Walcarius makes smart connections for steel structures with 3D tube laser

With the machining and joining capabilities of 3D laser cutting, the Belgian metal construction company Walcarius wanted to distinguish itself in the world of steel construction. With a large-format tube laser from BLM GROUP, the company delivers high-precision 3D-cut profiles that can be used to assemble structures without welding. "Our dream is to create a kind of construction kit for the steel construction market," says Francis Walcarius, one of the managers of the family business.

To respond to market demands, strategic investments in large format sheet metal working machines have always contributed to the company's growth in the past. It was precisely the enormous boost that 2D laser cutting on large plate sizes gave to the speed and accuracy of cutting plate runs that prompted brothers Philippe and Francis Walcarius to think about being able to do the same for processing large format tubes and profiles. This desire led to the investment in an LT24 tube laser from BLM Adige SYS, part of the BLM GROUP. 

"With the ability to laser cut holes and complex contours up to a maximum diameter of ø 610 mm pipe, tubes up to 500 x 300 mm and IPE500/HEA400/HEB300 profiles, we immediately made the distinction in the market," Francis Walcarius explains.

All operations in one process run

Whereas in steel construction drilling/sawing machines are mainly used for making holes and cutting off tubes, tubes and profiles, the use of a 3D tube laser is still an exception. Drill/saw lines in general are limited in the dimensions of drill holes, the maximum miter angle of 45º, do not offer the possibility of making contours and slotted holes. Making slotted holes and contours requires follow-up operations on a plasma cutter and or milling machine, which takes extra time and comes at the expense of accuracy. A tube laser can perform all those operations at high speed in a high, repeatable accuracy in one process run. "Cutting holes, contours and penetrations the tube laser does in seconds," stresses the business manager. "So one tool for all holes and geometries, with the advantage of shorter lead times in production and less travel on the shop floor."

• Connecting without welding

What Walcarius saw further opportunities for the steel construction industry in particular were the possibilities of 3D laser cutting to assemble structures. "Where previously attachment lips had to be welded onto a column to attach beams, we now do that with tongue-and-groove or man-woman connections. With these, in practice, the parts fit together exactly without the need for welding. This offers totally new connection possibilities for steel construction. So much so that we are developing all kinds of structures ourselves, such as carports that the customer can assemble as kits, which can be connected without welding and are also lighter. But even complex constructions for commercial buildings, such as roofs, bridges, skylights, etc., can be precisely fitted and assembled faster using the potential of the tube laser. We will have to show that to the architects in particular".

Pass on price advantage to customer

By investing in 2D and 3D laser cutting systems, the metal construction company manages to produce faster, reduce delivery times and pass on a price advantage to the customer. "However, the customer does not only compare on price, but also on delivery time, assembly time and durability. Other sectors saw the advantages of construction earlier and can now turn to several suppliers for laser cutting in smaller dimensions up to ø 200 mm. Yet we are also seeing OEM companies from the agri-food sector contact us with cutting work for tube frames." 

New business

The investment in the BLM 3D tube laser has brought more work for Walcarius. Especially from new customers. "Due to the high speed, we process more steel per day, the number of orders has increased significantly, and we process 5,000 tons of plate, tube and profile per year," concludes the business manager. ■