Photos: Courtesy of mbk Maschinenbau GmbH
When ground conditions are difficult and a firm foundation must be created, this is the time for pile foundations and bored piles. There is also great demand for precast driven concrete piles, ranging from simple halls to extremely complex constructions. Reinforcements in a wide range of dimensions form the basis for all these driven and bored piles, columns and beams. When special designs and gigantic dimensions are required, mbk Maschinenbau GmbH has long been known as a system solution partner. Individual concepts with added value are created with a high level of technical know-how, a great deal of experience, immense innovative power and the ability to engage fully with the concerns of its customers.
To produce round and square reinforcements for driven and bored piles, columns and beams, mbk has cage welding machines with different specifications in its product range.
ASM cage welding machine
The ASM cage welding machine, which was designed for the flexible production of reinforcement for driven and bored piles, columns and girders, is capable of producing cages with an outer diameter of up to 2,500 millimetres (depending on the number of longitudinal wires and wire combinations) and a maximum length of 24,000 mm. The longitudinal wire diameter is 12 to 25 mm (optionally 12 to 40 mm), the diameter for winding wire is six to 12 mm (optionally six to 16 mm).
Various welding processes are possible with the ASM: resistance welding, single and multiple inert gas shielded arc welding and the patented DualWeld – a flexible, dual welding concept that combines the advantages of both systems.
With DualWeld it is possible to change between welding processes or weld in parallel.
A straightening unit for winding wire, a hydraulic cage support, winding wire reels with or without drive, various longitudinal wire diameters and asynchronous divisions in one cage are all components of the ASM. The Local Area Network/Wireless Local Area Network (LAN/WLAN) connection, a touch screen with colour display and the setting of the reinforcement cage and welding data via stored programs are standard.
LSM, VSM-S and VSM-V cage welding machines
The LSM, VSM-S and VSM-V cage welding machines were developed to produce round and square reinforcements for driven and bored piles, columns and beams.
LSM cage welding machine
The LSM is available in two sizes (084 and 150) and two types: round (R) and round and square (S). For square cages of LSM type S, the outside flank length ranges from 90 mm to 1,108 mm, depending on the wire combinations. The outer cage diameter for round cages is between 170 mm and 1,570 mm, depending on the number of longitudinal wires and wire combinations.
Standardised cage lengths can range from 3,000 mm to 24,000 mm; other lengths are available on request. The longitudinal wire diameter is eight mm to 25 mm (optionally eight mm to 40 mm), the diameter for the winding wire is five mm to 10 mm (optionally five mm to 16 mm).
LSM-C cage welding machine
The LSM-C cage welding machine produces round and conical reinforcements for masts, driven and bored piles, columns and beams. It is also available in two sizes. The outer cage diameter for round cages is maximum 2,500 mm, depending on the number of longitudinal wires and wire combinations.
cage lengths range from 3,000 mm to 24,000 mm; other lengths are available on request. The longitudinal wire diameter is eight mm to 12 mm, the diameter for the winding wire is five mm to eight mm.
The cage welding machines of the LSM series with resistance welding technology require no consumption of inert gas shielded arc welding gas and electrodes. The ergonomic handling on the wire and cage side makes working noticeably easier. Winding wire cutters with and without drive as well as electric wire cutters ensure an efficient production process.
The electronic welding point control achieves a high welding capacity and welding quality – the precise dosage of the welding power, the contact pressure and the length of the respective welding impulses achieve very good results.
The possibility of setting reinforcement cage and welding data via stored programs is a great help in everyday production. The programmable winding wire pitch ensures high variability. Easy handling and programming are guaranteed by the use of touch panels and IPC/PLC (industrial PC/programmable logic controller) control. The LAN/WLAN connection is part of a modern production process.
The LSM can also be optionally equipped with DualWeld.
The LSM, VSM-S and VSM-V cage welding machines were developed to produce round and square reinforcements for driven and bored piles, columns and beams.
VSM-S cage welding machine
The VSM-S is distinguished by a number of features such as the performance package for higher welding and production capacities or the coil winder for winding standard coils onto LSM series coils.
For square cages of VSM-S, the outside flank length ranges from 94 mm to 450 mm, depending on the wire combinations. The outer cage diameter for round cages is between 132 mm and 636 mm, depending on the number of longitudinal wires and wire combinations. The number of longitudinal wires is defined by replacement discs (variable). The maximum standard length of the cages is 3,000 mm to 24,000 mm and can be individually determined on request.
The quick-change system for different cage geometries (round, triangular, square, etc.) supports economical work.
VSM-V cage welding machine
The VSM-V cage welding machine is used to produce square reinforcements for driven and bored piles, columns and beams. It only differs from the VSM-S in the manufacturing dimensions, the characteristics are identical.
For square cages of VSM-V, the outside flank length ranges from 111 mm to 422 mm, depending on the wire combinations. Cage lengths are 3,000 mm to 24,000 mm, including the possibility of customization. The machine has four longitudinal wires, with the option for double wire in the corner.
Automation solutions are available for the VSM series, ranging from simple automation accessories to fully automated production lines with buffer solutions.
VSM-S automation solution
In the case of the VSM-S, the automation solution includes longitudinal wire storage systems for the pre-assembly of the wires from the coil as well as the connection of a multiple wire straightening and cutting system (DRA-M) for the pre-assembly of the longitudinal wires, and a simplified quick-change system for the geometry changes using product discs. Other possible solutions include a processing system after the removal of the reinforcement, the automatic removal of the finished product for further processing and a buffer storage system with positioning of the products.
VSM-V automation solution
The VSM-V is also equipped with the DRA-M (wire straightening and cutting machine for wire diameters up to 20 mm) as part of the automation for the pre-assembly of the longitudinal wires. Quick adjustment to reduce changeover times when changing diameters is also part of the automation, as is the fully automated conversion of all relevant systems to other product sizes and the integration of a longitudinal wire feeder for welding a tight coil with short longitudinal wire projection. A chain conveyor as a buffer and for feeding the longitudinal wires into the machine (automatic loading also possible via DRA-M) and the processing station after removal of the reinforcement are sequences of the VSM automation. The automatic removal of the finished product for further processing and the buffer storage system with positioning of the products for removal complete the automation spectrum of this series.
For square cages of VSM-S, the outside flank length ranges from 94 mm to 450 mm, depending on the wire combinations.
RSM cage welding machine
The RSM cage welding machine is used to produce round and square reinforcements for driven and bored piles, columns and beams with or without cones. They are available in the versions V and S: square, single, double wire in the corner (V) and round, square, optional double wire in the corner for square (S).
For square cages of RSM type S, the outside flank length ranges from 92 mm to 422 mm, depending on the wire combinations. The outer cage diameter for round cages ranges from 130 mm to 596 mm, depending on the number of longitudinal wires and wire combinations.
There are four longitudinal wires, optionally double wire in the corner. The cage length has dimensions of 3,000 mm to 18,000 mm, other sizes are available on request.
The RSM includes features such as a very high variability in the winding wire pitch (multiple production of short cages in one long cage is also programmable), the production of cages with a taper (cone) by means of pre-bent longitudinal wires and the manual adjustment of the diameters. The RSM also eliminates the need for inert gas and electrodes. The cage welding machine also features easy handling, setting of the reinforcement cage and welding data via stored programs, low maintenance and the LAN/WLAN connection. Further automation solutions are also available on request. 
mbk is a specialist for the production of wire cage welding machines and can react with its design team to an innovative market with enormously short development cycles. mbk’s strength lies in being fully committed to special customer requirements and responding with a high degree of individualization with corresponding solution concepts. The company from Kisslegg, Germany, is a manufacturer of welding machines and systems for the reinforcing steel processing industry as well as the construction and precast concrete industry, and has customers in over 60 countries.