11/11/2025
Industrial Precast: the Flexible Alternative to Welded Mesh
In industrial precast, the decision to use welded mesh or bars, stirrups, and shapes has a direct impact on workflow organization, production times, and quality control of the final product.
When welded mesh is not used, production usually starts from coil or straight bars, which are then processed into stirrups, subsequently assembled according to the specific requirements of the project.
For these cases, Schnell offers a production setup designed to optimize cutting, bending, and assembly operations, consisting of a cutting bench and Robomaster (or the Bar Wiser 28/32), a stirrup bender, and the IDEA assembling machine.
Discover how to optimize the production of bars, shapes, and stirrups for industrial precast!
In the precast industry, the reinforcement of concrete elements can be produced in different ways, and precasters’ needs vary depending on the chosen production method.
While some precasters prefer the use of welded mesh, others decisively opt for bars, shapes, and stirrups, a flexible solution that ensures efficiency and maximum customization.
Those who choose to assemble pre-shaped elements (bars, shapes, and stirrups) often do so to overcome certain challenges:
- difficulties in handling and storing welded mesh
- high costs associated with purchasing and adapting custom-made mesh
- excessive dependence on external suppliers.
Assembly is the key to optimizing the process
Precasters who choose not to use welded mesh generally start their production from straight bars and coil.
In this case, Schnell offers a complete plant, made up of machines specifically designed to simplify and streamline the production process.
A system that optimizes cutting, manages bending, produces stirrups, and enables the pre-assembly of cages quickly and accurately, ensuring workflow continuity and high quality of the finished product.
These solutions include:
- Cutting bench (BAT), for cutting bars to length
- Bender, for processing cut bars
- Stirrup bender, for stirrup production
- IDEA cage assembling machine, for cage pre-assembly
The IDEA system is the real game-changer of the entire process: it enables the precise positioning of stirrups, creating a rigid and stable pre-structure even before the longitudinal bars are inserted.
At the same time, required by traditional methods to mark the bars and manually place the stirrups, IDEA produces true pre-cages.
Moreover, unlike conventional methods, the pre-assembled structure with IDEA is already self-supporting, reducing the number of ties required by up to 80%. The tying process becomes significantly faster: only one tie every 3–4 intersections is needed instead of one at every joint.
This results in doubling the amount of rebar assembled per hour, while ensuring superior quality standards.
The outcome is a reinforcement cage that is more stable, precise, and faster to produce. And in the precast industry, shorter production times combined with higher quality represent a decisive competitive advantage.
Robomaster: How to automate production
For plants aiming to further increase productivity, integrating the Robomaster bending robot into their production line is a strategic choice.
It automates bar processing, reduces the need for manual labour, and boosts overall output.
A concrete solution for industrial precast production
Choosing a system based on bars, shapes, and stirrups and producing them in-house with a plant composed of a Cutting Bench, Stirrup Bender, IDEA Cage Assembler, and Robomaster, is a proven configuration tailored to the needs of industrial precasters.
A simple solution, adaptable to production requirements, ideal to meet tight deadlines, ensure reinforcement quality, and keep costs under control.
With decades of experience in rebar processing and precast technologies, Schnell Group – AWM provides advanced solutions to support every project.
