Specialist in bridge and special steel construction: road and rail bridges up to 200 t unit weight from Zwickau.
ZSB Zwickauer Sonderstahlbau GmbH
ZwickauNew on Amplifa
About us
ZSB Zwickauer Sonderstahlbau GmbH specializes in demanding projects in bridge and special steel construction. On its 50,000 m² plant site in Zwickau, the company manufactures steel components for road and railway bridges with unit weights of up to 200 tonnes and processes up to 12,000 tonnes of steel per year. The range of services includes bridges with orthotropic decks, arch, truss, cable-stayed and steel composite bridges as well as doubly prestressed SAM tension-composite girders (PS girders), which have been produced since 1996. The value chain extends from oxy-fuel and plasma cutting through welding (MAG) and CNC machining to preservation in open blast booths with airless coating, complemented by in-house transport up to 50 m in length and 80 t in weight as well as installation including bridge launching. The company is, among others, prequalified with Deutsche Bahn (HPQ per DBS 918005, EXC3DB) and realizes projects throughout Germany.
- Site
- Zwickau
- Processes
- Steel and bridge construction (bridge and special steel construction), Machining (CNC travelling-column milling machines, machining and processing of individual parts and, Bridge construction (bridges with orthotropic deck, arch, truss, cable-stayed and steel composite, Production of doubly prestressed girders (PS girders) / composite precast construction, Steel derusting in open blast booths / blasting (preservation), Coating (airless systems, preservation area), Transport of steel components (up to 50.0 m length and 80 t), On-site installation incl. installation planning, coordination and bridge launching
- Materials
- Steel, Reinforcing steel, Concrete (prestressed concrete foot / concrete cladding)
- Certificates
- DIN EN ISO 9001:2015, ISO 3834-2 (QM welding), EN 1090-2 (welding certificate), EN 1090-1 WPK welding, ISO 17660-1 reinforcing steel welding, HPQ per DBS 918005 (EXC3DB), DB prequalification certificate, PS girder approval notice Z-26.2-65, CE marking bridge bearings, ISO 9001, EN 1090, ISO 17660-1 (reinforcing steel welding), HPQ per DBS 918005 (EXC3DB, Deutsche Bahn), PS girder approval Z-26.2-65 (DIBt), ISO 14001, IATF 16949
- Founded
- 2004
- Industries
- Bridge and infrastructure construction (road and railway bridges), Special steel construction
- 01
Technical design / drawings
- 02
Cutting (oxy-fuel/plasma cutting, sawing, drilling)
- 03
Welding (MAG) / mechanical CNC machining
- 04
Preservation (blasting, airless coating)
- 05
Transport up to 50 m / 80 t
- 06
Installation incl. bridge launching
Materials and processes
Steel
Base material for bridges, girders and special steel construction; up to 12,000 t processed annually.
Reinforcing steel
Processed, among other things, in reinforcing steel welding per ISO 17660-1.
Concrete (prestressed concrete foot / concrete cladding)
Used in the production of doubly prestressed SAM tension-composite girders in composite precast construction.
Locations
Zwickau
DEHeadquarters and manufacturing on a 50,000 m² plant site
- Part weight / size
- Components up to 200 t unit weight
- Materials
- Steel, reinforcing steel, concrete (composite construction)
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Steel and bridge construction (bridge and special steel construction)Assembly | – | – | 200 to | – | Steel |
| Machining (CNC travelling-column milling machines, machining and processing of individual parts andMachining | – | – | – | – | Steel |
| Bridge construction (bridges with orthotropic deck, arch, truss, cable-stayed and steel compositeAssembly | – | – | 200 to | – | Steel |
| Production of doubly prestressed girders (PS girders) / composite precast constructionAssembly | – | – | – | – | Steel, Concrete |
| Steel derusting in open blast booths / blasting (preservation)Surface | – | – | – | – | Steel |
| Coating (airless systems, preservation area)Surface | – | – | – | – | Steel |
| Transport of steel components (up to 50.0 m length and 80 t)Assembly | – | 50.0 m | 80 t | – | Steel |
| On-site installation incl. installation planning, coordination and bridge launchingAssembly | – | – | – | – | Steel |
| Welding (MAG)Joining | – | – | – | – | Steel |
| Oxy-fuel cutting (cutting)Machining | – | 24,000 mm × 4,000 mm | – | – | Steel |
| Plasma cuttingMachining | – | 19,000 mm × 4,000 mm | – | – | Steel |
| Plate shearing (shear cutting)Forming | – | 6,000 mm | – | – | Steel |
| Sawing and drilling (saw-drill line)Machining | – | 16,500 mm × 1,215 mm × 700 mm | – | – | Steel |
| Belt grinding of platesSurface | – | 14,000 mm | – | – | Steel |
| Pressing (hydraulic single-column press)Forming | – | – | 250 t | – | Steel |
45 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC travelling-column machining center | Bimatec Soraluce FP 6000 | 1 | X 6,000 mm, Y max. 2,600 mm, Z 1,500 mm; NC table 3,000 mm x 3,000 mm, max. load 30 t; | – | Zwickau |
| Travelling-column milling and drilling machine | M-ARX FTP | 1 | X 18,000 mm, Y 4,000 mm, Z 1,500 mm; NC table 4,000 mm x 3,000 mm, max. load 50 t; | – | Zwickau |
| Bed-type milling machine | Soraluce TA-A25 | 1 | X 2,500 mm, Y max. 1,000 mm, Z 1,000 mm; NC table 2,700 mm x 850 mm, max. load 5.7 t | – | Zwickau |
| Oxy-fuel cutting machine | ESAB SUPRAREX SXE500 | 3 | Lmax 24,000 mm, Wmax 4,000 mm, T 300 mm | – | Zwickau |
| Plasma cutting machine | ESAB SXE-P 5000 | 1 | Lmax 19,000 mm, Wmax 4,000 mm, T 300 mm | – | Zwickau |
| Oxy-fuel cutting machine | SATRONIK Type 4200 | 1 | L 16,000 mm, W 4,000 mm, T 300 mm | – | Zwickau |
| Hydraulic single-column press | PYE250 | 1 | Press force 250 t | – | Zwickau |
| Plate shear | Darley GS 3116 CL | 1 | L 6,000 mm, W 3,150 mm, T 16 mm | – | Zwickau |
| Saw-drill line (band saw) | Kaltenbach KBS 1301DG | 1 | L 16,500 mm, W 1,215 mm, H 700 mm; saw band 9,800 x 67 x 1.6 mm | – | Zwickau |
| Drilling machine | Kaltenbach KDX1215 | 1 | Drilling diameter 8 – 40 mm | – | Zwickau |
| Belt grinding machine | Krüger | 1 | Plates up to 14,000 mm length and 120 mm thickness | – | Zwickau |
| Belt grinding machine | KF IV-3000 | 1 | Plates up to 3,000 mm length and 100 mm thickness | – | Zwickau |
| Open blast booth | – | 2 | 30 m x 6.5 m x 6.5 m and 30 m x 10 m x 6.9 m (extendable to 40 m) | – | Zwickau |
| Paint and varnish preservation system (airless) | – | 1 | Spray areas of 1,500 m², ventilated (heatable) | – | Zwickau |
| Plate blasting machine | Wheelabrator Schlick Vertical Type Roto-Jet RB 4000 | 1 | max. plate width 4,000 mm | – | Zwickau |
| Profile blasting machine (horizontal blasting machine) | Gietart Sprint 1504 | 1 | – | – | Zwickau |
| Crane systems with crane cross beams | – | – | Load capacity up to 126 t | – | Zwickau |
| Magnetic cross beams | – | – | Load capacity 5.6 t / 8.5 t / 12 t | – | Zwickau |
| Self-propelled transporters (SPMT) | Goliath, David, Herkules, Zeus | 4 | Goliath 130 t, David 130 t, Herkules 200 t, Zeus 200 t load capacity | – | Zwickau |
| Mobile crane | Grove RT600E | 1 | – | – | Zwickau |
| Mobile crane | Grove GCK3045 | 1 | – | – | Zwickau |
| Telehandler | Bobcat T40140 | 1 | – | – | Zwickau |
| Telehandler | Manitou MRT 1640 | 1 | – | – | Zwickau |
| Telehandler | Genie GTH 5022R | 1 | – | – | Zwickau |
| Telehandler | Haulotte HTL 4014 | 2 | – | – | Zwickau |
| Semi-trailer tractor unit | MAN TGX 41.640 8x4 | 2 | – | – | Zwickau |
| Semi-trailer tractor unit | MAN TGX 33.580 6x4 BLS | 1 | – | – | Zwickau |
| Semi-trailer tractor unit | MAN TGX 26.510 6x2 | 1 | – | – | Zwickau |
| Semi-trailer tractor unit | MAN TGX 28.500 6x2 BLS | 1 | – | – | Zwickau |
| Semi-trailer tractor unit | MAN TGX 41.540 8x4 | 1 | – | – | Zwickau |
| Semi-trailer tractor unit | MAN TGX 33.580 6x4 BL SA | 1 | – | – | Zwickau |
| Semi low-loader | Goldhofer 2+6 axles | 1 | – | – | Zwickau |
| Semi low-loader | Ozgul 8-axle | 1 | – | – | Zwickau |
| Trailer combination with rear bogie | Faymonville Flexmax 3+5-axle | 1 | – | – | Zwickau |
| Semi low-loader | Broshuis 4SLA-18-48/1 | 1 | – | – | Zwickau |
| Telescopic semi-trailer | Faymonville Max Trailer 3-axle | 1 | – | – | Zwickau |
| Semi-trailer | Berger 3-axle | 1 | – | – | Zwickau |
| Tarpaulin semi-trailer | Kögel 3-axle | 1 | – | – | Zwickau |
| Platform trailer | Noteboom NL Double-Tele 49-03-V | 1 | – | – | Zwickau |
| Angled loader | Schmidt SANH SPK/38/E/13.6 | 1 | – | – | Zwickau |
| Concrete dolly | Faymonville 3-axle Flexmax Flex-N-3L | 1 | – | – | Zwickau |
| Modular trailer | Faymonville Combimax / 4-axle module | 1 | – | – | Zwickau |
| Articulated truck with loading crane | MAN | 1 | – | – | Zwickau |
| Dump truck | IVECO | 1 | – | – | Zwickau |
| Trailer | Fellechner 2-axle | 1 | – | – | Zwickau |
Additional services
Reference customers
Quality and certifications
Manufacturing is certified per DIN EN ISO 9001:2015 and backed by comprehensive welding qualifications (ISO 3834-2, EN 1090-1/2, ISO 17660-1). The company is prequalified with Deutsche Bahn (HPQ per DBS 918005, EXC3DB) and manufactures PS girders with a general building authority approval (Z-26.2-65, DIBt).
| Evidence | Zwickau |
|---|---|
| ISO 9001 | |
| EN 1090 | |
| ISO 3834-2 (QM welding) | |
| ISO 17660-1 (reinforcing steel welding) | |
| HPQ per DBS 918005 (EXC3DB, Deutsche Bahn) | |
| PS girder approval Z-26.2-65 (DIBt) | |
| CE marking bridge bearings | |
| ISO 14001 | |
| IATF 16949 |
History
- 1839
Foundation of the Saxon Iron Company (Queen Mary Ironworks) at the Cainsdorf site, origin of the 180-year tradition at this location.
- 1873
Works passes to the German Imperial and Continental Railway Construction Company; previously approx. 1,000 bridges manufactured from 1853 to 1873.
- 1996
Start of production of the SAM tension-composite girders (doubly prestressed composite girders) in July 1996.
- 2004
Foundation of ZSB Zwickauer Sonderstahlbau GmbH on 1 December 2004 with 24 employees, spun off from ZM Zwickauer Maschinen- und Anlagenbau GmbH.
- 2005
Takeover of the production facilities of SAM GmbH within the framework of an acquirer concept; approx. 60 employees after relocation.
- 2008
Acquisition of a 6-hectare industrial site (former light metal construction combine Zwickau) with 25,000 m² of production space.
- 2012
Full commissioning of the site at Äußere Dresdner Straße 12.