Proco, a leading Quebec-based company specializing in steel structure manufacturing, faced a significant hurdle in its production process: the metallization of large bridge girders. This task, essential for corrosion protection, was labor-intensive and hazardous, making it challenging to attract skilled workers. Proco partnered with Robexco, an automation specialist, to implement a robotic metallization system powered by Robotmaster programming software to address this.
Metallization is a process that involves spraying a protective zinc coating onto steel to prevent corrosion. While small steel parts can be dipped into zinc baths, the massive size of bridge girders—some reaching 150 feet long and 15 feet tall—makes traditional galvanizing impractical. Alexandre Blackburn, from Proco, explains the dilemma: “When you have a bridge girder that is 10 to 15 feet tall and 150 feet long, you can’t dip that part in a galvanizing bed, so you must use metalizing to spray zinc onto the surface.”
However, the manual process of metallizing these girders proved inefficient and dangerous. Workers operated in a toxic, dusty environment, often struggling to apply the correct amount of coating due to visibility issues and the physically demanding nature of the job. This challenge made it difficult to find laborers and created inconsistencies in the quality of the coating.
Proco's metallization process had become a bottleneck in production, limiting the number of projects it could complete each year. This situation, combined with a shortage of skilled labor, prompted the company to explore automation. Robexco, a Saguenay-based integrator specializing in robotic automation, provided a solution: a fully robotic metallization system equipped with two KUKA robots and powered by Robotmaster programming software.
The robotic system enabled consistent application of the zinc coating, addressing the problem of uneven coverage in the manual process. Blackburn explains, “With a robotic cell, you tell the robot your travel speed, you spray that amount of zinc, and then it's always the same pattern, the same speed, the same voltage, the same distance to the part.” This consistency was vital in reducing material waste and improving productivity
The Robexco-designed system required a powerful software solution to manage the complexity of metallizing large, irregularly shaped girders. Enter Robotmaster, an offline programming software that allows users to program high-mix, low-volume production runs efficiently. Proco could now import CAD models of each girder and quickly generate precise robot programs without the need for time-consuming manual inputs.
One of the critical benefits of Robotmaster is its flexibility, allowing users to easily adjust programs without starting from scratch. This adaptability was crucial for Proco, as the design of each girder varied significantly, with lengths ranging from 14 to 40 meters.
Additionally, Robotmaster’s simulation environment helped ensure that the robots achieved optimal spray coverage, further enhancing the quality of the coating while minimizing errors. Blackburn elaborates, “We lowered the zinc waste and the zinc consumption by adding a robot with always the same distance and the right angle. We make sure we get the most out of the process.” This reduction in waste translated directly to cost savings for Proco.
Automating the metallization process profoundly impacted both efficiency and employee well-being at Proco. The robotic system, programmed with Robotmaster, made the metallizing step three to four times faster than manual methods. “We’re four times more productive by automating this process than we were doing by hand,” Blackburn confirms.
The success of Proco’s automated metallization system has opened the door to further automation opportunities across its production line. With the metallization process no longer a bottleneck, Proco can now meet production demands more efficiently while maintaining high-quality standards. Moreover, implementing Robotmaster has demonstrated the power of combining advanced robotics with flexible programming software to tackle complex industrial challenges.
Looking ahead, Proco plans to adopt similar technologies in other areas of its value stream, continuing its journey toward full automation. Blackburn is optimistic about the potential, stating, “We see this as an opportunity to adopt similar technology in other areas and further eliminate repetitive tasks.” The company's proactive approach to automation is improving efficiency and reinforcing its reputation as a leader in steel structure manufacturing.
