Steelway Boosts Beam Welding Productivity with New Robotic Integration

Steelway Building Systems, a leading manufacturer of steel structures based in Elmer, Ontario, faced a familiar challenge in today’s industrial landscape: a shortage of skilled welding labor. Located in a rural area, the company struggled to attract and retain qualified welders, which began to impact throughput and operational efficiency. With a commitment to continuous improvement and product excellence, Steelway’s leadership sought a solution that could not only fill the labor gap but also elevate productivity across its beam welding operations.

Last year at the Fabtech tradeshow in Chicago, Steelway discovered AGT’s advanced robotic welding system, BeamMaster, a game-changing solution capable of rotating beams for full four-sided weld coverage. Impressed by the system’s capabilities, Steelway partnered with the FANUC Authorized System Integrator to bring the technology to their facility.

The goal: automate the welding of three-plate beams to increase output, reduce manual workload and optimize efficiency.

The results were immediate and measurable. The new system allowed Steelway to weld all four sides of a beam without manual repositioning, significantly speeding up production. Welders were redeployed to focus on finishing tasks, while the robot handled the bulk of repetitive welding.

“It’s better, easier to learn, and capable of more welding than our previous system,” said Randy Thiesen, a Steelway robotic weld cell coordinator.

Encouraged by the success of the new BeamMaster system, Steelway expanded by adding a second robot and extending the weld zone by 15 feet, which accommodates beams up to 60 feet long. This dual-zone setup enabled simultaneous welding of long and short beams, maximizing throughput and floor space utilization. The integration with Advanced Steel and Cortex software allowed seamless programming via IFC file exports, streamlining the transition from design to production.

Steelway’s investment in automation has not only addressed labor shortages but also positioned the company for scalable growth. With plans to extend robotic welding into its hot-rolled structural section, Steelway continues to push the boundaries of what’s possible in steel fabrication.

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The future for us is to buy more robots, and we’d like to continue to add on to the ones we have today.

Jake Giesbrecht Director of Product Excellence – Steelway Building Systems