Rekers Betonwerk relies on innovative reinforcement technology with integrated logistics and software

Processing reinforcement highly efficiently and transporting it to the right position – Rekers Betonwerk achieves this goal in a fully automated process using modern machines, robots, and customized software from Progress Group. The business uses three robot-assisted EBA stirrup benders, a state-of-the-art M-System mesh welding plant with bending system, innovative, fully automated logistics, and an integrated software suite.

Comprehensive concept for efficient production

In close collaboration with Progress Group, Rekers implemented a unique, comprehensive concept for automating the reinforcement fabrication process. Required stirrups are automatically delivered to the processing stations such that they can be integrated into the bent reinforcement cages. This just-in-time delivery is necessary for the efficient completion of cage production – providing the right stirrups at the right time and in the right place.

Not only does the plant design include robots removing the stirrups from the automatic EBA stirrup benders; it also features a completely new logistics setup. Several self-propelled vehicles transport the stirrups on racks to the cage completion area in an automated, networked process while ensuring utmost accuracy. The transport rack carries all stirrups required for the respective component. This solution enables Rekers to produce reinforcement cages for slabs and column-shaped components efficiently so that fewer people are needed on the shop floor.

Optimizing stirrup fabrication

In the initial phase of the plant upgrade, Rekers and Progress Group analyzed stored data from the last few years and installed three new automatic stirrup benders on this basis. The stirrup fabrication setup provides the capacity for producing the required quantity per shift in diameters from 6 to 16 mm from the coil in an end-to-end, fully automated process.

Automated cage fabrication using new mesh welding plant

The M-System mesh welding plant also processes diameters from 6 to 16 mm; it can fabricate flexible reinforcing mesh designs. Its beam bending system and the individual bending heads moving in parallel produce the required reinforcement cages automatically and just-in-time.

Plant upgrade – why choose Progress?

“When we started to rethink steel processing, Progress Group made a good impression on us by immediately embracing innovation. They were open to new ideas,” recounts Ulrich Rekers, who represents the third generation of the family running the business, adding: “A good example of this are the robots for removing the stirrups that also provide the option of changing the bending tool fully automatically.” This is why no manual work steps are necessary when changing bending dies. According to Ulrich Rekers, other suppliers were not prepared to fulfill this requirement, but Progress presented a 3D visualization of a modified bending head within a few weeks. Rekers Betonwerk considered this to be additional support of their decision to partner with Progress Group to elevate the automation of its operations to a new level.

Automation to counter shortage of skilled labor

The data-driven automation of the production process puts Rekers into a position to also tackle the increasingly severe shortage of skilled labor. According to the business, about ten shop-floor positions were made redundant to close the gap in terms of the required number of staff.

steelbos – the software suite for reinforcement fabrication including automated logistics

The steelbos software suite also provided by Progress Group provides the mesh welding plant with production data and controls the stirrup fabrication and logistics processes so that stirrups are manufactured accurately and always conveyed to the right place. CAD data is automatically adapted to the machine settings within the system and assigned just-in-time to available machines. In addition, the mobile production module was integrated with a total of five stationary display terminals distributed across the shop floor. This means that employees can access the right information on the spot and at the right time, view details of the product drawing more precisely by zooming in and dispense with paper documents in the production process. They also use steelbos to manage the stirrup logistics featuring the driverless transport system and to map warehouse management. In addition, forklift operators use the software on their mobile devices to interact with reinforcement logistics and accept picking orders.

What is the biggest advantage of digitalization?

If a change is required, staff can intervene directly and change over at short notice. This makes production more flexible and easier to manage while also allowing for bottlenecks to be identified and eliminated in good time. These aspects facilitate better planning and optimization of the production process, which results in both time and material savings. Digitalization has a long tradition at Rekers. The father of the current managing partner had launched several initiatives in this field as early as in the 1970s. Rekers continues to be acutely aware of the significance of the digital transformation today, for instance when it comes to countering the increasingly severe shortage of skilled labor as early as possible.

Successful collaboration

Ulrich Rekers is the managing partner of Rekers Betonwerk; he has been with the company for over 20 years. He concludes on the automation of reinforcement fabrication: “With systems of this complexity and degree of innovation, you obviously can’t expect everything to run smoothly from day one, but this investment is definitely worth it. Collaboration with Progress has always been constructive and open, and we got a very good result in the end.”

Production manager Andreas Frecken adds: “There were a few stumbling blocks at the beginning when integrating the data, which we had to clear away while the production line was in full service. We received a lot of support from the highly motivated people at Progress, who got to grips with a new concept and really made things work. This collaboration was a superb experience!”