Koch builds XXL drawing system for pre-stressed concrete steel wire

Compact and enormously powerful: a new machine with nine 1,200 mm drawing capstans produces high-tensile, pc wire 3 to 7 mm– and unlocks new quality territory.

“The queen of wire drawing machines” is what they’re already calling it inside the company. They’re referring to an imposing pre-stressed steel wire drawing system that Koch has recently completed on behalf of a client. This nine-block machine produces wire of diameters between 3 and 7 mm in the highest quality, and at impressive speeds. Newly designed drawing capstans with a diameter of 1,200 mm work in conjunction with an efficient cooling system inside the drums – a feature which was itself developed by this world-leading manufacturer of wire drawing machines.

This drawing machine can handle wire of up to 16 mm in diameter, with incoming strengths of 1,200 N/mm². The end product is wire in a diameter range of 3 to 7 mm and strengths of up to 2,000 N/mm2. The stability and elasticity of this wire makes it ideal for use in reinforcing bridges, high-rise blocks and other challenging structures. Like many other Koch systems, this one is controlled using OTA technology, enabling it to achieve the best possible technical specifications in the end product. Automatically regulated direct backpull without dancer rollers or any other deflection also simplifies the machine’s operation.
Koch took into account the high tensile forces produced during operation when it designed the machine and its electrical drives. The drawing machine and its motors alone weigh 75 tons and its driving power is more than a megawatt. “Big drawing capstans combined with efficient block cooling achieve record speeds and quality,” explains Georg Floren, authorized signatory and Head of Product Management at Koch. A gimballed adjustment system in the newly designed die holders achieves optimum directional results. Another feature is a newly developed, horizontal rolled wire pay-off with an integrated feed system and a protective wire diverter at the pay-off.

Big in size, big on results: “We’ve been building this type of machine for years, but this particular one sets a new benchmark,” believes Georg Floren. Operators will notice the difference. The machine can be quickly refitted, which saves time in the production process. Its guide rollers have been simplified by Koch’s designers and can be employed flexibly. A compact gearbox design has allowed the system to be built for ergonomic operation.

Koch manufactured the machine in its own production facilities, allowing engineers to monitor every single step of its manufacture. “Our customers will find safety and reliability built into this machine, because we’ve only used components from top-level suppliers,” explains Georg Floren. The pre-stressed steel wire line has added an especially high-performance new product to the company’s portfolio. Koch’s product range includes single-block machines, multiple drawing systems and cold rolling and stretching machines.

As a full system supplier that offers a high level of service, Koch supplies and installs complete plants for the manufacturing of wire, including all components. Based in Hemer-Ihmert, the company is also a pioneer in developing groundbreaking processes for quality assurance and process optimization. Customers in more than 60 countries appreciate the family company’s ability to innovate technologically, as well as its values and service outlook.

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