ए furring channel roll forming machine is an essential equipment used for producing furring channels quickly and efficiently. Furring channels are U-shaped metal channels used in construction for attaching wall panels, acoustic tiles, and other finishing materials to walls and ceilings. This guide provides a comprehensive overview of furring channel roll forming machines covering types, characteristics, applications, specifications, suppliers, operation, maintenance, and selection.
Overview of Furring Channel Roll Forming Machine
A furring channel roll forming machine forms C-shaped or U-shaped furring channels from coil strips of metal by progressive bending and shaping through a series of roller dies. The continuous channel profiles produced by these machines are used for furring purposes in drywall and ceiling systems.
The main advantages of using a dedicated furring channel roll former include:
- High productivity with line speeds up to 30 m/min
- Capability to produce constant thickness and depth channels in long lengths
- Adjustable forming stations to change channel parameters easily
- Sturdy construction for smooth and precise forming
- Automated control and safety features for efficient operation
- Low maintenance and operating cost compared to other forming methods
The key components and working principle involves feeding coil strips through roller dies to progressively cold-form the material into C/U channels with the desired dimensions. Decoilers, guides, forming stations, cutoff saws are main parts. Advanced furring channel roll forming lines have servo motor driven stands with PLC automated controls.
Major Types of Furring Channel Roll Forming Machines
| Machine Type | विवरण |
|---|---|
| C Type | Produces standard C shaped furring channels with 90-degree bends |
| U Type | Makes conventional U shaped furring channels for drywall framing |
| Custom Profile | Capable of making furring channels with non-standard shapes and sizes |
| Automatic Cut-to-length | Cuts formed furring channels to preset lengths and stacks |
| Single Layer Double Layer | Refers to number of channels that can be nested and rolled together |
Key Characteristics of Furring Channel Roll Forming Machines
| Characteristics | Details |
|---|---|
| Forming Material | Cold rolls mild steel, galvanized steel, stainless steel coils |
| Metal Thickness | Capable of forming up to 3 mm thickness strips |
| Channel Width | Standard machines make 35 mm to 300 mm wide furring channels |
| Channel Depth | Normal range is 6 mm to 50 mm depth channels |
| रोलिंग गति | Speeds range from 10 to 40 m/min depending on capability |
| Length Capacity | 6m, 8m, 10m, customized lengths |
| Automation Level | Manual, semi-automatic and fully automatic variants available |
Applications and Uses of Furring Channel Roll Forming
Furring channels produced by these roll forming machines are used for the following applications in construction:
Drywall Framing
- Wall furring for attaching drywall sheets to framework
- Ceiling furring for installing plasterboard ceilings and grids
Acoustic Panel Ceilings
- Carrying channels for mounting acoustic ceiling systems
- Framing for dropped ceilings with sound insulation tiles
Decorative Wall Paneling
- Mounting channels for installing decorative wall paneling
- Standard C and custom shaped furring used as reveals, trims
Mechanical Services
- Channels for attaching ducting, conduits and pipes
- Framing supports for electrical boxes, wiring
Insulation Spaces
- Channels create air spaces for insulation behind wall finishes
- Reduces thermal bridging and maintains energy efficiency
The advantage of using roll formed furring channels is the integrated 90-degree bends that provide perfect alignment and multi-point fastening for panels compared to plain meta studs. The U shape with perpendicular flanges ensures even wall finishing and flat plane for drywall, acoustic tiles etc. while providing adequate structural strength.
Specifications and Standards of Furring Channels
Furring channels are produced in various sizes and thicknesses for different applications. The specifications depend on channel dimensions, metal properties, load requirements, production tolerance, and standards compliance.
Design and Dimensions
| पैरामीटर | Typical Range |
|---|---|
| Channel Width | 35mm, 50mm, 65mm, 75mm, 90mm, 100mm |
| Web Depth | 6mm to 30mm in increments of 2mm |
| Flange Width | 10mm to 25mm based on total channel width |
| Metal Thickness | 0.4mm, 0.5mm, 0.6mm, 0.7mm, 0.8mm, 1.0mm, 1.2mm |
| Length | 3000mm, 6000mm or custom length |
| Leg Bend Radius | 1 to 1.5 times material thickness |
| Angle of Legs | Nominal 90 degrees |
Materials and Properties
| Material | मोटाई | Coating | Typical Properties |
|---|---|---|---|
| Mild Steel | 0.5 to 1.2 mm | Galvanized, Prepainted | Yield Strength: 230 MPa |
| Stainless Steel | 0.4 to 1.0 mm | Uncoated polished | Grade: 304, 316 |
| Aluminum | 0.7 to 1.0 mm | Mill finish | Alloy: AA3003, AA3105 |
Design Loads and Tolerances
| पैरामीटर | Value |
|---|---|
| Axial Load | ≤ 7kN/m |
| Bending Load | ≤ 11kN/m |
| Deflection Limit | L/240 at max load |
| Web Depth Tolerance | ± 10% of nominal depth |
| Web Out-of-Square | ≤ 2 mm over 1 m length |
| Flange Width Tolerance | ± 2 mm |
Standards and Codes
Furring channels are produced as per international and regional standards:
- ASTM C645 – Standard for Non-structural Steel Framing Members
- EN 14195 – Metal framing components for gypsum board systems Definitions, requirements and test methods
- AS/NZS 4600 – Cold-formed steel structures
- CAN/CSA S136 – North American Specification for Cold-Formed Steel Structural Members
The standards define materials, dimensions, structural performance, tolerances, testing methodology for furring channels.
Furring Channel Roll Forming Machine Manufacturers
There are many manufacturers producing furring channel roll forming equipment globally. Here are some of the major suppliers:
China
| Company | Location |
|---|---|
| Rollformer | Jiangsu |
| Sinowell | Jiangsu |
| Unitex | Shanghai |
| Rsen | Shandong |
| Erfurt | Shandong |
| Sunwin | Shandong |
| Formtek | Guangdong |
भारत
| Company | Location |
|---|---|
| S |
Europe
| Company | Location |
|---|---|
| Fom Industrie | इटली |
| RIB Spain | Spain |
| Dallan | इटली |
| Gasparini | इटली |
| Dittel | Germany |
| Metform | UK |
USA
| Company | Location |
|---|---|
| Rollformer Corporation | Tennessee |
| Samuel Mill Aluminum | Alabama |
| Advance Equipment | Iowa |
| Bradbury Group | Wisconsin |
| Metform International | California |
When choosing a furring channel roll forming machine manufacturer, some of the factors to consider are experience, production capabilities, customization options, quality certifications, local service support, cost, and production speed.
Furring Channel Roll Former Installation and Operation
Proper installation and operation procedures are required to achieve optimal performance from the furring channel roll forming line. Here are some key guidelines:
- Mount the machine on a firm flat foundation
- Level the entire frame longitudinally and transversally
- Tighten all bolts and nuts firmly
- Check and align all gears, sprockets, rollers before start
- Only qualified personnel should operate the machine
- Ensure electricals are properly wired as per drawings
- Lubricate sliding parts and apply grease
- Thread the strip coil through the decoiler and guides
- Set the forming stands gap based on metal thickness
- Set cut length, speed parameters, and trial run
- Constantly monitor for quality during production
- Wear safety gloves, goggles when working nearby
- Do not overload the forming rolls
- Clean and lubricate parts at end of production
The machine must go through commissioning, trial runs, and quality checks before full operation. The operating manual provides detailed start up and shutdown procedures. Proper maintenance is key for trouble-free working.
Maintenance of Furring Channel Roll Forming Equipment
A furring channel roll former requires scheduled preventive maintenance and servicing for reliable functioning. Here are some maintenance tips:
- Clean machine daily and keep rollers free of metal dust
- Lubricate bearings, sliding surfaces regularly
- Inspect gears, sprockets, and chains for wear
- Check rollers, guides for damage or misalignment
- Verify electrical wiring for fraying and tight connections
- Check hydraulic systems and pumps for leaks if any
- Monitor noise and vibration levels in bearings
- Repair or replace any damaged or worn components like belts
- Maintain fastener tightness
- Follow maintenance schedule given in manual
- Keep spare parts like forming rolls, bearings, belts available
It is recommended to inspect the machine thoroughly and test performance every six months. The forming rolls need regrinding or hard-surfacing based on wear. Production issues like jamming, inconsistent forming, etc. should be addressed promptly.
How to Select a Furring Channel Roll Forming Machine
Selecting the right furring channel roll former requires evaluating key parameters and supplier capabilities. Some guidelines for choosing the machine:
- Determine production output rate needed
- Material type and thickness to be formed
- Dimensions and profiles of furring channels
- Level of automation and edge trimming
- Type of cut-off and counting mechanism
- Number of forming heads and roller stations
- Power and space requirements
- Additional accessories needed
- Local service, parts support capability
- Budget and investment cost
- Relevant experience of roll former company
- Production efficiency and reliability
- Customization, special designs possible
- Certification and compliances
- Overall value relative to performance
The manufacturer will guide selection of optimal machine configuration based on application requirements and production goals. It is advisable to get quotes from multiple vendors and evaluate machinery on both technical and commercial criteria before purchase.
Advantages and Limitations of Furring Channel Roll Forming
Benefits of Roll Forming Furring Channels
- High production speed and volumes
- Consistent quality with precision forming
- Adjustable parameters for custom profiles
- Low labor requirement and cost saving
- Long production runs with minimal interruptions
- Reliable performance and durability of machine
- Lower cost than other forming methods
- Adaptable to produce new designs easily
Limitations of Furring Channel Roll Forming
- High initial machinery investment cost
- Limited to softer metals like steel, aluminum
- Size constraints of forming sections
- Trained staff needed for operation
- Regular maintenance requirement
- May require edge trimming and hole punching
- Limited flexibility compared to custom fabrication
Furring Channel Roll Former Comparison
| Machine A | Machine B | Machine C |
|---|---|---|
| Type: Automatic high speed | Type: Standard C-U former | Type: Basic manual line |
| Speed: 40 m/min | Speed: 25 m/min | Speed: 10 m/min |
| Motor power: 11 kW | Motor power: 7.5 kW | Motor power: 3 kW |
| Forming stations: 20 | Forming stations: 12 | Forming stations: 8 |
| Controls: Fully PLC, HMI | Controls: Semi-automatic | Controls: Manual switches |
| Coil capacity: 6000 kg | Coil capacity: 4000 kg | Coil capacity: 2000 kg |
| Channel width: 50-200 mm | Channel width: 50-100 mm | Channel width: 50-75 mm |
| Cost: $$ | Cost: $ | Cost: $ |
निष्कर्ष
- Machine A is fastest, most automated solution for high volume needs
- Machine B is balanced mid-range solution with good speed
- Machine C is basic roll former for intermittent usage
The production targets, budget, and automation needs dictate the type of furring channel roll forming machine selected.
पूछे जाने वाले प्रश्न
What materials can be formed into furring channels?
Furring channel roll formers typically form coils of mild steel, galvanized steel, stainless steel, or aluminum into furring channel profiles. Sheet thickness ranges from 0.4mm to 1.2mm.
What are the typical dimensions of furring channels produced?
Common furring channel sizes are 35 to 100mm width, 6 to 30mm depth and 0.4 to 1.2mm thickness. Custom profiles are also possible.
How long are the furring channels produced by these machines?
Standard length is around 3m with 6m and 8m long channels also produced. Automatic cut-to-length machines can make specific preset lengths.
What are the key components of a furring channel roll former?
Main components are decoiler, guides, forming heads, roller stations, cutoff saw, runout table. Advanced machines also include servo motors, PLC controls, and HMI touchscreen.
What factors affect the production speed?
Rolling speed depends on motor power, number of roller heads, automation, and machine rigidity. Higher speeds need more horsepower and stability. Typical speed range is 10 to 40m/min.
How to maintain and service the furring channel roll forming equipment?
Regular cleaning, lubricating moving parts, inspecting components for wear/damage, scheduled maintenance as per manual, and replacing worn parts when required.
What safety aspects should be considered for furring channel roll forming?
Machine safeguarding, emergency stops, wearing protective gear, training workers on procedures, no loose clothing, long hair or accessories, and ensuring qualified operation.
How to improve line efficiency and furring channel quality?
Optimizing forming parameters, using precision components, scheduled maintenance, monitoring and inspection at each stage, and ensuring proper raw material quality.
What causes common production issues in furring channel rolling?
Improper adjustment, worn/damaged forming rolls, poor lubrication, misaligned guides, unstable strip feeding, and material defects like burrs can cause issues.
How to reduce costs in furring channel roll forming?
Choose energy-efficient machines, optimize production planning to minimize material wastage, improve maintenance to increase machine life, and negotiate lower raw material costs.
References and Sources
- ASTM C645 – Standard for Non-structural Steel Framing Members
- AS/NZS 4600 – Cold-formed steel structures
- Design and Construction of Exterior and Interior Walls with Framing Members. Gypsum Association, USA.
- Light Gauge Metal Framing Members. CSSBI, Canada
- CAN/CSA S136 – North American Specification for Cold-Formed Steel Structural Members
- EN 14195 – Metal framing components for gypsum board systems Definitions, requirements and test methods
- Technical Guide for Cold Formed Steel Framing Members. American Iron and Steel Institute
निष्कर्ष
This guide covers everything related to furring channel roll forming machines – types, working principle, applications, specifications, suppliers, installation, operation, maintenance, selection criteria, pros/cons, and FAQs. The tabular format allows easy comparison of technical details to make an informed equipment selection based on production needs. With its high speeds, reliability, and precise forming capabilities, a furring channel roll forming line is indispensable for construction products manufacturers looking to maximize productivity and quality.