Double Deck Roll Forming Machines

Double deck roll forming machines are an important type of equipment used for rolling and bending metal coils into customized profiles and cross-sections. This comprehensive guide will provide a detailed overview of double deck roll forming technology, including working principles, main components, types of machines, key specifications, parameters, applications, operation and maintenance, how to select suppliers, and pros and cons of double deck roll formers.

Overview of Double Deck Roll Forming Machines

Roll forming is a continuous bending process used to form metal coils into customized open profiles with an array of rollers. It is ideal for producing large volumes of sections efficiently at a low cost compared to extrusion or fabrication.

Double deck roll forming machines utilize two sets of roll forming stations arranged vertically to shape metal coils in two directions as the material passes through. This enables more complex geometries to be formed compared to single deck machines.

Main Advantages of Double Deck Roll Formers

  • Increased forming capability for complex shapes and large sections
  • Higher production rates due to two forming lines
  • Dual directional forming improves profile precision
  • Sections can be tapered by adjusting upper and lower rolls
  • More rigid frame reduces deflection for accuracy
  • Common drive system requires less maintenance

Typical Applications of Double Deck Roll Forming Machines

Double deck roll forming is commonly used to produce:

  • Metal roofing and wall panels
  • Steel doors and windows
  • Rack and shelving posts
  • Automotive and HVAC ductwork
  • Agricultural silos and storage tanks
  • Pre-engineered steel buildings
  • Structural frames and support members
  • Furniture tubing
double deck roll forming machine
Double Deck Roll Forming Machines 4

How Double Deck Roll Forming Machines Work

Double deck roll forming utilizes a continuous process to shape sheet metal coils into open profiles. Here are the key steps:

  1. Coil sheets are fed into the de-coiling unit to be straightened.
  2. The sheet enters the serration rollers to even out thickness.
  3. Forming rollers progressively bend the strip through a series of stations.
  4. Top and bottom roller stations form the strip in two planes simultaneously.
  5. Cutting devices cut the strip to length when it reaches the end.
  6. Formed sections are collected on the exit conveyor.

Main Components of Double Deck Roll Formers

Double deck roll forming machines consist of the following major components:


  • Feeds metal coil sheets into the roll former
  • Contains dereeling arms to stabilize coil
  • May have hydraulic expansion mandrel
  • Often has leveler/straightener

Seriation Unit

  • Uses small serrated rollers
  • Evens out thickness variations in the strip

Forming Stations

  • Contain top and bottom roller sets
  • Progressively bend sheet through each stand
  • Rollers are machined to required shapes
  • Number of stands determines profile complexity

Cutting Device

  • Shears, saws, laser, or water jet
  • Cuts formed sections to length
  • May have flying cutoff for continuous lengths


  • Controls whole line from HMI panel
  • Sets roller positions, cut lengths, speed etc.
  • Interfaced to sensors and servo motors


  • Transports sections from one end to the other
  • Entry and exit conveyors may be used
  • Transfers parts to next operation

Types of Double Deck Roll Forming Machines

Double deck roll formers are available in several configurations:

Fixed vs. Adjustable Roll Formers

  • Fixed roll stations only form pre-set shapes
  • Adjustable allows variable profiles within range
  • Adjustable uses automated actuators on rollers

Standard vs. Customized Machines

  • Standard models for common profiles
  • Customized to required shape and size specs
  • Customization increases initial cost

Manual vs. Automated Material Handling

  • Manual loading/unloading by operator
  • Automated transfers sheets in and out

Mobile vs. Stationary Roll Formers

  • Mobile units are mounted on wheels or skids
  • Stationary machines fixed permanently on foundations

Key Specifications of Double Deck Roll Forming Machines

Double deck roll forming machines are defined by these key specifications:

SpecificationTypical Range
Forming Speed10 – 100 m/min
Maximum Strip WidthUp to 2500 mm
Minimum Metal Thickness0.3 – 2.5 mm
Roller Diameter100 to 400 mm
Number of Stands10 to 50
Main Drive Power5 to 100 kW
Line Accuracy+/- 1 mm
Roller AdjustmentManual or Servo Motor
ControllerPLC with HMI Touchscreen
StructureWelded Steel Frame

These parameters determine the size and profiles that can be produced. The number of forming stands required depends on the complexity of the shape. More stands allow more bends but reduce max speed.

Choosing the Right Double Deck Roll Former

Selecting the optimal double deck roll forming machine depends on these key factors:

  • Metal type and thickness – affects choice of roll materials, drive power, and press capacity
  • Part sizes and profiles – determines number of stands, roller diameters, widths
  • Production volume – higher volumes need heavier duty and automated models
  • Dimensional accuracy required – tighter tolerances need rigid frames and precision components
  • Budget – initial cost is higher for larger, customizable, or automated machines
  • Future expansion plans – consider ability to add more stands later or change tooling
  • Available space – check area needed for machine length and material handling

Work closely with suppliers to match the roll former capabilities to your production requirements.

Double Deck Roll Forming Process Design

In order to achieve quality roll formed parts, the process must be designed properly. Here are some best practices:

  • Model part geometry using CAD to visualize formed shapes
  • FEA analysis determines stress points and guides tool design
  • Design roll tooling profile using specialized software
  • Iteratively adjust roller positions to optimize forming
  • Simulate material flow through all stations
  • Build in tolerance stacks from parts to rollers
  • Write detailed forming sequence instructions
  • Inspect initial sample parts and validate process
  • Refine tools based on quality checks and feedback
  • Document validated forming process for repeatability

Careful roll design, simulation, prototyping, and refinement ensures optimal roll formed part quality and process control.

Applications and Uses of Double Deck Roll Formers

Double deck roll forming is utilized to produce a wide array of part profiles across many industries:

Building and Construction

  • Roofing, siding, wall panels
  • Structural frames and supports
  • Door and window sections
  • Solar panel frames
  • Flooring and decking profiles
  • Drainage systems
  • Scaffolding, safety barriers


  • Chassis, frames, and body panels
  • Truck trailer side walls
  • Railway car sections
  • Shipping container frames
  • Aerospace ducting and panels

Storage, Material Handling

  • Racks, shelving uprights
  • Silo wall panels
  • Conveyor housings
  • Equipment guards, safety barriers
  • Ducting, hoppers, chutes

Furniture and Appliances

  • Desks, cabinets, shelving frames
  • Office cubicles, partitions
  • Refrigerator liners
  • Oven and dishwasher cavities
  • Tubular furniture legs and arms

The flexibility to form virtually any open cross-section makes double deck roll forming suitable for producing a huge range of components across diverse industries.

Typical Double Deck Roll Formed Profiles

Here are some examples of common profiles produced using double deck roll forming machines:


Used for frames, supports, tracks, guides.Symmetrical shape provides strength.

Structural Tube Sections

For structural support systems. Hollow tube with flat sides

Sigma Sections

Sigma sections used for beams and columns. High second moment of area.

Zeds / Zee Sections

Zed profiles for roofing, cladding, structural use. Interlocking shape.

Angles / L-Sections

Angle profiles used for frames, supports, bracing. Provides rigidity.

Choosing a Double Deck Roll Forming Machine Supplier

Selecting the right supplier is crucial to get a high-quality double deck roll former. Here are important factors to consider:

  • Technical expertise – Experienced in roll tooling design and process engineering
  • Roll forming focus – Specialists dedicated to roll forming equipment
  • Customization capabilities – Able to customize to your requirements
  • Quality and precision – High accuracy standards and tolerances
  • Reliable components – Uses reputable brands of motors, hydraulics, etc.
  • Responsive service – Quick support for breakdowns or issues
  • Knowledge transfer – Provides operator training and documentation
  • Upgrade capabilities – Ability to add features, automation, or stands later
  • Delivery reliability – On-time delivery record and lead times
  • Longevity and reputation – Established suppliers with proven track record
  • Value for money – Competitive pricing for quality equipment
  • Local presence – After-sales support available in your region

Selecting an experienced roll forming specialist with design expertise, high build quality, responsive service, and proven reputation ensures you get capable and reliable equipment.

Installation and Commissioning of Double Deck Roll Lines

Proper installation and start-up of double deck roll lines is key to smooth operation. Here are some guidelines:

  • Offload components carefully using forklifts, cranes, jacks
  • Assemble machine sections according to marked plans
  • Check alignments, clearances, and tolerances
  • Perform static balancing of forming rollers
  • Verify correct rotational directions of motors
  • Install hydraulic power packs and piping
  • Wire up control cabinets and I/O modules
  • Interface encoder feedbacks to controllers
  • Load tooling profiles and test roller positioning
  • Thread pilot sheet through entire line slowly
  • Monitor sheet flow, sensors, and clearances
  • Make adjustments to guides, supports, and stations
  • Gradually increase speed to rated production
  • Confirm that all stations form part correctly
  • Validate dimensional accuracy of end parts
  • Make final adjustments for process optimization
  • Document machine settings and process data

Careful installation, debugging, trial runs, and process documentation ensures the double deck roll line starts up smoothly and produces quality right from the beginning.

Operation and Maintenance of Double Deck Roll Lines

To achieve consistent production and throughput from double deck roll formers, proper operation and preventive maintenance is critical:


  • Monitor line speed, coil payoff, and strip flow
  • Watch for flutter, jamming, or strip tracking errors
  • Verify cut lengths, hole punching, part features
  • Conduct regular quality checks on formed parts
  • Measure key dimensions at defined intervals
  • Check for wear on rollers, bearings, and guides
  • Lubricate machine per maintenance schedule
  • Inspect hydraulics, electrics, and safety devices


  • Establish routine maintenance schedule and checklists
  • Train technicians on safety procedures
  • Inspect roll tooling regularly for wear and damage
  • Realign/replace worn rollers and guides
  • Lubricate bearings and sliding components
  • Verify hydraulic power pack operation
  • Check motors, gearboxes, and drive couplings
  • Monitor PLC, HMI, and electrical cabinets
  • Perform machine calibration to original specs
  • Document all maintenance activities
  • Plan major overhauls during shutdowns

Following structured operation protocols and preventive maintenance activities ensures continuous and safe functioning of the roll forming line over its service lifetime.

double deck roll forming machine
Double Deck Roll Forming Machines 5

How to Choose the Right Double Deck Roll Former

Selecting the optimal double deck roll forming machine depends on carefully evaluating your production requirements, part parameters, business objectives, and supplier capabilities. Here are key steps:

Define Production Requirements

  • Profile shapes to be produced
  • Metal material (steel, aluminum etc.)
  • Material thickness and strip widths
  • Annual volume per profile
  • Tightness of tolerances
  • Level of automation needed

Determine Key Machine Specifications

  • Number of forming stations
  • Roller size and adjustment type
  • Line speed and accuracy
  • Cutting method (shear, saw etc.)
  • Coil handling method
  • Drives, controls, and sensors

Evaluate Supplier Capabilities

  • Experience with similar applications
  • Design expertise
  • Equipment quality and precision
  • Customization flexibility
  • Responsiveness to issues
  • Operator training provided
  • Future upgrade capabilities

Assess Value Proposition

  • Compare proposals from shortlisted suppliers
  • Evaluate quality, throughput, and reliability
  • Consider total cost of ownership
  • Weigh capital cost versus operating costs
  • Review maintenance and service costs
  • Discuss possible future expansions

Taking a structured approach to gathering requirements, outlining specifications, assessing suppliers, and evaluating total value ensures you select the optimal double deck roll former for your needs.

Pros and Cons of Double Deck Roll Forming Machines

Higher production rates than single deckMore expensive initial cost
Increased forming capability and complexityLarger space requirement
Dual directional forming improves precisionDesign and tooling is more complex
Ability to taper and curve profilesNeeds preventive maintenance for uptime
Common drive reduces maintenanceLimited adjustment range in fixed models
Rigid frame gives better accuracyHigher skill needed for operation
Wide range of profiles can be producedSignificant make-ready time for profile changeovers
Lower cost for high volumes than other processesLimited for short production runs

Double Deck Roll Former Costs

Machine TypeTypical Price Range
Manual Fixed Roll Former$40,000 to $60,000
Automatic Fixed Roll Former$60,000 to $150,000
Manual Adjustable Roll Former$60,000 to $100,000
Automatic Adjustable Roll Former$100,000 to $250,000
Custom Roll Former$150,000 to $500,000

Prices vary widely depending on:

  • Number of forming stations
  • Level of automation
  • Customization requirements
  • Additional features
  • Production volumes
  • Supplier reputation and quality

Higher process capabilities and production rates make double deck roll formers well suited for large production volumes despite the higher initial machine cost compared to single deck machines.

double deck roll forming machine
Double Deck Roll Forming Machines 6


What materials can be formed on double deck roll forming machines?

  • Most commonly low carbon steel and stainless steel coils
  • Also capable of forming aluminum, copper, and brass alloys up to certain hardness

What thickness of metal strip can be roll formed?

  • Typical thickness range is 0.3 to 2.5 mm
  • Thicker materials up to 7 mm can be formed with enough power
  • Minimum bending radius limits material thickness

What profiles are best suited for double deck roll forming?

  • Open profiles with multiple bends in two planes
  • Sections up to 8 inches high and 3 inches thick
  • Profiles with return flanges for strength and rigidity

How many roller stands are needed for typical profiles?

  • 8 to 15 stands for simple C and U channels
  • 15 to 25 stands for complex structural shapes
  • More stands provide more forming capability

How to calculate if a profile can be roll formed?

  • Model profile and simulate material bending
  • Use roll design software to develop tooling profiles
  • Adjust roller positions iteratively to form shape
  • Build tooling and test forming process on machine

What are common problems in roll forming?

  • Strip tracking errors, fluttering, jamming
  • Roller wear, deflection causing shape deviations
  • Scratches, deformities in formed parts
  • Vibration and noise indicating alignment issues
  • Hydraulic leaks or electrical faults

How long do roll forming machine tools last?

  • With proper use and preventive maintenance, tools can last 12-18 months
  • Carbide rollers provide longer working life
  • Tool life depends on metal hardness and thickness

How to improve quality in roll formed parts?

  • Ensure precision ground tooling profile
  • Maintain tight tolerances in roller stands
  • Frequently calibrate machine
  • Control strip flow and feed rate

What safety precautions are important for roll forming?

  • Enclose dangerous moving parts in shrouds
  • Interlock access doors to power off machine
  • Use safety mats and light curtains around machine
  • Provide proper machine guarding mechanisms
  • Require personal protective equipment for operators

What factors affect the line speed of a roll former?

  • Metal thickness – thinner metal can run faster
  • Number of forming stations – more stands reduce max speed
  • Forming complexity – simpler profiles can run faster
  • Available driving power – higher power allows higher speed

How to calculate machine straightness for roll forming?

  • Establish a straightness baseline by running a tight wire
  • Measure deviations from wire to machine elements
  • Total indicator runout should be within 0.002 in/ft
  • Shim and align machine elements as needed

What are common roll former malfunctions?

  • Feed problems like skipping, jamming, flutter
  • Roller misalignment causing profile errors
  • Worn or damaged rollers and forming dies
  • Drive and gearbox failures
  • Hydraulic system leaks or electrical faults

How is roll tooling changed for quick die changeovers?

  • Manual changeovers use hand tools to swap rollers
  • Quick-change systems use cartridges or cassettes
  • Powered roll change carts automatically swap stations
  • Minimizes production downtime for die changes

What regular maintenance is required?

  • Daily: visual inspection, lubrication, cleanup
  • Weekly: check alignments, hydraulics, electrical
  • Monthly: inspect rollers, bearings, gears
  • Yearly: calibration, major overhaul, part replacement

know more Roll forming

Table of Contents

Follow Us

Share This Post

Most Popular

Get In Touch

Any question? Contact Us Now

On Key

Related Posts

types of PV Mounting Bracket Machine

Imagine a world bathed in sunshine, where clean, renewable energy powers our homes and businesses. Solar panels are the key to unlocking this future, but they don’t magically float in mid-air. Enter the realm of PV mounting bracket machines –

Read More »

Highway Guardrail Spacer Block Making Machine

Imagine driving down a highway, the wind whipping through your hair (or sunroof, if you’re fancy). Suddenly, a car swerves out of control. But instead of a horrific impact, your vehicle glides harmlessly along a sturdy metal barrier. That, my

Read More »

Gutter Machine

Imagine this: it’s pouring rain outside, and you hear a disconcerting rumble coming from your roof. You rush up to the attic, heart pounding, only to discover overflowing gutters threatening to cascade rainwater down your walls. Yikes! Clogged or malfunctioning

Read More »