10/24/2025
From Custom Girders to Optimized Production: The Next Step in Prefabrication with Girderflex
In the production of precast slabs and double walls, the variety of lattice girders required can significantly complicate the manufacturing process, as multiple types must be managed, large storage areas are occupied, and high costs are incurred due to inventory and scrap.
Girderflex was designed to address these challenges: a plant capable of producing customized lattice girders directly from coil, with automatic just-in-time adjustments.
A single system to streamline production, improve efficiency, and reduce waste.
Find out how to optimize lattice girder production for precast elements!
In the precast industry, production efficiency also depends on the smart management of structural components. One of these is the lattice girder, a key reinforcement element in slabs (such as predalles floors) and double walls. Its role is crucial: ensuring the stability and strength required for precast elements to withstand transport, handling, and on-site installation.
However, due to the variety of structural requirements they must meet, lattice girders can vary in height, wire diameter, and overall dimensions.
For this reason, a precast manufacturer typically has to manage up to 20 different types of lattice girders, with all the consequences this entails in terms of logistics, warehouse organization, and costs.
The Challenges of Traditional Production
The traditional method involves purchasing lattice girders in various heights and diameters, which are then stored and cut to size using either manual or automated systems.
This leads to:
- Occupying large warehouse areas, needed to manage each girder type;
- The need to maintain large inventories of every size;
- High production waste, due to cutting standard bars to length;
- Constraints in production management, as it must be planned according to available stock.
In this complex scenario, Girderflex represents a real breakthrough.
Custom Girders, Just-in-Time Production
Girderflex is the plant developed by AWM – Schnell Group for the automatic and just-in-time production of girders directly from coil.
It ensures maximum flexibility and smart integration into the production line, thanks to:
- Real-time adjustments of girder height;
- The ability to work with different wire diameters depending on the project;
- The option to produce girders in the desired length, reducing waste;
- Just-in-time production of girders directly in line, eliminating the need for large warehouses and simplifying logistics.
A New Production Model
Girderflex makes it possible to produce girders for floor slabs and double walls without interruptions or machine changes. This significantly improves production management and allows immediate adaptation even to variable batches and special requests.
Another advantage is the patented AWM – Schnell Group system for producing girders with a "short" top wire, meaning no protruding ends.
This results in:
- Steel savings, through reduced material usage
- Increased safety on site by avoiding sharp ends and reducing accident risks
Less Waste, More Efficiency
With Girderflex, precasters can drastically reduce warehouse stocks, optimize cutting, and minimize downtime.
Girder production becomes a customized, automated, and highly integrated process, a concrete solution for those seeking quality, flexibility, and cost savings in a single machine.
