How to Choose the Mesh Welding Machine for B500B Hot Rolled Rebar Mesh

As a renowned local contractor in French Polynesia, the client has numerous commercial building projects underway and needs to source a large quantity of reinforcing mesh from both local suppliers and China to ensure construction progress and on-time delivery; However, in actual construction, different structural components of a building and varying load-bearing requirements result in differing specifications for the width, length, mesh size, and wire diameter of the reinforcing mesh. This has complicated the client’s procurement process, leading them to plan the purchase of a reinforcing mesh welding machine to produce the mesh in-house.

Specifications for some of the wire mesh products the customer currently sources from external suppliers:

I. Client Background, Needs, and Pain Points:

(1) Client Background: A local construction contractor in French Polynesia; requires approximately 35–60 sheets of 2.4 × 6 m rebar mesh per day; 4–7.5 metric tons per day. Due to the massive demand for rebar mesh, the client has chosen to produce some of the commonly used rebar mesh in-house to reduce project costs.

1. Main specification：

(2) Production Challenges:

• Hot-rolled rebar has an oxide layer on its surface that impedes the flow of electricity; as a result, welds are not strong enough when using the same welding parameters.
• Hot-rolled rebar conducts and dissipates heat rapidly. When welding hot-rolled rebar mesh, insufficient welding pressure or a short welding time can easily result in weak welds that come apart at the slightest touch.
• The surface of hot-rolled ribbed rebar features protruding crescent-shaped transverse ribs, which reduce the effective contact area of the cross-section.
• The current production volume of rebar mesh cannot meet customers’ daily project demands.

Ⅱ. DAPU Quotation Solution：

Reinforcing mesh welding machine DP-GW-2500B 4-12mm

Automatic mesh falling and moving out system, for max.6m mesh length

Air compressor 2.6m^3/min, air tank, SMC drier and SMC filters

Industrial chiller MG-15C(D), with water pipes

Wire Straigtening and cutting machines:

Option 1: GT4-12 Wire Straigtening and cutting machine

Option 2: GT6-14 Wire Straigtening and cutting machine

Option 3: GT5-10 Wire Straigtening and cutting machine

Option 4: GT6-12 Wire Straigtening and cutting machine

How to Choose a Wire Straightening and Cutting Machine:

If you choose a standard-speed GT4-12 or GT6-14 wire straightening and cutting machine (maximum speed 60 m/min), you will need to purchase four units: two for line wires and two for cross wires.

Conversely, if you choose the high-speed GT5-10H or GT6-12H wire straightening and cutting machines (maximum speed of 130 m/min), you will only need to purchase two units: one for the line wires and one for the cross wires.

The specific reasons are as follows:

First, given that the customer primarily produces reinforcing mesh panels measuring 2.4 m x 6 m with a mesh spacing of 150 mm x 150 mm: a total of 41 cross wires and 17 line wires are required, with the line wires totaling approximately 98 meters and the cross wires totaling approximately 102 meters.

Second,

First, let’s calculate the welding time required to weld a single 2.4 m x 6 m mesh panel:

1. Wire feed carriage travel time: 10 seconds

2. Welding time: 31 seconds (welding speed of 80 welds per minute)

3. Mesh pull carriage return time to starting point: 12 seconds

4. Mesh pull carriage time for pulling and collecting the mesh: 12 seconds

Welding time for one 2.4 m x 6 m mesh panel: 65 seconds.

Approximately 3,600 / 65 ≈ 55 mesh panels can be produced in one hour.

Welding a single 2.4 m x 6 m mesh panel with a mesh size of 150 mm x 150 mm takes approximately 1 minute.

2.How to Address Customer Pain Points:

(1) Increase welding current: Our pneumatic reinforcement mesh welding machine uses custom-made new 90 multi-force air cylinders from SMC (Japan), which increase the output current by 20% and deliver a welding pressure of up to 570 kg. The welding pressure remains stable, and the machine achieves an overall energy savings of 30%.

(2) Extend welding time; the speed can be controlled at 80 times/min (max. 100 times/min).

3.Finished products of hot-rolled reinforcing rebar mesh：

4.Machine Technical Specification：

5.2D & 3D Layout of Reinforcement Mesh Welding Machine: 

Advantages of Pneumatic Rebar Mesh Welding Machines：

1.European design with Chinese price, similar to the Italian Schnell brand machine.

2.High production speed: equipped with Japan SMC 90 multi-force & energy saving air cylinders, saving energy, the speed is 80-100times/min, normal speed is 80times/min.

For example, if you produce 7mm wire, 2.4*6m mesh, 150*150mm mesh:

Automatic line wire feeding trolley: 12s

Mesh welding time: 31s

Mesh carriage return time to starting point: 12s

Mesh pulling & collecting time: 12s

Then one 6m long mesh will need 65s to make. One hour 3600/65=55pcs

If you work 12 hours one day, then then daily production will be 660pcs meshes

The weight of one 2.4*6m reinforcement mesh is approximately 60KG

On hour can produce 55*60KG=3300KG 

3.High configuration of electric cabinet, gurantee the precise control:

Panasonic (Japna) PLC & servo driver + Weinview (Taiwan) touch screen;

Schneider (France) low-voltage apparatus & air switch;

Phoenix (Germany) wire terminals;

ABB (Switzerladn sweden) switch

4.Automatic mesh pulling system: CNC control, equipped with Panasonic (Japan) servo motor 2KW and SMC air cylinder

5.Automatic mesh falling and moving out system, controlled by SMCair cylinder, support Max.6m mesh

Client Positive Feedback：

"Nous sommes une entreprise de bâtiment à Tahiti, nous utilisons exclusivement du treillis soudé en acier B500B pour tous nos logements et parkings souterrains. Avant, nous commandions tout le treillis importé, les délais de livraison étaient interminables, et nous n’avions pas la flexibilité de fabriquer des dimensions sur mesure pour les terrasses, les étages ou les toits.

Nous avons acheté la ligne DP-GW-2500B il y a un mois, le plus gros problème que nous avions avec le fil laminé à chaud était l’oxyde de surface qui empêchait la soudure, les points de soudure se détachaient facilement. Cette machine a des vérins SMC à haute pression et un réglage de courant et de temps de soudure ajustable pour l’acier B500B. Dès le premier essai, les soudures sont parfaites, aucun décollement, nos contrôleurs techniques valident tous les panneaux sans réserve.

Nous produisons environ 55 panneaux de 2,4m×6m par heure, soit plus de 4 tonnes par jour, cela couvre totalement nos besoins quotidiens sur les chantiers. Plus besoin de stocker des tonnes de treillis importé ni de subir les surcoûts du transport maritime entre les îles. Je recommande vivement cette solution à tous les entrepreneurs de Polynésie française ! "

Looking for a Tailored Reinforcement mesh welding Solution?

Talk to our technical engineers today to get a free layout design and the latest quotation for your factory!