Mesh, Rebar and Precast Industry

AUTOMATIONENGLIS

H

2 3

The Company

We have been developing machinery and plants for rebar processing from coil for the past 50 years.

In the last few years we have successfully realised our vision of implementing innovative leading-edge solutions for our customers all over the world.

Our custom-made solutions we design in close collaboration with each customer and the competent advice we give from preparation of the proposal up to technical assistance on handover are the outstanding hallmarks of our company.

Full-range supplier Turnkey solutions for rebar shops, mesh manufacturers and precast concrete plants

Expertise Quick, precise, maintenance-free processing from coil in wire diameters of 4-26 mm

Flexibility Custom-made plant layouts, feed and logistics systems

Software Complete solutions from the machine through work scheduling to complete order processing

Efficiency Very little wear and tear and low maintenance costs thanks to the use of electric servo motors and pneumatics

Speed Experienced technicians and pre-commissioning at our factory guarantee short installation times

Service Our service department offers you uncomplicated, efficient support

PassionAn enthusiastic, skilled team guarantees customer-oriented solutions

Innovative from Experience Our Efforts – Your Benefits

The continous development of our machines and solutions has made us a full-range supplier for rebar shops and manufacturers of mesh. We not only develop, construct, deliver and install individual machines and plants, we also design whole factories, offer additional equipment and implement software and safety solutions.

Whether you intend to start a new business, expand or modernise your production process, our strengths enable us to find the right solution for your individual requirements.

ProductionEngineering Software

4 5

16

24 28 31

22 17

14

9

34

Contents

2 Innovative from Experience

6 Mesh Welding Plants M-System Series Tunnel Master Versity Series

14 Further Processing of Mesh Smart BGM BGM

16 Straightening, Cutting and Bending MSR Series ESR

21 Run-offs, Logistics Systems and Tying Systems

22 Automatic Stirrup Benders EBA S Series Pluristar

24 Lattice Girder Welding Machines VGA VGA Versa

26 Radial Bending Machines Radial Master

27 Cage Welding Machines VTA Series

28 Additional Equipment

30 Software for Rebar Shops ProFit

32 Solutions for Precast Concrete Plants Shuttering Robots Wire Center

36 Software for Precast Concrete Plants ebos®

erpbos®

38 In-house Competence

6 7

The M-System product family makes its mark through accuracy, flexibility and just-in-time production of custom-made bespoke mesh from coil.

Thanks to the machine‘s modular design the customers‘ individual requirements can be met. In addition, the low power consumption values achieved by the progress inverter welding process and production without cutting waste and without complicatedre-cutting of the mesh result in efficiency and cost-effectiveness.

The manufacture and processing based on CAD specifications of the mesh in diameters ranging from4-20 mm is, moreover, flexible and accurate.

Bending systems are also available, which can be used for processing both single bars and whole mesh.

An ingenious logistics system and an automatic bar code labelling system for the finished product also contribute to optimising your work flow.

M-System Series

M-System Series

Flexible Mesh Production

The mesh welding plants‘ strengths lie in their versatility and in the infinite number of possibilities for adapting them to the needs of the individual customer. Whether you are looking for high production output, production from coil or from rebar, just-in-time production or for stock – we develop and build the right machinery for your requirements.

Mesh Welding Plants

Flexible just-in-time production Efficiency and cost-effectiveness Integral bending and logistics systems Various performance levels

8 9

Piece production of custom-made mesh Adaptable performance Efficiency

M-System EvolutionThe strengths of the M-System Evolution mesh welding plant lie in the individual production of custom-made and bent mesh. This can be finished with various spacings, dimensions, wire diameters and bending angles.

The active feedback from the machine on the producibility of mesh, plus an ingenious logistics system significantly optimise the production process.

M-System Series

Standard mesh

Special mesh

Mesh with bends and cages

M-System BlueMeshEfficiency on the whole line is the hallmark ofM-System BlueMesh.

This mesh welding plant makes its mark with its low energy and space requirements and its low costs. Like the M-System Evolution it welds and bends the rebar mesh from coil to comply with individual specifications. Moreover, it also guarantees the well-known high quality of the finished product.

In this respect M-System BlueMesh is particularly suitable for factories with low to mid volume production.

Efficient in every respect Low energy and space requirements Low costs

Standard mesh

Special mesh

Mesh with bends and cages

Mesh Welding Plants

10 11

M-System PowerMeshThe crowning characteristic of the M-System PowerMesh mesh welding plant is its high performance.

Innovative technical solutions ensure high production. By this process a double line longitudinal and cross wire straightening machine speeds up steel preparation. In addition, the number of welding heads can be adjusted to the desired performance.

M-System PowerMesh HSThe recently developed M-System PowerMesh HS is configured for maximum production performance. This is achieved by the high cutting speed of the flying shears, the revolving run-out and the elaborate bar transport system.

The high speed model is also extremely flexible. The wire diameter is changed automatically, the mesh size can be individually set and the machine can also produce small batch sizes.

High performance Flexibility Efficiency

Maximum production Maximum speed Efficiency

Standard mesh

Standard meshSpecial mesh

M-System SeriesMesh Welding Plants

12 13

Tunnel MasterThe Tunnel Master welding machine makes possible fast, sophisticated, cost-conscious production of straight and curved ladders from coil for tunnel segments and similar precast concrete elements.

The Tunnel Master processes up to four longitudinal wires and arranges them, in the same manner as the cross wires, according a continuously variable grid.

Mesh Welding Plants Welding Machine for Ladder Production

High level of automation Flexible and precise production

Straight ladders

Curved ladders

Versity SeriesVersity is a mesh welding plant which concentrates on the serial production of standard mesh with regular geometry.

The wire is fed through by rebar material and if required, also from coil.

Versity also guarantees the highest operation reliability, while also providing the very best production performance.

Serial production of mesh with regular geometry Optimum production performance Wire fed from coil or from rebar

Versity Series

Standard mesh

14 15

Smart BGMThis innovative machine is flexible and precise. TheSmart BGM comprises two independently driven bending machines, which bend mesh fully automatically.

There are many possible configurations and bending angles. Square, rectangular, triangular and open forms with angles of 90° to 135° can be produced.

Depending on the mesh it is possible to produce various cage sizes with different wire diameters. Even the number of cages to be stacked can be determined according to need. The Smart BGM is suited to the fully automatic series production of storage cages.

BGMThe BGM is designed for the fully automatic bending of individual bespoke mesh. The machine can be fitted with a beam and individual bending device.

In combination with the grid-less mesh production and with the beam bending system it is possible to produce cages to an exact size with bars in the corners of the cages.

Single bars can also be bent automatically for door and window openings. Complete plant concepts and flexible transport and logistics systems round off this solution.

Further Processing of Mesh Smart BGM

Various bending angles and formsVarious bending angles and forms

BGM

Fully automated mesh bending machine Serial production Versatility in bending shapes

Fully automated mesh bending machine Bending of individual bespoke mesh Beam and individual bending device

16 17

The MSR product family is designed for high production output. The tried and tested multi-rotor straightening technique, the flying shear, the precise formers and the robust bending heads ensure precise, gentle straightening, cutting and bending. This guarantees constant high quality for the finished product.

The processing from coil and the custom-made collection systems optimise the production flow and minimise storage costs. This leads to an exceptionally cost-efficient production.

Coupled with a double bending system with automatic former changeover, the machines become amulti-functional, high-performance coil processing centre.

Straightening, Cutting and Bending

MSR Series

High production output Unrivalled product accuracy Optional double bending system

MSR Series

Rotor Straightening Technology

progress rotor straightening technology combines a variety of benefits in one system.

It guarantees optimum straightening quality for all types of steel and is particularly gentle in processing the wire surface. This results in a finished product of highest quality and a trouble-free production output.

It is a particularly energy-efficient system. In addition, thanks to the separated wire feed and the straightening system, it has exceptionally low maintenance requirements.

18 19

Straightening, Cutting and Bending Twin MSRMSR

Twin MSRThe Twin MSR is the ideal solution for businesses with high production volumes.

This high-performance machine features double strand processing on two lines, each independent of the other. Both the bending and the cutting system are designed for processing two bars with diameter up to 20 mm at the same time.

Production is further increased by various straightening, collection and logistics systems, which can be adapted based on the customers’ requirements.

The highest production output thanks to double strand processing Adjustable straightening, collection and logistics systems

Bars with bends and closed stirrups

Straightened, cut bars

Processes large wire diameters from coil Rotor straightening technology ensures gentle, reliable

and precise processing

MSR The various types of MSR can process wire diameters of 6-26 mm. When large diameters are processed, a wire insertion tool facilitates feeding the wire in the machine frame. It is also possible to work with coils weights up to 6.5 tons.

This takes the tried and tested characteristics of the MSR machines into a new dimension of rebar processing from coil.

Straightened, cut bars

Bars with bends and closed stirrups

20 21

ESR The ESR single rotor straightening machine is anall-rounder and has been designed for flexible production, together with high output. As in the MSR line the rotor straightening technology and the flying shear ensure a consistently high-quality result and fast processing. The Vario Rotor processes different wire diameters and types of wire with one rotor fully automatically.

A number of accessories and individual components plus various automation stages make the ESR into a machine which gives optimum conditions for satisfying specific production requirements.

Straightening, Cutting and Bending ESR

Straightened and cut bars

Bars with bends and closed stirrups

Run-offsprogress run-off systems are multi-talented and make a significant contribution to ensuring production continuity.

The fixed length run-off serves the buffering and tying of the straightened material. With the 2BK bending run-off it is also possible to make bars with bends on one or both ends and to produce large shapes and closed stirrups. The fully automatic former changeover ensures efficiency and flexibility.

Logistics SolutionsCustom-designed logistics solutions create optimum processing, a good material flow and the conditions for efficient production.

These solutions are always adapted to suit each plant and its specific requirements. There is a varied range of logistics solutions available, from collection pallets through distribution carriages and roller conveyors to chain conveyor systems and robot grippers.

Whether for rebar in fixed lengths, bent bars or large stirrups, the variety of possibilities we offer will allow you to create an efficient logistics system to achieve your production output.

Tying SystemA range of automatic tying systems supports production and prepares finished products perfectly for further transportation.

Flexibility and low costs A variety of possible uses

Run-offs, Logistics Systems and Tying Systems

22 23

EBA SThe EBA S line automatic stirrup benders are robust, compact and high-performance.

A fast system for wire changeover, an automatic changeover from double to single strand processing and automatic roller adjustment ensure high productivity, while the robust bending system ensures precision.

A 3D bending system is also available for the production of three-dimensional stirrups. If the EBA S is combined with a run-off, straight bars with or without bends can be produced.

Adapts flexibly to customer requirements Versatility in production

EBA S Series

Stirrups

3D stirrups

Automatic Stirrup Benders

PluristarPluristar is an automatic stirrup-bender, straightening and double bending machine in one and thus covers the whole spectrum of rebar processing from coil.

It allows flexible production of stirrups, straight bars and bars with end bends in a range of wire diameters from 6-16 mm. The central core of the Pluristar is the fully automated combined straightening system, featuring a roller and a rotor straightening unit.

Thanks to the optional 3D bending system which can produce three-dimensional stirrups in various forms the Pluristar is a complete solution.

Pluristar

Four in one: automatic stirrup-bender, straightening and double bending machine with 3D bending system

High-quality finished products thanks to the combined straightening system

Stirrups

3D stirrups

Straightened bars ad bars with bends

24 25

VGAThe VGA lattice girder welding machine is ideal for producing standard lattice girders from coil in large batches.

A combined roller and rotor straightening system, a diagonal wire bending unit and fully automatic spot welding machine ensure highest quality standards for the finished product.

The two basic versions of the VGA which differ from each other in terms of production speed can be adapted on request to individual requirements.

Serial production of standard lattice girders from coil Efficient, flexible configuration

VGALattice Girder Welding Machines

VGA VersaThe VGA Versa facilitates flexible just-in-time production of lattice girders from coil.

The highlight is the fully automatic height adjustment and diameter setting during production, which makes it possible to manufacture each product exactly to measure, without having to waste time in refitting. This eliminates high storage costs, and the problem of waste. In addition, the variable length adjustment of the welding spots of the diagonal wire allows the wire to be cut exactly to measure.

The Versa can also be specifically designed for the manufacture of KTS lattice girders for taking transverse or shearing loads.

KT lattice girders with flexible height

KTS lattice girders (for taking transverse or shearing loads)

VGA Versa

KT lattice girders

Just-in-time production of custom-made lattice girders Fully automatic height adjustment and wire diameter changeover

No waste

26 27

Radial MasterThe Radial Master radial bending machine bends rebar for tunnel, tower and foundation construction.

The machine can bend even rebar 40 mm in diameter with the highest accuracy. The bending roller is adjusted automatically by computer.

This enables several different radii to be produced within one bar.

Specially designed collection systems collect the finished products. An additional bending machine allows completely different bend shapes to be produced at each end of a single rebar.

Radial Bending Machines Radial Master

Processes diameters up to 40 mm Different radii within one rebar Optional bending machine

Cage Welding Machines VTA Series

VTA Series The VTA Series cage welding machines are used for the manufacture of cylindrical and, on request, oval or rectangular cages.

The configuration possibilities for these machines are almost infinite. The longitudinal bars can be fed manually or automatically. Alternatively, it is possible to process from coil in combination with a progress rotor straightening machine.

The inverter welder, an automatic winding wire cutter, plus automatic cage removal ensure an efficient and precise production output.

Versatile configuration possibilities Various stages of automation Low wear and maintenance costs

Bent bars

Bent bars with end bends Rectangular, oval and egg-shaped cages ( special forms)

Round and bell-shaped cages

28 29

Wire Feeding DeviceWhen processing large wire diameters the reel section can be fitted with a wire feeding device. This facilitates and speeds up wire feeding.

Additional Equipment

Coil ClawFaster, safer coil changeover is very important for smooth production.

With the progress coil claw, suitable for the various diameters, wound coils can be transported saftely and without hazard.

Extra safety is provided by an automatic locking and unlocking mechanism.

Butt WelderWhen a coil comes to its end, it is recommended to weld the ends of the wires together with a butt welder. This eliminates the time wasted in feeding in the new wire and production can be started up again immediately.

Pre-straightenersPre-straighteners from progress make the processing of large wire diameters easier and ensure that the wire feeding into the machine is under control.

Equipment for Safety at WorkA comprehensive safety plan is included in the scope of delivery. This consists of safety fences and doors, plus safety light barriers. This equipment creates a safe, convenient working environment.

Bar Code ScannersThe bar code scanner allows production dates to be registered easily and rapidly. Instead of expensive typing, bar codes can be scanned with this machine and be included in digital administration.

Stirrup CollectorsManufactured stirrups can be collected by a two-arm stirrup collector. At the same time this serves as a buffer.

As soon as one arm has reached the pre-programmed number of stirrups to be collected, the collection device can swing and bring the second arm into operation.

30 31

Coil ControlMaterial

Tracebility

Machine Control

Machine Feedback

Production List

CAD Link

ERP Link

Main Module

Report Print

Standard Mesh

Flex Mesh Production Scheduler

ProFitPTS

Production Test Service

ProFitProFit is a custom-made software solution for the control and organisation of production process in rebar processes.

This tool controls and manages production processes, order lines and the machines themselves. Reinforcement data can either be directly entered or transferred by CAD systems. In addition, ProFit functions as the interface to ERP systems such as SAP, GESYS and erpbos®.

The machines are controlled via the network or bar code labels. Machine feedback ensures smooth production, while the possibility of tracking material contributes to efficient quality control.

Together with a vast range of program functions, such as coil management and calling up statistics, ProFit provides a freely expandable bending form library.

Software for Rebar Shops ProFit

Control of production output, order sequences and machines Direct entry and/or acceptance of reinforcement from

CAD systems Machine feedback and materials tracking Modern surfaces and simple operation

32 33

Solutions for Precast Concrete Plants

Fully automatic shuttering process Gap-free shuttering Modular to suit production requirements Cost-efficient and reliable

Form Master

Shuttering Robot

An efficient shuttering system is the core of a fully automated precast concrete plant. The Form Master shuttering and de-shuttering robot performs all the individual operations fully automatically. This guarantees high precision and exact compliance with production times.

The Form Master is the ideal solution for the manufacture of all types of precast elements, starting from lattice girder floors through double walls to solid slabs and walls. The possibility to distribute the shuttering, storage and de-shuttering functions across several robots allows scaling the capacity individually. Moreover, the flexible machine layout of the Form Master makes it ideal for upgrading any existing plant.

Shuttering SystemsThe innovative, patented Infinity Line® system makes it possible to shutter precast concrete elements without any gaps and without using polystyrene extensions. The aim is to use as few types of shutters as possible. The notch-free system also allows shuttering to be performed without any notches. The elimination of filler elements and notches guarantees perfect outer edges.

Emplacement of Built-in PartsThe shuttering robot can be used for the fully automatic emplacement of electrical outlet magnets. The magnets are cleaned manually, stored temporarily in a magazine and aligned by means of recording templates. The robot then transports the electrical outlet magnets to the pallet with a special magnet receiving rail and places them precisely.

De-shuttering FunctionOnce the finished concrete element has been removed, a scanning device scans the pallet surface and communicates the position of the shutters to thede-shuttering robot. It then releases the magnets, removes the shutters and transports them to the storage.

34 35

Custom-made solution Fully automatic reinforcement preparation:

Straightening, cutting, bending, emplacement Spacer automation where required

Wire Center

Wire CenterWire Center is a fully automated solution for reinforcement preparation in modern circulation plants.

This system straightens and cuts wire from coil fully automatically and, in a second stage, emplaces it with or without spacers based on CAD data. The production and emplacement of lattice girders is also possible.

Wire Center optimizes production output and processes, increases precision, and helps minimize defects. The compact, modular structure also makes the system flexible in use.

Solutions for Precast Concrete Plants

Single Bar ReinforcementThe longitudinal and cross wire required for the reinforcement is produced by a fully automatic MSR straightening and cutting machine. The bars are transported from a buffer magazine to the pallet by a robot and emplaced fully automatically.

Lattice GirdersThe lattice girders required are transported from active storage to a GTA lattice girder cutting machine. There they are cut to size and then emplaced on the pallet. A welding machine is used to weld the residual pieces.

SpacersThe use of spacers guarantees that the concrete fully covers the reinforcement emplaced on the pallet. Spacers are available in a range of heights. Custom-made sorting and feeding devices ensure fast preparation of the spacers.

36 37

ebos® is much more than just a master computer. It is a comprehensive solution for work preparation, production, and process analysis, and addresses all aspects of the manufacturing process, from start to finish.

With ebos®, you can replace a large number of stand-alone software solutions with a single, well-integrated system. Complicated interface problems become a thing of the past, and workers can carry out their entire work process in a single, homogeneous, and user-friendly system.

PROGRESS GROUP has joined forces with ebos® to develop a software product combining a wide range of services with extremely simple user navigation. The result has been an extremely innovative tool for manufacturing facilities.

ebos®

A complete solution for all aspects of production Intuitive user concept 5 years of free updates

Software for Precast Concrete Plants erpbos®

erpbos® is a custom-made complete software solution for the precast concrete industry.

As a planning and management tool for all business and production processes, it helps in accurately setting off manufacture against logistics for each construction project.

The different versions of erpbos® are designed for the specific requirements of various processes – structural precast concrete parts, concrete blocks, concrete ceilings, staircases or garages – and together are a complete solutions family for the concrete industry.

A large range of central applications and features, such as data transfer from CAD or CAM, DMS integral document management, working time and operational data capture and central maintenance of master data provides support for every function in the industry.

Calculation of quotations, production and logistics planning are not organised as separate applications in erpbos®; they form part of a powerful and efficient ERP system. These components are perfectly compatible, which reduces induction costs and makes future expansion and modification of the system easier.

erpbos®ebos®

A comprehensive, custom-made solution for all aspects of your business

Maximum networking Perfect compatibility of all components

38 39

In-house Competence

Tried and Tested Technology

In our in-house precast concrete plant we compile ideas for new developments. This is a unique situation and guarantees innovative, reliable machines and plants, responding to ever-changing production demands in the real world.

Two fully automated pallet circulation plants produce lattice girder floors and double walls.

Form Master shuttering robot Spacing laying robot M-System Evolution mesh welding plant VGA Versa lattice girder welding machine Automatic concrete distributor

PROGRESS double wall PROGRESS lattice girder floor with insulation

PROGRESS lattice girder floor

PROGRESS XM lattice girder floor

PROGRESS Klimadecke® air-handling ceiling

PROGRESS Thermowand® thermal wall

Progress Maschinen & Automation AGJulius-Durst-Straße 10039042 Brixen (BZ), ItalyTel.: +39 0472 979 100 info@progress-m.comwww.progress-m.com