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Precision Surface Technology for Heavy Steel Fabrication
Automated Blasting and Coating Solutions for Large-Dimension Steel Components
MEKON Metallkonstruktions GmbH, based in Rastdorf (Germany) specializes in the production of large-format and highly load-bearing steel structures. Its product portfolio includes, among other things, lattice constructions such as massive masts and support structures for substations for energy infrastructure, which are used under demanding environmental conditions. Accordingly, the requirements for surface quality and sustainable corrosion protection are equally high.
In order to meet these requirements, MEKON Industriebeschichtungs GmbH & Co. KG, also based in Rastdorf, was founded in 2024. The new company thus expands the existing business division to include precise surface technology.
Against this background, a continuous blasting system designed for industrial series and project production, including a blasting robot as well as two combined spray and drying booths, was realized by SLF Oberflächentechnik GmbH together with MEKON Industriebeschichtungs GmbH & Co. KG. The system ensures both high throughput rates and maximum occupational and process safety. SLF Oberflächentechnik has more than 35 years of experience in the development and manufacture of well-engineered, customer-specific systems for industrial surface technology.
In 2025, MEKON expanded the plant with a new production hall in which the modern surface technology was also integrated. The project is supported by funds from the Lower Saxony Multi-Fund Programme 2021–2027. SLF Oberflächentechnik accompanied and supported the planning from the very beginning.
System Concept: Continuous Process Chain from Blasting to Coating to Drying
The plant technology consists of a large-scale free-blast room with an integrated blasting robot, a ReCo-Blaster® and two combined spray and drying booths. The objective was to realize a media- and air-technology-optimized process chain that enables reproducible surface conditions in accordance with common corrosion protection and coating standards.
Combination of Robotics and Manual Blasting Technology
The blast room has dimensions of 21 m in length and 7 m in width and height. This geometry allows the processing of components with a maximum workpiece size of up to 16.5 × 2.75 × 2.75 m (L × W × H). The system is designed for two-shift operation and enables both automated and manual processing within the same booth. Corundum or steel grit is used as blasting media.
The automated longitudinal conveying system (belt conveyor) and the transverse conveying system with screw conveyor beneath the heavy-duty grating floor transport the blasting media to the recovery system located in the technical room adjacent to the blast room. The generously dimensioned abrasive silo is also located here and is equipped with two chambers for storing the two different blasting media.
A key feature of the blast room concept is the hybrid strategy combining fully automated robotic technology and manual blasting technology. In addition, both operation of the ReCo-Blaster® and manual operation can be easily switched to the gentler sweeping mode. This combination not only increases flexibility in day-to-day production but also enables economical processing of varying workpieces and batch sizes.
ReCo-Blaster®: 8-Axis Blasting Robotics for Large-Format Workpieces
The ReCo-Blaster®, an 8-axis blasting robot specifically designed for large-format, heavy components, is capable of combining high blasting power with precise nozzle alignment.
The kinematic structure is divided into two functional units:
A 3-axis overhead gantry consisting of bridge axis, trolley axis and vertical axis, as well as a compact 5-axis kinematic unit below the vertical axis consisting of rotation axis, shoulder axis, elbow axis, wrist axis and swivel axis.
The gantry axes enable large-area positioning of the robot within the blast room and form the basis for long travel paths along the workpiece geometry.
The 5-axis kinematic unit ensures precise orientation of the blasting nozzle with regard to angle of attack, distance and blasting direction – decisive for uniform surface roughness and reproducible blasting profiles.
All eight axes are synchronously controlled, enabling both large-area path movements and the finest real-time corrections.
Programming and Process Stability
The creation and optimization of blasting programs is carried out using an offline programming system specifically tailored to the plant architecture. This allows motion sequences and process parameters to be developed and tested independently of ongoing operations.
As part of a practice-oriented user training program, the employees of MEKON Industriebeschichtungs GmbH & Co. KG were intensively trained in the process. The training included, among other topics, the creation and adjustment of path programs, optimization of blasting angles and travel speeds, process monitoring and fault diagnosis, as well as maintenance-relevant parameters and wear control.
For automated processing, the components are rail-guided into the blast room. An automatic longitudinal position detection of the workpiece by means of a sensor unit in the ReCo-Blaster® eliminates the need for manual positioning by the operator. As a result, errors are excluded and the time required is significantly reduced.
Spray and Drying Booth: Airflow and Energy Concept
The downstream spray and drying booths, with lengths of 15 m and 18 m respectively, are each 7.3 m wide and 4 m high. The use of two booths allows clear functional allocation of the process steps and thus provides high flexibility and time savings in coating and drying the workpieces.
Thermal System
Heating is carried out via a gas surface burner that heats the booths to the desired temperature without flue gas energy losses. In combination with a heat recovery system, energy consumption is further significantly reduced. This system ensures uniform temperature distribution throughout the entire booth volume and rapid heating and cooling phases for changing production cycles.
Customized System Integration
The entire plant technology was individually planned, manufactured, installed and commissioned in close coordination between the responsible teams at MEKON and SLF. The new plant technology is optimally designed for the production processes of MEKON Industriebeschichtung.
In this project, the SLF system technology was combined with sound-insulated booth enclosures in panel construction as well as large loading and unloading doors – features that can also be realized upon request in individually planned systems.
The result is a scalable and future-proof solution that meets both the high technical requirements and the economic and operational aspects at MEKON Industriebeschichtungs GmbH & Co. KG.cations while ensuring operational efficiency and long-term economic viability.