Corrugated roof panels made of sheet metal are a popular roofing solution for industrial, commercial and agricultural buildings. Corrugated sheet metal is lightweight, durable, easy to install and provides excellent drainage. These corrugated metal roof panels are manufactured on specialized roll forming equipment.
This comprehensive guide will provide a deep understanding of corrugated roof panel roll forming machines. We will cover:
- Overview of the corrugated roof panel roll forming process
- Types of corrugated roof panel profiles and standards
- Key components and working principles
- Specifications and parameters to consider
- Major manufacturers and suppliers
- Estimated equipment cost and pricing
- Factors influencing corrugated sheet roll forming machine selection
- Installation, operation and maintenance considerations
- Pros and cons of corrugated metal roof panel roll forming lines
Let’s get started!
Overview of Corrugated Roof Panel Roll Forming
Roll forming is a continuous bending operation in which sheet or coil material is passed through consecutive sets of rollers to shape the material into a desired cross-section profile.
Corrugated metal roof panels with sinusoidal Wave shapes are commonly formed by roll forming machines. The corrugated profile provides excellent stiffness and load bearing capacity compared to flat sheets.
A typical corrugated roof panel roll forming line contains:
- Uncoiler and guiding equipment
- Shearing or slitting station
- Entry guides
- Forming rolls
- Corrugation forming stations
- Cutoff press
- Exit guides
The sheet or coil material gets gradually bent into the corrugated shape by passing through the different stations sequentially. The profiles are finally cut to length before stacking.
This continuous process enables mass production of corrugated roofing sheets with a high output rate. The roll formed corrugated sheets provide consistent quality and dimensional accuracy.
Next, we will look at the commonly used corrugated profile types and standards.
Corrugated Roof Panel Profiles and Standards
There are some standard corrugated profiles that are most commonly formed by these machines. The key corrugated roof sheet profiles are:
|Standard||Most common symmetrical single wave profile with ~3″ wave height|
|5V Crimp||Single wave with more depth, ~5″ wave height|
|Box Rib||Double wave symmetrical profile|
|Widespan||Shallow, wide single wave for longer spanning sheets|
|3/4″ Corrugated||Smaller wave for fine corrugation|
Some of the major governing standards for corrugated metal panels are:
|ASTM A792||Covers steel sheets with corrugated profiles|
|ASTM A463||For aluminum corrugated sheets|
|AS/NZS 2728||Australian / New Zealand standard|
|IS 277||Indian standards for corrugated sheets|
|BS EN 494||British standard specifications|
Manufacturers design the roll forming machine according to the profile shape and dimensions specified in these standards. The forming rolls are machined precisely to form the required corrugation profile havig standard wave geometry.
Now, let’s understand the key components of a corrugated roof panel roll forming machine.
Key Components of Corrugated Roof Panel Roll Forming Machines
Corrugated sheet roll forming lines contain a sequence of functional elements assembled in a logical order. The major components are:
|Decoiler||Holds sheet coil, allows unwinding|
|Feeder rolls||Feeds metal sheet into the line|
|Positioning rolls||Aligns sheets before forming|
|Slitter||Trims sheet edges or slits coil|
|Guiding rolls||Guides sheet through each station|
|Forming rolls||Bend sheet in stages into corrugation|
|Corrugating rolls||Forms the wave profile|
|Hydraulic station||Applies pressure for shaping|
|Cutoff shear||Cuts corrugated sheets to length|
|Stacker||Collects cut sheets|
|PLC Control||Controls automation and parameters|
The roll forming machine gradually forms the sheet by bending it in incremental steps using a series of rolling stations. The rotating forming rolls continuously apply pressure to deform the metal until the corrugated shape is achieved.
The corrugating station uses special rolls for creating the wavy profile. It may consist of a male-female roll arrangement.
Hydraulic pressure can be applied by presses at the corrugating station to get the required deformation. Guide rolls accurately position the sheet as it proceeds through the roller sets.
The line is operated and monitored via a PLC-based control system. It allows adjusting forming parameters and machine speed for the desired output.
Next, we will go over the key specifications and parameters for these machines.
Key Specifications and Parameters of Corrugated Roof Panel Roll Forming Lines
The corrugated roll former is customized to produce the desired sheet metal profile to required dimensions and tolerances. Here are the key specifications considered:
|Forming Speed||10 – 25 m/minute|
|Sheet Thickness||0.3 – 2 mm|
|Sheet Width||800 – 2100 mm|
|Wave Height||50 – 150 mm|
|Wave Pitch||175 – 300 mm|
|Wave Shape||Sinusoidal, curved, triangular|
|Roller Diameter||100 – 250 mm|
|Roller Material||Steel, CFE|
|Number of Stations||8 – 16|
|Cut Length||1000 – 10000 mm|
|Production Rate||150 – 1200 sheets/hour|
- Speed: High forming speeds of 15 – 25 m/min are used to maximize output.
- Thickness: Rolls can form thin sheets up to 2 mm thickness. Thicker gauges possible through customization.
- Width: Standard sheet widths from 800 to 2100 mm are used. Wider coils require slitting.
- Wave size: Wave height and pitch determine the profile geometry. 50-150 mm height and around 250 mm pitch are typical.
- Roller size: Roll diameters between 100-250 mm are commonly used. Bigger rolls allow longer service life.
- Stations: More stations distribute bending gradually for better quality. 8 to 16 stations are generally used.
- Cut length – Sheets up to 10 meters long can be produced by adjusting the cutoff press.
- Output rates – Production capacity ranges from 150 to 1200 sheets per hour based on the profile.
Next, we will look at the major corrugated roll forming equipment manufacturers.
Major Manufacturers of Corrugated Roof Panel Roll Forming Equipment
There are a number of leading corrugated sheet roll former manufacturers across the world. Some of the major vendors are:
- Machine maker, ZUANI, Epic offer economical Chinese machines.
- European companies like Gasparini, Dah Chong, Entec provide premium European and Korean machinery.
- Metform and Rollformer also export good quality equipment.
- German company Goebel offers high precision roll forming lines.
It is recommended to choose an established manufacturer having relevant experience, proven machine quality and good after-sales support.
Next, let’s look at the estimated equipment cost.
Corrugated Roof Panel Roll Forming Machine Costs
The price range of corrugated sheet making lines is influenced by:
- Type of profile
- Production speed
- Sheet width
- Level of automation
- Optional accessories
- Buying location
Here is an overview of price range:
|Machine Rating||Price Range|
|Small||$40,000 – $80,000|
|Medium||$80,000 – $150,000|
|Large||$150,000 – $250,000|
- Small machines for waves up to 75 mm height and 1 m width cost $40,000 to $80,000.
- Medium range machines for standard 1.5 m widths and common profiles cost $80,000 to $150,000.
- Large high speed lines for sheets above 2 m wide and complex profiles cost $150,000 to $250,000.
- Extra large multi-profile industrial lines with high automation can cost over $250,000.
- Chinese machines are around 30% cheaper than European equipment for similar specifications.
- Second hand refurbished machines are available at 50% lower cost.
- Additional 10-15% cost for shipping, installation and commissioning.
- After-sales service contracts, spare parts are charged separately.
We will next look at the factors to consider when selecting a corrugated sheet making machine.
Selection Criteria for Corrugated Roof Panel Roll Forming Equipment
The key aspects to evaluate when choosing a corrugated profile roll forming line are:
|Required profile||Match machine to profile dimensions|
|Material grade||Specify material thickness, coating, hardness|
|Production rate||Match speed to monthly output requirement|
|Sheet width||Standard 1-2 m widths or custom wider|
|Wave tolerance||Specify max allowable variation|
|Automation level||Manual to fully automated lines|
|Line flexibility||Quick changeover between profiles|
|Serviceability||Ease of maintenance and service|
|Reliability||Reputation for robust durable equipment|
|Manufacturer||Technology level, experience, support capability|
|Total cost||Equipment cost, shipping, installation, training|
- Firstly, the profile dimensions must match the application roofing sheets needed.
- The line must be suitable for forming the specified material grade and thickness.
- Production speed should match the monthly or yearly output capacity needed. Speed can be increased later by upgrades.
- Standard sheet widths of 1-2 meters are commonly used. For wider coils, slitting may be needed.
- For high quality, tolerance on wave dimensions should be specified, for example ± 0.5 mm
- Level of automation selected based on production volumes and cost.
- Flexible machines allow quick profile changeovers with minimum setup time loss.
- Opt for rugged heavy-duty equipment with reliability guarantees from maker.
- Choose reputed manufacturer with proven experience in corrugated profile forming applications.
- Consider total delivered cost including loading, shipping, installation help given.
Next, we will go over the installation and operation guidelines for these machines.
Installation and Operation of Corrugated Roof Panel Roll Forming Equipment
Proper installation and operation practices are required to achieve top performance from the corrugated sheet making line. Here are some key guidelines:
|Site preparation||Ensure sufficient space, power supply, earthing|
|Unloading||Use forklifts, cranes to carefully unload|
|Positioning||Keep adequate access space around machine|
|Leveling||Use shims to accurately level forming line|
|Commissioning||Electrician to complete power, sensor connections|
|Trial runs||Initially run at low speed with reject sheets|
|Parameter tuning||Gradually optimize roll pressures, positions, speeds|
|Staff training||Train workers thoroughly for each work station|
|Operation||Follow SOPs for startup, running, shutdown|
|Safety||Implement lockout/tagout, emergency stop buttons|
- Carefully prepare installation site, provide cranes, tools.
- Unload elements safely, avoid damage.
- Position line on robust foundations, leaving sufficient access space.
- Precision level the machine frame for smooth running.
- Commissioning must cover all mechanical, electrical, pneumatic connections.
- Conduct trial runs initially at low speeds of 10-15 m/min to stabilize process.
- Adjust operating parameters until desired quality achieved.
- Train staff fully on equipment operations, safety, maintenance.
- Strictly follow standard operating procedures.
- Install safety guards, interlocks and allow only authorized access.
Proper maintenance practices are also required for reliable functioning.
Maintenance Practices for Corrugated Roof Panel Roll Forming Machines
Regular preventive maintenance is key for trouble-free operation of corrugated profile forming equipment. Here are some key maintenance guidelines:
|Inspections||Daily checks for abnormalities|
|Roller wear||Replace rolls when surface wears out|
|Roller balancing||Re-balance or replace unbalanced forming rolls|
|Roller lubrication||Use light mineral oils or grease|
|Fastener tightening||Re-tighten any loosened bolts or fittings|
|Alignment||Realign forming rolls if sheet shifting observed|
|Hydraulics||Inspect hoses, cylinders, check oil|
|Electricals||Check cables, sensors, motor condition|
|Drive lubrication||Grease gearbox bearings and chains|
|Chain tension||Adjust chain tension if needed|
|Cleanliness||Keep equipment clean, remove metal dust|
- Perform daily inspections and observation of any abnormalities.
- Monitor roller surface wear and resurface or replace as needed.
- Re-balance or change worn rolls causing vibration.
- Apply light lubricating oil on rolls periodically for smooth rolling.
- Ensure all station bolts, drives, chains are fastened firmly.
- Realign forming rolls if sheet position gets offset during forming.
- Inspect hydraulics – hoses, cylinders, reservoirs regularly.
- Check electrical connections, sensors, motors and repair if needed.
- Lubricate gearbox bearings, drive chains periodically.
- Adjust chain tension if looseness develops.
- Always keep equipment in clean condition. Remove metal dust and particles frequently.
Next, we look at the pros and cons of corrugated profile roll forming machines.
Advantages and Limitations of Corrugated Roof Panel Roll Forming Lines
Some of the main benefits and limitations of corrugated sheet making roll formers are:
|High production speed||High initial investment|
|Low operating cost||Limited to light gauge sheets|
|Consistent quality||Limited profile shape flexibility|
|Dimensional accuracy||Significant maintenance|
|Simplified material handling||Process fine-tuning needed|
|Compact layout||Skilled operators required|
|Versatile performance||Significant noise level|
- High forming speeds around 25 m/min maximize output.
- Low operating costs due to electric drives and minimal wastage.
- Consistent and uniform profile quality achieved.
- Close dimensional tolerances and repeatability obtained.
- Coil feeding simplifies material handling.
- Compact layout reduces space needed.
- Versatile performance – wide range of materials, thicknesses.
- High initial equipment investment cost.
- Generally limited to thinner sheets below 2 mm thickness.
- Fixed tooling restricts profile shape changes.
- Significant maintenance needs – roll wear, lubrication, alignment.
- Process fine tuning required to achieve desired quality.
- Skilled technicians needed for operation and maintenance.
- Running equipment causes noticeable high noise.
Now we will address some common questions regarding these machines.
|What materials can be formed?||Commonly G550 galvanized steel or AZ150 aluminum sheets. Other metals possible with alloy-specific tooling.|
|What is the typical tolerance?||Standard machines achieve ± 1.5 mm tolerance on wave height and pitch. Precision machines can achieve ± 0.3 mm tolerance through profile monitoring and closed-loop control.|
|What safety features required?||Operators should wear hearing protection due to noise. Safety guards, emergency stops provided. Interlocking access doors are recommended.|
|What is the typical production rate?||Around 300-600 square meters per hour normally achieved for standard corrugated profiles and 1 meter width. Complex multi-layer profiles have lower production rate.|
|How to increase capacity later?||Additional slitting station can be added for wider coils. Speed can be increased by installing stronger motor, drives. Quick die change systems allow fast profile changes.|
|How much area is needed?||Around 15×3 meters for a standard line. Additional uncoiler and exit conveyor space needed.|
|What utilities needed?||Mainly stable power supply, compressed air for hydraulics. Some oil or air-mist lubrication.|
|What is the service life?||Around 3-5 years on average if maintained well. Rollers need replacement every 1-2 years depending on running hours.|
Some common issues faced during corrugated sheet roll forming and remedies are shown below:
|Problem||Possible Causes||Corrective Actions|
|Inconsistent wave profile||Worn forming rolls|
Improper roll gap
|Resurface or replace forming rolls|
Realign rolls to precision
Adjust roll gaps
|Sheet jamming||Sheet alignment error|
Roll surface damage
|Correct sheet positioning|
Smoothen roll surface
Apply lubricant on rolls
|Scratches on sheet||Dirty roll surface|
Damaged roll surface
|Clean roll thoroughly|
Repair roll surface damage
|Oil stains on sheets||Excessive lubricant application|
|Optimize lubricant quantity|
Fix oil leaks from hydraulics, gearbox
|Sheet deformation||Non-uniform roller wear|
Loose roller bearing
|Equalize roller wear|
Tighten loose bearing
|Excessive noise||Loose fasteners|
|Tighten loose parts|
Realign forming path
|Hydraulics issue||Blocked filter|
|Clean or replace filter|
Seal cylinder leakage
|Electrical fault||Loose wiring connection|
|Check and tighten connections|
Replace faulty sensor
Repair or replace motor
- For wave inconsistency – First replace worn forming rolls. Also ensure precise alignment between upper and lower rolls. Adjust vertical gaps between roller stations.
- For jamming – Check sheet guiding at each station. Rolls should have smooth surface finish. Apply light oil as lubricant.
- Scratches from dirt or damage on roll surface. Thoroughly clean and restore roll finish. Replace damaged rolls.
- Excess oil application creates stains on sheets. Fix any hydraulic or gear oil leaks. Optimize oil quantity.
- Non-uniform deformation indicates uneven roller wear. Equalize wear or replace worn rolls. Check bearing tightness.
- Noise from loose parts. Re-tighten fasteners to torque specs. Realign forming stations. Balance or replace noisy rollers.
- Hydraulic problems – Clean filter and pump. Replace leaking cylinder seals. Use specified grade hydraulic oil.
- Check electrical connections. Replace any faulty sensors or motors. Follow troubleshooting manual.
Proper maintenance and adjustments will resolve most operational issues and restore performance.
We have discussed corrugated roof panel roll forming machines in great depth. The key takeaways are:
- Roll forming efficiently produces corrugated roof sheets of consistent quality at high speeds.
- Corrugated profiles like standard sinusoidal, 5V Crimp and widespan are commonly produced.
- Machines contain unwinding, feeding, slitting, forming, curtting and stacking modules.
- Gradual bending is done on the sheet metal by the forming rollers to create the wave profile.
- Production speeds from 10-25 m/min allow capacities of 150-1200 sheets/hour.
- Roll forming lines are available from small $40k models to large $250k models based on output, automation and features.
- Careful site preparation, commissioning, maintenance and safety practices are needed.
- With regular upkeep and part replacement, service life of 3-5 years can be expected.