation machinery and last but not least ISO 9001 certification.