Corrugated sheet roll forming machines are used to produce corrugated sheets and panels from flat metal coils. Corrugated metal sheets have a wide range of applications including roofing, siding, flooring, walls, and packaging. This article provides a comprehensive overview of corrugated roll forming equipment.
Overview of Corrugated Sheet Roll Forming Machines
Corrugated sheet roll forming is a continuous process of bending and shaping metal coil strips into corrugated panels. The sheets have a rippled pattern consisting of alternating ridges and grooves for added strength and rigidity.
Roll forming machines gradually shape the flat strip through a series of rolling stands containing pairs of forming rollers. As the coil passes through each successive stand, it is progressively bent into the corrugated profile.
Key Characteristics:
- Highly automated machines for mass production of corrugated metal sheets
- Capable of processing coils of steel, aluminum, copper in different gauges
- Forming sections with roller dies to bend and shape the strips into corrugated sheets
- Adjustable forming rollers for changing profiles and pitches
- Available in single and double layer configurations
- Produce panels at fast line speeds up to 100 m/min
- Advanced controls and instrumentation for precision monitoring
Types of Corrugated Roll Forming Machines
| Type | Description |
|---|---|
| Single Layer | One layer of corrugated sheet is formed from a single strip. Simple and economical design. |
| Double Layer | Two corrugated sheets interlocked together are formed simultaneously from two strips to create stronger composite panel. |
| Semi-automatic | Basic equipment with manual feeding of coils. Lower speeds and production. |
| Fully Automatic | Advanced programmable controls, servo motors, powered decoilers, conveyors, and coil joining. Higher throughput. |
Main Components
Coil Loading: decoiler, powered unwinding, coil carousel, threading table
Forming Sections: forming rollers, pre-bending rolls, sheet guides
Corrugating Rollers: male and female corrugation dies
Finishing: cutting unit, stacker
Drives: motors, gear reducer, chain drive
Controls: PLC, HMI, instrumentation
Design Factors
- Type of material – steel, aluminum alloys
- Sheet width and thickness
- Corrugation profile and pitch
- Single vs double layer
- Production speed and output
- End-use application and specifications
Industry Standards
- ASTM A653/A653M for steel sheets
- EN 10143 for corrosion resistant steel sheets
- ASTM B209 for aluminum alloy sheets
Applications of Corrugated Metal Sheets
Corrugated sheets produced by roll forming have various industrial and commercial uses:
| Application | Description |
|---|---|
| Roofing and Siding | Widely used for roof cladding and wall cladding in buildings due to lightweight, drainage, spans greater distances. |
| Interior Walls and Ceilings | Provides decorative look along with acoustical benefits for interiors. |
| Structural Decking | Fluted corrugated sheets used for flooring systems in industrial buildings, walkways, platforms. |
| Culverts | Corrugated steel culvert pipes are commonly used for road drainage and sewers. Withstands traffic loads. |
| Grain Bins and Silos | Used for constructing grain storage bins owing to strength, weather resistance, and ventilation. |
| Shipping Containers | Corrugated sheets are ideal for walls and doors of heavy-duty shipping containers. |
| Signage | Durable and lightweight material for road signs, billboards, safety signs. |
Specifications of Corrugated Sheet Roll Forming Machines
| Specifications | Typical Values |
|---|---|
| Sheet Width Capacity | 650 – 1300 mm |
| Sheet Thickness | 0.3 – 2 mm |
| Corrugation Pitch | 6 – 12 mm |
| Profile Shape | Sinusoidal, Curved, Trapezoidal |
| Machine Speed | 10 – 100 m/min |
| Main Drive Power | 5 – 15 kW |
| Roller Diameter | 60 – 150 mm |
| Roller Material | Alloy steel, hardened |
| Machine Weight | 6000 – 15000 kg |
| Line Length | 5 – 12 m |
Suppliers of Corrugated Roll Forming Equipment
There are many manufacturers providing corrugated roll forming machines and production lines globally. Some of the major international suppliers are:
| Company | Location |
|---|---|
| Botou Xianfa | China |
| Zhangjiagang Ruifeng | China |
| Foster Automation | India |
| Metform International | Turkey |
| Bradbury Group | UK |
| Hardwick Enterprises | USA |
| OMCO Roll Forming | Canada |
| Sen Fung Rollform | Taiwan |
When choosing a corrugated sheet roll forming machine supplier, some key factors to consider are:
- Experience and reputation in corrugated roll forming
- Customization options for the required sheet profiles
- Quality of materials and components used
- Technical expertise for design, engineering, and manufacturing
- Automation capabilities and production output levels
- Options for line integration and upstream/downstream processes
- Installation support, training, and after-sales service
Roll Formed Corrugated Sheet Price Ranges
| Material Type | Sheet Thickness | Indicative Price Range |
|---|---|---|
| Galvanized Steel | 0.5 mm | $2.5 – $3 per sq.m |
| Galvanized Steel | 0.8 mm | $3.5 – $4 per sq.m |
| Aluminum | 0.7 mm | $4 – $6 per sq.m |
| Aluminum | 1 mm | $6 – $8 per sq.m |
| Copper | 0.6 mm | $10 – $14 per sq.m |
| Copper | 0.8 mm | $12 – $16 per sq.m |
*Prices vary based on order quantity, material grade, coatings, and supplier. Quotations should be obtained from manufacturers for current estimates.
How to Choose a Corrugated Sheet Roll Forming Machine Supplier
Choosing the right corrugated sheet roll forming machine supplier is key to getting equipment that meets the production needs. Here are important tips for selection:
- Review technical capability to produce the required profiles and quality
- Ensure available roll tooling suits the material type and thickness
- Look for customizable features for future flexibility
- Prioritize suppliers with strong experience in the application area
- Evaluate overall production output rate against requirements
- Consider automation level based on operation skills
- Check options for line integration and peripheral equipment
- Opt for quality components and international certifications
- Compare offerings from multiple suppliers
- Verify after-sales support network and quick service
- Negotiate price, payment terms, and shipping costs
- Check lead time and availability for quick delivery
Reputable manufacturers with proven track record in corrugated roll forming are recommended for best results.
Installation and Operation of Corrugated Roll Forming Machines
Proper installation and operation practices are vital for optimum performance of corrugated roll forming lines. The key aspects are:
Site Preparation
- Ensure adequate space and proper foundations for securing the machine
- Have power supply, compressed air and ventilation setup ready
- Prepare unloading and handling equipment like forklifts, cranes
Installation
- Position and bolt down the roll forming sections as per layout
- Install electrical cabinets, control desk, and interconnect cables
- Connect hydraulic, coolant, and lubrication systems
- Integrate decoilers, straighteners, stackers, and safety guards
- Perform trial runs to tune and test all functions
Setup and Operation
- Install roller dies, guides, sensors as required for sheet profile
- Set the forming speed, bend angles, pre-bending pressures
- Thread the coil strip through the roller passes and corrugating stands
- Adjust decoiler tension and guide alignment for stable feeding
- Run machine and monitor all running parameters and safety devices
- Conduct regular maintenance and checks according to manual
Tooling Changeover
- Safely stop machine and de-energize all power sources
- Remove existing roller tooling and dies carefully
- Clean the machine and install new tooling per procedures
- Adjust stroke length, speed, and re-test operation
Following the manufacturer’s guidelines will ensure efficient functioning and maximum longevity of the roll forming equipment.
Maintenance of Corrugated Roll Forming Machines
A systematic maintenance program is essential for continuous productive operation and longevity of corrugated roll forming lines. Typical activities include:
| Maintenance Task | Frequency |
|---|---|
| Inspecting rollers and bearings | Daily |
| Checking drive chain/belt condition | Weekly |
| Lubricating bearings and gears | Monthly |
| Replacing worn out rollers and guides | 6 months |
| Inspecting seals, sensors, motors | Yearly |
| Alignment of shafts and rollers | Yearly |
| Replacement of hydraulic oils and coolants | As needed |
| Calibration of sensors and instrumentation | As needed |
Key maintenance tips:
- Follow schedule for cleaning, lubrication, adjustments
- Keep records of completed maintenance work
- Check for abnormal noise, temperature or vibrations
- Monitor wear on forming rollers and guides
- Replace damaged electrical wiring immediately
- Confirm backups of control parameters and settings
- Test emergency stops, alarms regularly for safety
- Train personnel on proper maintenance procedures
With regular upkeep, the roll forming machines will deliver consistent output quality and maximize service life.
Advantages of Corrugated Sheet Roll Forming
Roll forming yields several benefits that make it ideal for mass production of corrugated metal sheets:
- Continuous operation for high output upto 100 m/min
- Capable of long production runs with coil raw material
- Consistent quality and dimensional accuracy of sheets
- Ability to create complex corrugated and fluted profiles
- Adaptable to alternate materials like steel, aluminum
- Lower tooling costs than conventional press forming
- Safer enclosed forming with less noise compared to press brakes
- Minimal scrap generation leading to material savings
- Lower equipment investment than press brakes or stamping presses
- Compact footprint relative to production capacity
The automated high speed process enables roll forming lines to meet large volume needs efficiently.
Limitations of Corrugated Sheet Roll Forming
While roll forming has major advantages for long production runs, it does have some limitations:
- Higher initial setup time for forming rollers and trial runs
- Difficult profile changes require roll tooling changes
- Limited thickness range of about 0.3 mm to 2.5 mm
- Not efficient for small batch or prototype production
- Close tolerance control more complex than sheet metal stamping
- Limited to coil input material, cannot use metal blanks
- Central divider needed for double layer sheets
- Oil film buildup on sheets may need post-cleaning
- Larger footprint than press brakes at same capacity
For some applications like custom enclosures or panels, sheet metal stamping may be better suited than roll forming.
Comparison Between Roll Forming and Press Brake Bending
| Parameter | Roll Forming | Press Brake |
|---|---|---|
| Setup time | High initial time | Low setup per batch |
| Tooling cost | Lower for rolls | Higher for dies |
| Accuracy | +/- 1 mm | +/- 0.5 mm |
| Surface finish | Smoother | Risk of flats and marks |
| Productivity | Higher for long runs | Better for small batches |
| Automation | Highly automated | Semi-automatic |
| Operating cost | Lower | Higher due to manual operation |
| Safety | Safer with enclosed sections | More hazardous exposure |
| Equipment cost | Lower for same capacity | Higher cost |
How are Corrugated Metal Sheets Made?
Corrugated sheets are produced by the roll forming process in the following steps:
- Decoiling: Sheet metal coil is loaded onto a powered unwind decoiler which unrolls the strip.
- Feeding: Decoiler feeds the strip through a straightener into the roll forming sections.
- Pre-Bending: Initial rolling stands start gradual bending to the required radii.
- Corrugating: Specially shaped male and female roller dies form the corrugated profile.
- Calibration: Further roll stands calibrate and stabilize the corrugated shape.
- Finishing: End cut-off shears cut sheets to length and stacker collects them.
- Automation: Servo motors, PLC controls, sensors provide automatic operation.
The materials used are galvanized steel, aluminum and copper coils. The roll formed corrugated sheets offer durability, strength, and attractive appearance.
Corrugated Metal Sheets – An Ideal Building Material
Corrugated metal sheets offer unique properties that make them ideal for roofing, siding, and construction applications:
- High strength-to-weight ratio – Spans greater distances
- Pliable and easy to shape on site
- Light weight reduces transportation costs
- Excellent drainage from water shedding corrugations
- Vented profiles – Good air circulation and ventilation
- Quick and simple installation – Lower labor costs
- Withstand weathering, rust, fire hazards
- Reflective surface reduces heat gain – Energy savings
- Low maintenance and long service life up to 40 years
- Recyclable and environmental friendly
- Visually appealing aesthetic options
The roll formed sheets provide robustness along with design flexibility at affordable cost for modern sustainable buildings.
Future Outlook for Corrugated Roll Forming
The corrugated roll forming process will continue to gain share in metal sheet production due to its efficiency, flexibility, and cost-effectiveness.
Key trends shaping the future of the industry:
- Growing demand from rapidly developing economies globally
- Infrastructure investments driving construction sector
- Focus on energy efficient building designs
- New material advancements like corrosion resistant steel
- Manufacturing automation and IoT integration
- Virtual prototyping for quicker tooling design
- Rising environmental regulations on sustainability
- Declining storage and transportation costs
With increasing urbanization and industrialization, the market for corrugated roll forming equipment is projected for steady growth worldwide.
Conclusion
Corrugated sheet roll forming is a high speed manufacturing process that delivers durable and lightweight panels from metal coils. The versatile corrugated products serve diverse construction, infrastructure, packaging, transportation, and agriculture applications. With precision automation, these machines offer efficient mass production capabilities with flexibility to adapt to evolving needs and materials. When appropriate forming tooling is combined with proper installation, operation and maintenance, corrugated roll forming lines provide an economical solution for metal forming needs while maintaining quality and reliability.
FAQ
What materials can be roll formed into corrugated sheets?
The most common materials are steel, galvanized steel, and aluminum. Other metals like copper, brass and stainless steel can also be roll formed into corrugated profiles.
What gauges of metal can be used for corrugated roll forming?
Standard metal gauges from 0.3 mm to 2 mm can be roll formed. Specialized machines can handle up to 3 mm thick material.
How long does a corrugated roll forming machine last?
Properly maintained machines have a typical lifespan of 15-20 years. With regular maintenance and part replacement, the service life can extend beyond 25 years.
How much does a complete corrugated roll forming line cost?
Costs vary based on size, production speed, and options. Typical price range is $100,000 to $500,000 for an automated corrugated sheet production line.
Can I get customized corrugated profiles from a roll former?
Yes, most roll former suppliers offer customized tooling design services to produce special non-standard corrugation profiles if required.
How quickly can roll tooling be changed on these machines?
Simple profile changeovers can be done in 1-2 hours. For major retooling, the typical time is about 8-12 hours.
Can a roll forming machine make curved sheets?
Yes, with special tooling and bending arrangements, curved corrugated panels for arched structures can be produced on some roll formers.
What safety equipment should be used for corrugated roll forming?
Safety guards, light curtains, e-stops, protective clothing like gloves and eyeglasses, and work shoes must be used as per guidelines.
How much training is needed to operate corrugated roll machines?
1-2 weeks of on-site training for loading coils, threading, control settings, troubleshooting is usually provided by the equipment supplier.