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From 94.5% to 99.6% Utilization: How Triple Optimization Cuts Rebar Waste
CHITUO Engineering Team · 2026-11-04
Key Engineering Takeaway
Chituo's Automated Straight-Rebar Smart Line combines mill-length procurement optimization (comparing 9m, 12m, and custom mill lengths), ≥30cm mixed long-short bar nesting, and 50-pocket sorting to boost material utilization from ~94.5% to ~99.6%.
1. Why Manual Rebar Shops Lose Over 5% in Offcuts
When a project requires high volumes of 5270 mm (5.27 m) main bars, cutting from 9000 mm stock leaves 3730 mm per bar, while cutting two pieces from 12000 mm stock leaves 1460 mm per bar. Because conventional spaced rollers drop short bars under 1.5m, crews avoid mixed short-bar nesting.
2. Triple Optimization: Procurement, Cutting & Pocket Scheduling
| Layer | Manual Shop Practice | CHITUO Industrial Robot Line | Practical Impact |
|---|---|---|---|
| 01. Mill Procurement | Fixed 9m or 12m stock | Evaluates 9m, 12m, and custom mill lengths (e.g., 10.54m) | Eliminates predictable main-bar offcuts at the source |
| 02. Mixed Nesting | Avoids short cuts | Nests ≥30cm short bars onto tail remnants | Gapless chain bed transfers every piece automatically |
| 03. Pocket Scheduling | Manual stacking & counting | Maps cuts to Pockets #01–#50 | Reconciles physical stock with financial books in real time |
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