AUTOMATED REBAR ASSEMBLY
Every concrete structure stands on a rebar cage. These cages carry load, resist stress, and ultimately determine whether a building or bridge endures for decades. Yet for over a century, assembling them has been done largely by hand – relying on the availability of skilled workers, tolerating variation, and accepting the time that manual work demands. As construction grows more complex, project timelines compress, and labor markets tighten, those limitations are no longer sustainable. The industry has outgrown the way rebar cages have always been built.
THAT'S CHANGING NOW
A new approach is transforming how rebar cages are built – and it goes well beyond incremental improvement. By connecting digital design directly to robotic execution, without manual programming in between, the Rebar Assembly Functional Module brings the precision and repeatability of industrial automation to one of construction's most labor-intensive processes. What once required hours of skilled manual work can now be planned digitally, simulated before a single bar is touched, and then executed by a coordinated robotic system. The result is faster production, consistent quality across every cage, and the ability to scale without depending on a shrinking pool of specialist labor.
REBAR ASSEMBLY FUNCTIONAL MODULE IS FOR YOU
If you are responsible for keeping production moving, delivering projects on schedule, or scaling industrialized construction, you already know what is at stake. Demand is rising, timelines are getting tighter, and skilled labor is harder to find than ever. Every new cage design adds a layer of complexity – one more variable that can slow things down or introduce inconsistency across your production floor. The Rebar Assembly Functional Module is built for exactly this environment. It gives you a production process that is controlled, consistent, and designed to scale – so you can meet growing demand without compromising on quality or stretching your workforce beyond its limits. The solution is relevant across a wide range of applications:
HOUSING & COMMERCIAL BUILDINGS, CIVIL INFRASTRUCTURE, PRECAST MODULES
LET REBAR ASSEMBLY FUNCTIONAL MODULE DO THE WORK
DESIGN
- DESIGN
- PLAN
- BUILD
DESIGN
Your cage design is where everything begins. The Rebar Assembly Functional Module works directly from the digital rebar cage model created in your existing design environment – whether that is Tekla Structures, Autodesk Revit, or another BIM-compatible platform. The cage geometry and associated production data become the direct input to the automated assembly workflow, with no need to re-enter or reinterpret the design at any stage in the process.
Within the defined workflow, the BIM model is exported as an IFC file, giving the system everything it needs to understand exactly what needs to be assembled – before a single robot motion is generated.
PLAN
Once the cage design has been imported, the software automatically generates the full assembly sequence and multi-robot motion program – no manual programming required. The path-planning technology calculates precisely how the robots need to move and coordinate throughout the process, accounting for the specific geometry of each individual cage.
Before production begins, the entire workflow can be reviewed and simulated in a digital environment. This allows you to validate the planned sequence and robot motion, catch any issues early, and make adjustments – all before a single bar is handled on the floor. It is a step that significantly reduces the risk of rework and unplanned downtime.
BUILD
With planning complete and the program validated, the Rebar Assembly Functional Module executes the automatically generated robot program on the configured production cell. A three-robot gantry system takes over the physical assembly process – handling, positioning, and tying the rebar until the finished cage is complete. The result is a seamless digital-to-physical workflow in which cage design, planning, and robotic execution are connected in one continuous, automated process.