A Stapu steel construction specialist at work with solid metal components in a production hall. The worker is wearing protective equipment and inspecting a vertically positioned steel plate.

50+ years of experience in metalworking

Although we specialize in the design and construction of counterweights, we also develop and manufacture many other steel structures, such as tanks, machine enclosures, base plates, etc. Unlike many of our competitors, our facilities are designed to handle large dimensions. It goes without saying that we work with millimeter precision even on large-scale projects. Even if you need something very specific, please contact us.
In steel construction, we cover the following techniques and dimensions:

Design

With our experienced design team of 7 employees, we use modern 2D and 3D CAD software to plan and design components exactly according to our customers’ specifications. When creating the drawings, we are also happy to take into account, upon request, all factors that will make the subsequent construction of the project as efficient and cost-effective as possible.

Mechanical Processes

At our facilities in Germany and Romania, we have equipment for a wide variety of machining techniques, such as:

Cutting Methods

  • Oxy-fuel bevel cutting
    Our oxy-fuel cutting systems are designed for material thicknesses between 5 and 200 mm. The sheets can have a length of up to 8000 mm and a width of up to 4000 mm.
    Our system for robotic oxy-fuel beveling is suitable for sheet metal thicknesses up to 100 mm and a maximum workpiece length of 5,000 mm and produces dimensionally accurate flame-cut parts based on your CAD drawings.
  • Laser Cutting
    Our high-precision CNC laser systems can cut sheet metal with a thickness ranging from 1 to 25 mm.
    If the workpiece is to be chamfered, the maximum sheet thickness is 15 mm. Our high-quality 6 kW CO₂ laser cutting systems can process sheet metal in sizes up to 2,500 mm x 8,000 mm. Possible cut parts include strip and quarto sheets.

Mechanical or thermal
machining­processes

  • MIG, MAG, TIG, and pulse welding
    We have equipment for manual and robot-assisted welding certified to EN 1090-2 EXC3 and for ­welding of fine-grained steels up to S960.
  • Drilling and thread cutting
    Our radial drilling machine cuts threads up to M 42 and drills holes with a diameter of up to 60 mm.
  • Straightening
    Our straightening press, with a pressing force of 200 metric tons, enables us to straighten steel up to 30 mm thick.
  • CNC Milling
    Our CNC-controlled milling machines enable precise and accurate machining of workpieces measuring up to 8000 x 4000 x 3000 mm.
  • Chamfering
    Our CNC press brake has a maximum pressing force of 600 metric tons, with a possible bend length of 4,000 mm and a maximum sheet thickness of 15 mm. This press can achieve angles ranging from 5° to 90°. Using computer-aided design, we can calculate and implement even the most complex forming operations for our customers.

Forming

  • Press Braking
    Our CNC press brake has a maximum pressing force of 600 metric tons, with a maximum bend length of 4,000 mm and a maximum sheet thickness of 15 mm. This press can achieve angles ranging from 5° to 90°. Using computer-aided methods, we can calculate and execute even the most complex forming operations for our customers.
  • A high-performance industrial robot carrying out automated oxy-fuel bevel cutting on thick steel sheets. An employee wearing protective clothing monitors the process of precision flame cutting in the workshop.
  • A computer-controlled laser cutting machine is processing a thick steel plate in the Stapu workshop. The laser’s bright spot and the precise cut highlight the modern technology used in shaping heavy components.
  • Stapu employees programming a CNC-controlled machine in the production hall. The picture shows one of the steps involved in mechanical machining processes such as milling or thread cutting.
  • A heavy-duty industrial machine is bending a solid steel plate in Stapu’s production hall. The focus is on the precise shaping of the thick material and the enormous force involved in this forming process.

Surface Treatment

Steel components must be protected against corrosion. That is why we have three painting facilities capable of painting components weighing up to 63 metric tons. For painting, the necessary pretreatment, and the finish ­, our plants offer the following technical capabilities:

  • Sharp-Grain Blasting
    To prepare surfaces for painting, we have a blasting­system in which we can treat components up to 16 m in length with sharp-edged material to SA 2½ grade. Other blasting classes can, of course, also be provided upon customer request.
  • Filling and Shaping
    To achieve a flawless surface, we have specialists who focus on filling and shaping to fulfill your design requirements.
  • Painting
    With our three painting systems, we can apply a two-component wet-painting process to components weighing up to 63 metric tons, protecting these components from chemical, thermal, and mechanical influences.
  • Markings and Effects
    We fulfill individual customer requests—such as custom markings or the application of company logos—either using plotted stencils during the painting process or by applying vinyl wraps afterward. You can choose colors from the ­entire RAL palette.
    We also offer a range of gloss levels to bring your design vision to life.
  • An employee of Stapu GmbH & Co. KG, wearing protective clothing, is applying a primer to a solid steel component. The even coat of paint protects the material from corrosion and prepares it for industrial use.
  • A yellow counterweight, already primed, in the workshop. The uniform surface coating protects the solid steel component from external influences.
  • A close-up of an employee carefully peeling the white protective film off a large black numeral on a component. The image illustrates the precise, detailed work involved in the final marking and numbering of industrial products.

Quality Control

Our goal is to deliver the highest quality, which is why a team of materials testers continuously ensures that our products meet the most stringent requirements. To ensure comprehensive testing and flawless results for our components, we use a variety of tests and inspection methods:

  • Eddy current testing (ET)
  • Magnetic particle testing (MT)
  • Visual inspection (VT)
  • Ultrasonic testing (UT)
  • Non-destructive material testing
  • An employee of Stapu GmbH & Co. KG is checking the dimensions of a solid steel component using a precision measuring tool. This meticulous inspection ensures that every counterweight complies exactly with the customer’s specifications and safety standards

Shipping and Logistics

Our logistics team is always available to answer any questions you may have regarding loading and shipping and will take care of all the details. Upon request, we’re also happy to handle customs clearance and deliver your products just in time.
Thanks to our long-standing partnerships and the resulting relationships with a wide variety of logistics companies, we can always offer you a customized solution for shipping your products.

  • Loading of a fully machined and painted counterweight on the factory premises. The photograph illustrates the handling of heavy loads as part of the logistics chain.