1 Product Production Process
The production process can be divided into the following sections: raw material storage and transportation and processing section, steel bar loading section, bar steel bar cutting section to length, bar steel bar bending and forming section, bar wire lining section, and wire rod steel bar processing section.
(1) Raw Material Storage, Transportation and Processing Section
Steel bar raw materials are purchased according to the production plan, and are pulled into the factory by trucks and stored in zones according to diameter specifications and raw material types.
If there are full-foot (random-foot) steel bars in the raw materials (which is a major source of profit), the raw materials need to be sorted according to specifications and lengths before processing the steel bars for processing.
(2) Rebar Loading
According to the production plan, the steel bars are lifted from the raw material storage area to the equipment raw material rack using a crane to prepare for processing.
(3) Bar Steel Bar Cut-To-Length Section
Due to the variety of building structure compositions and types of projects, the steel bars used in buildings are often of different lengths, and the lengths of bar steel bars sold by steel mills are often standard sizes such as 12 meters and 9 meters, so the processing of bar steel bars is the first The first process must be cutting to length.
(4) Bar Steel Bar Bending Section
Part of the steel bars cut to length need to be further bent and used for reinforcement of beams, columns, etc.
(5) Wire Rod Steel Bar Processing Section
The wire rod steel bar processing section uses wire rod steel bars as raw materials to produce stirrups, long curved bars, and straight and fixed-length steel bars.
2 product specifications
(1) Bar bending and forming steel bars
Type of raw material: bar threaded steel bar; processing diameter specification: ￠12～￠40㎜;
Curved shape: any flat shape
(2) Small-diameter stirrups, curved or straight steel bars. Types of raw materials: wire rods, plain round or threaded steel bars;
Processing diameter specification: Φ5.5～Φ12㎜;
Dimensions: Any planar shape and spiral steel bars
(3) Processing of steel bar threaded joints Types of raw materials: threaded bars and steel bars;
Processing diameter specification: Φ16～Φ40㎜;
3 Economic Benefit Analysis
- Automated equipment can reduce processing costs
The use of automated equipment and advanced production technology can reduce the number of workers by 2/3, reduce the material waste rate by 2%, and reduce other comprehensive management costs;
- Comprehensive tailoring at multiple construction sites can reduce the total cost
The processing and distribution center can deliver formed steel bars to multiple construction sites at the same time, and can perform comprehensive nesting, which improves the utilization rate of steel bars, saves resources, and greatly reduces the cost of steel bar production in the processing and distribution center;
- The price difference between full-length and fixed-length raw materials generates profits
Using a large number of general rulers as raw materials to process finished products also ensures that the quality is recognized by the construction party, and can earn a large price difference between general rulers and fixed rulers, about 30USD /ton, and the annual profit can be 1 050 000USD.
4 Construction scale and conditions
1 Construction scale
On the basis of market analysis and combined with the financing capacity of the construction unit, the construction scale is determined to be an additional production capacity of 35,000 tons of processed steel bar products.
2 Yield distribution
According to the annual steel bar processing requirements of 35,000 tons, combined with the types of steel bars required for civil buildings and their proportions, bar processing accounts for about 65%, and wire rods account for about 35%. The specific steel bar processing amounts are as follows:
| NO. | Name | Annual output (10,000 tons) |
| 1 | Bars and steel bars are cut and finished products are shipped out of the warehouse | 1.1 |
| 2 | Bars are cut and then bent to form steel bars | 0.28 |
| 3 | Bar steel wire covering | 0.28 |
| 4 | Circle straightening and shearing | 0.56 |
| 5 | Disc round processing stirrups | 0.17 |
| 6 | Steel cage | 0.43 |
| Total | 3.5 |
3 Rebar equipment configuration and investment
| Device Name | Quantity | Daily output/unit | Annual output | power/unit | Staffing/desk |
| rebar shearing line | 1 | 40Tons | 11000 Tons | 27KW | 1 |
| CNC rebar bending center | 1 | 10 Tons | 2800 Tons | 15KW | 2 |
| Threading machine | 4 | 10 Tons | 2800 Tons | 20KW | 4 |
| steel bar straightening and cutting machine | 2 | 20 Tons | 5600 Tons | 30KW | 1 |
| CNC rebar bending machine | 1 | 6 Tons | 1700 Tons | 25KW | 1 |
| Cage welding machine | 1 | 30 Tons | 11000 Tons | 11.2 | 4 |
| Scrap steel bar straightening machine | 1 | 3 Tons | 850 Tons | 11KW | 1 |
| Total | 11 | 119 Tons | 35000Tons | 139KW | 14 |
4 Auxiliary equipment investment
There is one 5-ton forklift, one 10-ton crane, one 20-ton dump truck, and two 10-ton dump trucks.5 area, power supply
- Covered area
Workshop area: 4000 square meters
- Power supply
(1) Load calculation and electricity consumption
The rated power of multiple production lines in this project is 139 KW, with an average power consumption of 40 kw/h. The power supply used in the production line is introduced by a special transformer.
(2) Selection of power supply system equipment
This project plans to build a new power transformer and distribution room, install a 150KVA transformer, and add a new set of power distribution devices (high and low voltage switch cabinets, metering panels, compensation panels, etc.).
(3) Workshop power supply plan
The low-voltage distribution lines in the factory area adopt a mixed method of radiation and tree trunks, and buried cables are laid.
The production workshop uses low-voltage power distribution panels to directly supply power to the equipment; power lines are laid with cables along the bridge and BV lines through pipes; all lighting lines are laid concealed through BV lines through pipes. Energy-saving lighting fixtures are used for lighting in the workshop, and emergency lighting is installed in the main passages of the workshop.
5 Workshop layout
The wire rod raw materials and bar raw materials are stored on one side of the workshop, and the finished steel bars are placed on the other side. A production line is formed from the raw material entrance of the workshop to the finished product exit. This layout reduces the secondary circulation and transportation links of steel bars in the middle. The entire process layout is reasonable and compact, and the flow is smooth to ensure the continuous progress of the production line. In addition, air compressor stations, power transformation and distribution stations, etc. are close to the main production line, which is beneficial to reducing energy consumption and saving investment. However, in order to reduce noise, it is recommended that the air compressor station be arranged in a closed house outside the workshop.
5 Price
| Device Name | Model | Quantity | Price(USD) |
| rebar shearing line | ZGYJ-500 | 1 | 60000 |
| CNC rebar bending center | ZGW-32L | 1 | 30000 |
| Threading machine | ZTD | 4 | 5000 |
| steel bar straightening and cutting machine | GT6-14 | 2 | 10000 |
| CNC rebar bending machine | 4-12C | 1 | 35000 |
| Cage welding machine | ZHLS-1500 | 1 | 55000 |
| Scrap steel bar straightening machine | AF8-22 | 1 | 4500 |
| Total | 11 | 199500 |
- The intelligent steel bar shearing production line has a cutting speed of up to 3-8s/time, with neat cuts and quick completion of steel bar cutting;
- The CNC steel bar shearing production line adopts a servo motor positioning system to ensure shearing accuracy;
- The length range of sheared steel bars is wide, up to 2-12m, which can meet the needs of different sheared steel bar lengths;
- The shearing machine has a wide width (the cutting width of the sawing machine is 600mm) and the width is 450 ~ 500mm. It can place dozens of steel bars at a time and process them at the same time, which increases the production capacity;
- The steel bar transmission speed is as fast as 0.8 ~ 0.9m/s, which can quickly and accurately transport raw materials and finished products; the shearing length error can be as small as millimeter level, fully meeting the market accuracy requirements;
- The intelligent steel bar shearing production line can realize two-way unloading and the silo is divided into two levels to ensure the separate storage requirements of different products;
- The tightening method adopts hydraulic + pneumatic method to ensure that the tightening is firm and will not loosen. If a fault occurs, the human-machine interface will display a prompt message to prompt on-site maintenance personnel to quickly eliminate the fault;
- The intelligent steel bar shearing production line can be freely connected with downstream wire-threading or bending production lines to achieve linked production, enabling the entire production line to achieve automated production;
- The intelligent vertical bending center adopts an integrated high-strength moving track design to perform multiple bends simultaneously in the same work unit;
- Two bending hosts can work at the same time, and multiple steel bars can be bent more efficiently at one time, greatly improving production efficiency;
- The bending spindle is controlled by the servo host, and the positioning and clamping mechanism of the bending host is designed to improve bending accuracy;
- The intelligent vertical bending center ZGW-32L has visual processing graphics, can process a variety of graphics, and can automatically block and align materials;
- The mobile bending machine automatically determines the bending length, and the telescopic bending axis can bend in two phases and bend at multiple angles in one cycle;
- The electrical equipment is controlled by a programmable controller, which not only ensures the stability and reliability of the equipment, but also makes the operation simple and easy to learn;
- The high-strength track design is durable; the control system is high and the error is small;
- The high-strength automatic loading rack can carry more raw materials.
| HSG40 | |
| Bending Capacity | 14-40mm |
| Threading Length | 50mm |
| One Rebar Threading | 60s |
| Motor Power | 4kw(3 Phase) |
| Weight | 450kg |
| Dimension | 1050*440*1000 |
| Voltage | 380v |
- It also has the functions of straightening, bending and cutting, making one machine multi-purpose.
- Using intelligent control, it can process squares, rectangles, diamonds, polygons, etc. of various sizes and specifications.
- From wire rod raw materials to stirrup products, it is formed in one step, and can process cold and hot-rolled high-strength wire rod steel bars.
- The production efficiency is high and the equipment is highly practical. It only needs one person to operate, which is equivalent to 7 to 10 laborers.
- Save raw materials, and there is almost no loss of steel bar head during continuous molding during work.
- It occupies a small area, saves straightening work area and cutting work area, and can operate in narrow areas.
- Equipment maintenance costs and energy consumption costs are very low. Comparison between fully automatic bending hoop forming machine and traditional manual semi-mechanized production: traditional manual semi-mechanized production (straightening—shearing–bending—–forming)
- Fast processing speed: Under normal circumstances, a shift of 5 people in the material preparation and seam welding part can process more than 10 12-meter-long finished cages in one day (material preparation, seam welding, reinforcement installation, detection tube installation, guide pad installation, etc.), the work efficiency is very high. Processing the same finished product in the traditional way requires 4 times the number of workers.
- The processing quality is stable and reliable: Due to the CNC mechanized operation, the spacing between the main bars and the winding bars is even, the diameter of the steel cage is consistent, and the product quality fully meets the specification requirements.
- No overlapping is required for tightening stirrups, which saves 1.5% of materials compared with manual work and reduces construction costs.
- Since the main bars are evenly distributed on its circumference, it is very convenient to overlap multiple steel cages, saving lifting time.
- Mechanized processing of steel cages ensures quality control.
| Model | 6-12 | 6-16 | 8-22 |
| Diameter | 6-12 | 6-16 | 8-22 |
| Speed | 20m/min | 20m/min | 20m/min |
| Power | 4kw | 7.5kw | 11kw |
| Reducer Type | AF250 | AF350 | AF400 |
| Size | 1050*680*1280 | 1050*680*1280 | 1200*880*1300 |
| Weight | 400KG | 600KG | 850KG |
6 Enterprise Organization, Labor Quota and Personnel Training
1 Enterprise organization and work system
This project is a new energy-saving building materials project. After the project is completed, it will be managed uniformly by the company.
The operation and management personnel work in one shift, and the production workers work in one shift (8 hours per shift), with 300 days of production throughout the year.
2 Labor capacity
The labor quota of this project is allocated according to the production line process, and the principle of streamlining and efficiency and the specific domestic requirements are fully considered.
(1) Production personnel composition (single shift): 1 production supervisor (also responsible for incoming and outgoing goods management), 1 financial officer, 1 equipment supervisor (equipment management and maintenance), and 7-14 equipment operators.
The total number of employees in the company is 10-17.
3 Personnel training
After the project is completed, the manufacturer should pay attention to personnel training. Before the equipment is delivered, the main management and maintenance personnel of the equipment can go to the site for training; equipment operators and engineering technicians will be trained at the production site during or after the equipment installation and commissioning process. In addition, engineering and technical personnel receive technical training, and after the equipment installation is completed, they should follow the technical personnel of the installation unit to learn processing task design and steel bar processing and distribution management system software, so as to master steel bar engineering technology and production management control technology as soon as possible.
