Intelligent Stirrup Bending and Welding Technology for Reinforcement Processing in Smart Girder Yards

With the rapid development of prefabricated bridge construction, traditional manual bending and welding techniques for stirrups increasingly reveal limitations in efficiency, quality, and safety. To promote intelligent technologies in smart girder yards, this study establishes and reports an automated logistics system covering the entire workflow of bending–delivering–welding–storage for reinforcement processing, alongside key innovations, including an integrated stirrup bending workstation, an intelligent rebar cage welding station, and laser-adaptive seam-tracking technology. The results demonstrate that the system achieves fully automated and standardized construction of rebar cages, achieving 100% compliance in quality parameters (e.g., rebar spacing) while eliminating quality risks. Implementation in the G107 Chinese National Highway retrofit project reduced the site footprint by 27%, labor input by 40%, and construction duration by 60% compared with conventional prefabrication yards, saving CNY 3.38 million per thousand girders and reducing rebar consumption by 50 metric tons. This research provides a replicable technical pathway for intelligent bridge construction and significantly advances the mechanization and digitalization of rebar processing and welding.