Color steel roll forming machines are used to produce colored metal roofing and wall cladding from coil stock. This versatile equipment can manufacture panels with complex profiles and surface finishes for architectural and industrial applications.
Overview of Color Steel Roll Forming
Roll forming is a continuous bending process that transforms flat sheet or coil stock into shaped profiles with long lengths. The colored metal coil is fed through a series of roller dies that gradually bend the material into the desired cross-section profile as it moves through the machine.
Key characteristics of color steel roll forming:
- Produces long, continuous colored metal panels up to 50 m in length
- Capable of forming complex and customized profiles
- Forms prepainted, color coated steel and aluminum coils
- Quick changeover between profiles with adjustable rollers
- Automated production with PLC and HMI controls
- Used for roofing, cladding, curtain walls, facade systems
- Output width up to 1250 mm for architectural cladding
- Materials include prepainted galvanized steel, aluminum, copper, etc.
Roll formed profiles have uniform quality and dimensional precision along the length. The color coating provides UV protection, weather and corrosion resistance. Roll formed panels are lightweight yet strong, providing design flexibility for building exteriors.
The prepainted metal coils allow for unlimited colors and finishes like wood grain or metallic. Special coatings can be applied for solar reflectivity or thermal conductivity. Roll formed panels are an economical cladding solution for low and mid rise structures.
Applications of Roll Formed Colored Metal Panels
Roll formed color steel sheets have become a popular choice for cladding and roofing across residential, commercial and industrial structures due to the aesthetic appeal, durability and cost effectiveness.
Some major applications include:
| Application | Description |
|---|---|
| Roofing | Used for pitched roofs and concealed fastener standing seam roofs. Suitable for any roof shape. |
| Wall cladding | Provides exterior rainscreen facade and wall coverings for beautiful exteriors. |
| Canopies | Widely used for entrance canopies, gas station canopies, car port canopies. |
| Partitions | Cost-effective choice for interior partitions and mezzanine floors. |
| Silo, tank cladding | Used for cladding large silos, oil tanks, grain bins for protection. |
| Door panels | Roll formed metal door skins provide security, aesthetics and durability. |
| Architectural features | For aesthetic and functional architectural features like column covers, cornices, sun shades. |
The modular design, quick installation and lightweight nature of the panels make them ideal for both retrofit and new construction projects.
Types of Color Steel Roll Forming Machines
There are two main types of roll forming mills used for color steel panel production:
| Type | Description |
|---|---|
| Single pass machines | Form the profile in one pass through sequential stands. Suitable for high volumes and long panels. |
| Two pass (or double pass) machines | Use two sets of roll stations to gradually form the profile in two passes. Allow more complex, asymmetric shapes. |
In terms of forming direction, there are two designs:
| Direction | Features |
|---|---|
| Horizontal roll forming | Strands move horizontally through rollers to bend the profile. Require less headroom, suitable for long parts. |
| Vertical roll forming | Strands pass vertically through roll stations. Compact footprint, convenient operation. |
Within these types there can be variation in the number of roller stations, forming sequences, roller precision, speeds, and level of automation.
Main Components of Color Steel Roll Forming Lines
A complete roll forming line has several components that work together to feed, form, cut and stack the finished panels:
| Component | Purpose |
|---|---|
| Decoiler | Holds coil stock and feeds into line at set speed. Has straightening rolls to flatten coil. |
| Feed table | Supports and guides sheet through line. |
| Roll forming stations | Progressively bend metal to desired profile. |
| Pinch rolls | Further calibrate and stiffen the formed profile. |
| Shear/cutting station | Cuts panels at predetermined length. |
| Stacker | Collects finished cut panels. |
| Control console | Controls line speed, cut lengths and overall operation parameters via PLC. |
Additional components like punching units, embossing rollers, pressing stations can be integrated for secondary processing operations.
Design and Working Principle
The basic working principle involves passing flat sheet metal through a series of roller dies to gradually bend it into the specified profile shape. Each set of rolls makes a small deformation until the final profile is obtained.
The roll tooling is designed according to the profile geometry and metal properties. The longitudinal forming is continuous while transverse bends are made sequentially. Roller materials and treatments are important for friction control during forming.
The sheet is fed from the coil hold down feeds into the entry guides. It gets center aligned before entering the initial forming rolls. As it passes through each stand it gets progressively formed. Finishing rolls calibrate the profile before end cutting.
Forming parameters like roller dimensions, distances, sheet thickness, strength, line speed are precisely matched to control material flow and springback during bending. Advanced machines can achieve high tolerances up to +/- 0.5mm for panel flatness.
Color Steel Roll Forming Process Specifications
Typical process values for roll forming lines are:
| Parameter | Range |
|---|---|
| Sheet thickness | 0.3 – 2 mm |
| Strip width | Up to 1250 mm |
| Rolling speed | 10 – 25 m/min |
| Profile width | 100 – 700 mm |
| Formed length | 6 – 50 m |
| Roll stations | 10 – 26 |
| Roll barrel diameter | 100 – 250 mm |
| Motor power | 5.5 – 11 kW |
- Materials: Hot-dipped galvanized steel, pre-painted steel, aluminum and copper coils
- Coil ID: 508 mm, 610 mm
- Coil OD: 1200 mm to 1500 mm
- Coil weight: Up to 6 tonnes
Roll tooling is customized as per profile shape and sheet material properties. Roll materials include different steel grades as well as coated rolls and wear-resistant surfacing.
Roll Forming Machine Standards
The main standards governing panel roll forming equipment are:
- ISO 10581 – Test methods for color fastness of coil-coated metals
- ASTM A463 – Standard for steel sheet, zinc coated by hot dip process
- ASTM A755 – Steel sheet, metallic coated for exterior panels
- ASTM A792 – Steel sheet, coated with 55% aluminum-zinc alloy
- EN 10169 – Color coated steel flat products
Standards for collected panels:
- ASTM E1592 – Structural performance of sheet metal roofing systems
- ASCE 7 – Minimum design loads for buildings and other structures
- IBC – International Building Code
Benefits of Roll Forming Colored Sheet Metal
Key advantages of using roll forming for color steel panels:
- High quality, uniform panels with good flatness
- Excellent surface finish and color consistency
- Lower cost than extrusion or other processes
- Ideal for high productivity and large scale production
- Flexible in producing customized and complex profiles
- Quick product development and fast tooling changes
- Consistent mechanical properties along length
- Efficient material utilization with no waste
- Automated process requires less labor
Roll formed panels offer benefits like design versatility, durability, fast installation time and lower lifecycle costs compared to traditional building materials.
How to Choose A Color Steel Roll Forming Machine
Selecting the right roll forming equipment requires balancing production needs, cost considerations and capability. Key factors in choosing color steel roll forming lines:
Production Volume Requirements
Estimated monthly or yearly production volume is the primary determinant for the machine capacity. High volume capacity lines above 1500 tons per month require heavier roll tooling and higher motor power for 24 hour production. For lower volumes up to 300 tons per month, compact roll formers are more suitable and economical.
| Volume | Type |
|---|---|
| > 1500 tons/month | Heavy duty high speed lines |
| 300-1500 tons/month | Standard roll forming lines |
| < 300 tons/month | Light duty compact lines |
Metal Specifications
- Sheet thickness – Thicker sheets above 2 mm need heavy roll tooling. Most architectural panels are below 1.5 mm.
- Sheet width – Common widths are 600 mm, 900 mm and 1250 mm. Wider coils require edge trimming.
- Material grade, coating – Machines can run different materials but this determines roll materials.
- Custom profiles – Complex shapes may require two-pass forming and additional tooling.
Automation Features
Higher automation like automatic thickness and width changeover, profile change with auto-adjustable rollers, PLC recipe control allows quicker production changeovers with less labor. This adds cost but offers more flexibility.entry guides. It gets center aligned before entering the initial forming rolls. As it passes through each stand it gets progressively formed. Finishing rolls calibrate the profile before end cutting.
Forming parameters like roller dimensions, distances, sheet thickness, strength, line speed are precisely matched to control material flow and springback during bending. Advanced machines can achieve high tolerances up to +/- 0.5mm for panel flatness.
Color Steel Roll Forming Process Specifications
Typical process values for roll forming lines are:
| Parameter | Range |
|---|---|
| Sheet thickness | 0.3 – 2 mm |
| Strip width | Up to 1250 mm |
| Rolling speed | 10 – 25 m/min |
| Profile width | 100 – 700 mm |
| Formed length | 6 – 50 m |
| Roll stations | 10 – 26 |
| Roll barrel diameter | 100 – 250 mm |
| Motor power | 5.5 – 11 kW |
- Materials: Hot-dipped galvanized steel, pre-painted steel, aluminum and copper coils
- Coil ID: 508 mm, 610 mm
- Coil OD: 1200 mm to 1500 mm
- Coil weight: Up to 6 tonnes
Roll tooling is customized as per profile shape and sheet material properties. Roll materials include different steel grades as well as coated rolls and wear-resistant surfacing.
Roll Forming Machine Standards
The main standards governing panel roll forming equipment are:
- ISO 10581 – Test methods for color fastness of coil-coated metals
- ASTM A463 – Standard for steel sheet, zinc coated by hot dip process
- ASTM A755 – Steel sheet, metallic coated for exterior panels
- ASTM A792 – Steel sheet, coated with 55% aluminum-zinc alloy
- EN 10169 – Color coated steel flat products
Standards for collected panels:
- ASTM E1592 – Structural performance of sheet metal roofing systems
- ASCE 7 – Minimum design loads for buildings and other structures
- IBC – International Building Code
Benefits of Roll Forming Colored Sheet Metal
Key advantages of using roll forming for color steel panels:
- High quality, uniform panels with good flatness
- Excellent surface finish and color consistency
- Lower cost than extrusion or other processes
- Ideal for high productivity and large scale production
- Flexible in producing customized and complex profiles
- Quick product development and fast tooling changes
- Consistent mechanical properties along length
- Efficient material utilization with no waste
- Automated process requires less labor
Roll formed panels offer benefits like design versatility, durability, fast installation time and lower lifecycle costs compared to traditional building materials.
How to Choose A Color Steel Roll Forming Machine
Selecting the right roll forming equipment requires balancing production needs, cost considerations and capability. Key factors in choosing color steel roll forming lines:
Production Volume Requirements
Estimated monthly or yearly production volume is the primary determinant for the machine capacity. High volume capacity lines above 1500 tons per month require heavier roll tooling and higher motor power for 24 hour production. For lower volumes up to 300 tons per month, compact roll formers are more suitable and economical.
| Volume | Type |
|---|---|
| > 1500 tons/month | Heavy duty high speed lines |
| 300-1500 tons/month | Standard roll forming lines |
| < 300 tons/month | Light duty compact lines |
Metal Specifications
- Sheet thickness – Thicker sheets above 2 mm need heavy roll tooling. Most architectural panels are below 1.5 mm.
- Sheet width – Common widths are 600 mm, 900 mm and 1250 mm. Wider coils require edge trimming.
- Material grade, coating – Machines can run different materials but this determines roll materials.
- Custom profiles – Complex shapes may require two-pass forming and additional tooling.
Automation Features
Higher automation like automatic thickness and width changeover, profile change with auto-adjustable rollers, PLC recipe control allows quicker production changeovers with less labor. This adds cost but offers more flexibility.
Additional Secondary Operations
Integrated punching, drilling, embossing, notching, curling require custom tooling. This expands product range and reduces secondary processing but needs higher initial investment.
Technical Expertise Requirements
Roll forming requires precision tooling design and maintenance skills. Machines with quick change modular tooling and preset recipes simplify operation and reduce expertise needed.
Budget Constraints
Higher production capacity, automation features, and secondary processing increase machine cost. The appropriate investment depends on current needs and growth projections for 5-10 years.
Manufacturer Reputation and Support
Established manufacturers offer better support for designing tooling, installation, training, maintenance and troubleshooting. Quick response and service quality also matter.
Comparing Color Steel Roll Forming Machine Brands
There are many roll forming machine manufacturers to choose from. Here is an overview of leading color steel roll forming machine brands:
| Brand | Location | Features |
|---|---|---|
| Formtek | Taiwan | Max width 1250 mm, heavy duty lines for high volume |
| Superstep | China | Cost effective standard roll lines with good reliability |
| Gasparini | Italy | High precision rollers for architectural profiles |
| DAH CHING | Taiwan | Quality machines with high automation features |
| Metform | Turkey | Wide width capacity up to 1500 mm |
| Samco Machinery | Canada | Customized lines for challenging profiles |
| Rolling Plan | China | Affordable smaller roll lines |
| Bradbury Group | US | Complete high volume production lines |
| Form Process Engineering | China | Two pass machines with universal joint shafts |
| Ernst | Germany | High speed roll forming up to 130 m/min |
When comparing options, production output, line speed, overall construction quality, precision and features relative to cost are key considerations. Reputed brands with many successful installations provide confidence along with good after-sales support in the region. New entrants have to be evaluated for proven capability and reliability before selection.
Cost Analysis of Color Steel Roll Forming Machines
Roll forming equipment represents a major capital investment for producers. Here is an overview of the typical cost structure involved:
| Component | Indicative Cost |
|---|---|
| Basic roll forming mill | $100,000 to $500,000 |
| Roll tooling | $20,000 to $60,000 |
| Decoiler | $15,000 to $35,000 |
| Shearing machine | $10,000 to $25,000 |
| Stacker | $5,000 to $15,000 |
| Controls | $5,000 to $15,000 |
| Total | $150,000 to $650,000 |
- Costs vary based on production capacity, width, automation level and additional secondary processing units.
- Higher speeds above 45 m/min require more powerful AC drives.
- Tooling costs depend on profile complexity based on design time and materials.
- Additional $50,000 to $100,000 for integrated punching, drilling or notching.
- Requires installation and commissioning services costing $10,000 upwards.
- Spare parts inventory recommended at 5% of machine cost.
The cost of roll formed panels is $2 to $3 per square meter depending on order size. Return on investment period typically 1.5 to 3 years for active production. Roll formed panels offer 20-30% material savings compared to sheets.
Overall equipment cost can be minimized by selecting standard roll forming lines without unnecessary features and optimizing tooling design. Used machines are also available at 30-50% discount but have higher risk. Leasing equipment is an alternative financing option.
Installation and Operation
Correct installation and operation procedures are vital for trouble-free functioning and output quality.
Installation
- Floor should be flat and level concrete able to take high loads.
- Provide sufficient space around for safe operation and maintenance access.
- Bolt machine securely on foundation and grout gaps.
- Connect electric power supply according to specified rating.
- Install safety guards and supports.
- Position decoiler and straightener correctly.
- Integrate stacker, shear and other units.
Operation
- Ensure input power supply is stable without fluctuations.
- Thread coil material through the entry guides up to the shear.
- Adjust rollers gradually up to operating gaps as per procedure.
- Set speed, shear length as required. Start with slow jog.
- Monitor panel quality and tune gaps to eliminate defects.
- Carry out regular maintenance for lubrication, adjustments etc.
- Ensure all safety systems function properly.
- Operate as per manufacturer’s instructions.
Proper training and adherence to operational guidelines is necessary for achieving design production rates and expected lifetime.
Maintenance and Troubleshooting
Regular maintenance activities are required for continued smooth functioning of roll lines:
- Clean metal dust and residue from all parts daily using compressed air.
- Lubricate all bearings and moving joints as per schedule.
- Check roller gaps and adjust if not in tolerance.
- Verify all fasteners and couplings are tight.
- Monitor motors, pumps for abnormal noise or temperature rise.
- Inspect electrical connections and cables periodically.
- Replace worn out rollers and forming dies.
- Keep back up stock
Problem: Panel defects like wrinkles, twist, warp, markings
- Check material alignment before entry
- Adjust roll gaps, supports, speeds
- Replace worn forming and finishing rolls
Problem: Excessive noise or vibration
- Fix loose parts, realign couplings
- Check bearing wear, lubricate if needed
- Correct roller parallelism if disturbed
- Balance rotating components
Problem: Motor overload tripping
- Check if forming load exceeds capacity
- Lubricate bearings and guides
- Clean ventilation ducts of motors
- Verify electrical wiring connections
Problem: Hydraulic power unit leakage
- Trace and arrest leaks from hoses, cylinders etc.
- Check pump, valves condition and replace if worn
- Change hydraulic oil filter
Problem: Electrical malfunctions
- Check fuses, breakers, wiring faults
- Measure insulation resistance
- Ensure contacts are clean and tight
- Verify PLC program and inputs
Roll forming machines should be regularly inspected for early detection of potential problems. Support from the manufacturer is recommended for complex repairs. With proper maintenance and operation, color steel roll forming lines provide years of consistent production.
FAQs
What are the key benefits of roll forming for colored metal panels?
The main benefits are high precision continuous production, versatility for complex profiles, superior surface quality, efficient material usage, fast assembly and lower installed cost compared to other panel building systems.
What types of structures use roll formed color steel cladding?
Roll formed panels are ideal for roofs and facades on warehouses, manufacturing plants, aircraft hangars, shopping complexes, sports arenas, commercial buildings, gas stations, institutional buildings etc.
How long does it take to changeover between profiles on a roll former?
On machines with quick change tooling and preset recipes, profile changeover can be accomplished within 1-2 hours. On standard machines with manual setup it may take 4-6 hours.
What is the typical thickness of color coated steel used for roll forming?
Most architectural panels use steel thicknesses between 0.40 mm to 0.80mm. Heavier 1 mm sheets are used for industrial cladding or silo panels.
What is the maximum length that can be produced by roll forming coils?
Standard roll lines produce 6 meter to 15 meter panels. Long length lines with special configurations can produce up to 50 meter panels in a single continuous length.
How many color or finish choices are available for roll formed products?
There are over 200 standard colors and finishes like wood grains and metallics available from leading coil coaters. Custom colors can also be produced.
What happens if the roll former stops unexpectedly during production?
If the line stops for a brief period, the partially formed panel moves back due to elastic recovery. A new sheet end has to be rethreaded through the machine to restart.
How to calculate the roofing panel requirement for a building?
Multiply the total roof surface area by 1.15 to 1.3 to account for overlaps. Divide this by standard panel width to get number of panels. Add 5-10% extra for wastage, cutting and stock.
What are the maintenance tasks required on roll formers?
Daily cleaning of metal dust, regular lubrication of moving parts, inspection of wear items like bearings and rollers, observation of noise and temperature and periodic replacement of worn components.
Conclusion
Color steel roll forming lines enable economical production of precision metal panels with high quality finishes for architectural cladding and roofing needs. Selecting equipment with appropriate capacity, features and cost based on production requirements, coil specifications and budget allows manufacturers to profitably venture into this growing construction material segment. With proper installation, operation and maintenance, these versatile machines can deliver high productivity and low cost colored metal panels.