Double Layer Corrugated and IBR Sheet Making Machine – Dual Output Metal Roofing Sheet Cold Roll Production Line
This double layer sheet making machine manufactures two distinct metal roofing sheet products from a single production unit by integrating two complete roller forming decks within one welded structural steel chassis. The lower deck is configured for making corrugated wave sheets — the classic sinusoidal metal roofing profile that has served as affordable building envelope material for residential homes, farm structures, and economy construction projects in every developing market worldwide. The upper deck is tooled for making IBR (Inverted Box Rib) trapezoidal sheets — a structural roofing panel with deep stiffening ribs that delivers superior span strength, wind uplift resistance, and weather performance for industrial warehouses, commercial buildings, and cyclone-prone regions. Housing both sheet making capabilities in a single machine frame allows roofing sheet manufacturers to supply the complete range of metal roofing products their customers require from one production investment.
Sheet Making Transformation — From Flat Steel Coil to Finished Roofing Sheet
| Making Stage |
Roller Stations |
Metal Deformation During Sheet Production |
| Material Reception |
Station 1 |
The flat steel strip enters the first roller pair from the hydraulic decoiler at controlled tension. The entry rollers align the strip to the machine centerline and constrain it laterally, establishing the sheet reference axis. The initial edge flange formation begins as the strip passes through the entry guide channel into the making zone |
| Bend Initiation |
Stations 2–5 |
Profile-specific roller contours apply gentle bending pressure at the exact longitudinal positions where corrugated wave crests or IBR stiffening ribs will form. Each station contributes 5–10 degrees of angular change. The steel remains within its safe forming envelope, preventing zinc coating micro-fractures on galvanized raw material |
| Profile Development |
Stations 6–12 |
Wave trough depth increases and crest radius tightens for corrugated sheets; rib side walls steepen and valley floors flatten for IBR sheets. Seven consecutive stations distribute the total deformation evenly, achieving uniform plastic flow that maintains consistent sheet gauge thickness throughout all bent profile regions |
| Sheet Geometry Finalization |
Stations 13–16 |
The final active forming rollers establish the exact finished sheet dimensions — wave amplitude and pitch for corrugated output; rib crown height, valley base width, and side lap geometry for IBR output. Springback compensation engineered into the roller profiles ensures the made sheet holds its design dimensions after leaving the forming zone |
| Quality Calibration |
Stations 17–18 |
A final sizing roller pair performs a quality verification pass that corrects any residual dimensional deviation. At this stage the sheet has reached its complete engineered cross-section, verified to within ±0.5mm of the profile engineering drawing across the entire sheet cover width |
Sheet Making Roller Tooling Specifications
| Tooling Parameter |
Corrugated Sheet Making Deck |
IBR Sheet Making Deck |
| Forming Station Count |
13–16 pairs of upper and lower making rollers |
14–18 pairs of upper and lower making rollers |
| Roller Base Material |
45# medium carbon forged steel billet stock; ultrasonically inspected for internal soundness before CNC machining |
45# medium carbon forged steel billet stock; ultrasonically inspected for internal soundness before CNC machining |
| Profile Contour Machining |
CNC lathe contour turning using sinusoidal wave form cutting tool; profile geometry accuracy ±0.05mm |
CNC lathe contour turning using trapezoidal rib form cutting tool; profile geometry accuracy ±0.05mm |
| Heat Treatment |
Controlled-atmosphere gas carburizing furnace processing; oil quench hardening; surface HRC 58–62 with impact-resistant ductile core retained |
Controlled-atmosphere gas carburizing furnace processing; oil quench hardening; surface HRC 58–62 with impact-resistant ductile core retained |
| Chrome Surface Plating |
Industrial hard chrome electrodeposition; 0.05mm minimum deposit thickness; mirror-grade polished finish for zero friction sheet making |
Industrial hard chrome electrodeposition; 0.05mm minimum deposit thickness; mirror-grade polished finish for zero friction sheet making |
| Drive Shaft Specification |
Φ75–Φ80mm 40Cr alloy steel bar; precision ground to h7 dimensional tolerance; keyway machined for drive sprocket mounting |
Φ75–Φ80mm 40Cr alloy steel bar; precision ground to h7 dimensional tolerance; keyway machined for drive sprocket mounting |
| Bearing Assembly |
Split cast iron pillow block housing; double-row self-aligning spherical roller bearing element; lubricated through Zerk grease fitting |
Split cast iron pillow block housing; double-row self-aligning spherical roller bearing element; lubricated through Zerk grease fitting |
Finished Sheet Product Specifications
| Sheet Output Parameter |
Corrugated Sheet Product |
IBR Sheet Product |
| Effective Sheet Cover Width |
660mm to 1000mm coverage per sheet |
762mm to 1100mm coverage per sheet |
| Profile Depth Measurement |
12–18mm crest-to-trough wave amplitude |
28–43mm rib crown elevation above valley plane |
| Waves or Ribs per Sheet |
5, 7, 9, or 11 sinusoidal wave repetitions |
4, 5, or 6 trapezoidal stiffening ribs |
| Sheet Length Making Range |
1.0m minimum to 14.0m maximum per made sheet |
1.0m minimum to 14.0m maximum per made sheet |
| Sheet Side Joint Design |
1.5-wave minimum overlap for weatherproof longitudinal sheet connection |
Single overlap with optional anti-capillary groove profile for water-sealed side lap joint |
| Coil Input Width Requirement |
914–1220mm flat strip before making process |
1000–1250mm flat strip before making process |
Machine Frame, Power Drive, and Digital Control Engineering
| System |
Construction and Build Specification |
| Welded Main Frame Assembly |
Heavy channel steel longitudinal beams and cross-braced H-beam vertical columns in 300H–400H structural grade steel. The complete welded chassis undergoes post-fabrication thermal stress-relief annealing in an industrial furnace to eliminate residual welding stresses. After heat treatment, every bearing mounting pad is precision machined flat to ensure absolute shaft axis parallelism through all roller stations in both sheet making decks |
| Motor and Reduction Drive |
5.5kW or 7.5kW AC induction motor (4-pole, 1440 rpm rated speed, IP54 protection class) driving a worm-type dual-output shaft speed reducer with oil-bath gear lubrication. Available reduction gear ratios: 1:40 for higher-speed making of thinner gauge sheets or 1:59 for higher-torque making of heavier gauge sheets. Each gearbox output shaft independently powers one complete sheet making deck through a dedicated heavy-duty double-row industrial roller chain circuit with hardened alloy steel sprockets and individual chain tension adjustment per loop |
| Hydraulic Sheet Cutting Unit |
4.0kW gear-type hydraulic pump motor feeding an 80-liter oil reservoir system equipped with inline return filtration, breather cap, sight glass oil level gauge, and oil temperature monitoring. The flying shear carriage rides on precision linear guide rails and features a pneumatic sheet clamping mechanism. The Cr12MoV cold-work die steel blade set is vacuum heat treated to HRC 60–64 and profile-ground to precisely match the sheet cross-section for clean, burr-free cuts that preserve the made sheet profile geometry without deformation |
| PLC Digital Control Architecture |
Programmable logic controller processor (customer-selectable brand: Siemens S7-1200 series, Delta DVP series, or Mitsubishi FX3U series) with variable frequency drive inverter providing stepless sheet making speed regulation. Operator interface: 7-inch or 10-inch color LCD touchscreen HMI panel with multi-language display support and programmable recipe storage memory. Real-time sheet length measurement via rotary pulse encoder mounted on the final forming shaft with continuous digital feedback to the PLC auto-correction algorithm. Safety infrastructure: mechanical limit switches at shear carriage home and over-travel detection positions plus three emergency stop mushroom-head pushbutton stations located along the sheet making line at the operator control position, shear cutting station, and finished sheet discharge area |
Complete Sheet Making Production Line Equipment
| No. |
Line Equipment |
Function in Sheet Making Production |
| 1 |
Hydraulic Mandrel Uncoiler |
Supports the raw steel coil on hydraulically expanding jaw elements with 5-ton or 8-ton load capacity rating. Pneumatic or mechanical disc brake system provides adjustable drag resistance for consistent strip pay-off tension ensuring uniform sheet making quality from coil start to coil finish |
| 2 |
Entry Alignment and Pre-Shear Station |
Adjustable-width side guide roller rails center the incoming strip precisely on the sheet making machine axis. Integrated manual guillotine blade squares the coil leading edge prior to threading the strip into the selected roller deck entrance for production commencement |
| 3 |
Main Double Layer Sheet Making Unit |
Central production station integrating the lower corrugated sheet making roller deck and upper IBR sheet making roller deck within a single welded structural frame. A pivoting material diverter plate at the machine entry directs the strip into whichever deck is active. Both decks share a common drive motor, dual-output gearbox, chain drive circuits, hydraulic post-cut shear, and PLC digital control system |
| 4 |
Flying Hydraulic Post-Cut Shear |
Upon receiving the cut command signal from the PLC controller, the shear carriage assembly accelerates to synchronize with the sheet making line speed. A pneumatic clamp secures the formed sheet, the hydraulic actuating cylinder drives the profiled cutting blade through the sheet cross-section, then both blade assembly and carriage retract to the home position — the complete cut-and-return operating cycle is executed without interrupting continuous sheet making production flow |
| 5 |
Digital Electrical Control Cabinet |
IP54 weather-resistant steel enclosure housing the PLC central processing unit, VFD inverter module, motor contactors, thermal overload protection relays, circuit breakers, and terminal connection blocks. The color touchscreen HMI operator panel is externally mounted for convenient access to sheet length value programming, production batch quantity setting, making speed adjustment, and fault condition diagnostic display |
| 6 |
Sheet Discharge Roller Conveyor |
3m–5m free-roller receiving table with height-adjustable support legs. Receives finished cut sheets as they exit the hydraulic shear station and provides a stable ergonomic platform for manual sheet collection, stacking into product bundles, strapping, and transport to finished goods warehouse storage |
Technical Specification Data Sheet
| Specification Parameter |
Technical Data Value |
| Compatible Raw Material Types |
Hot-dip galvanized steel coil (zinc coating mass Z60–Z275 g/m²), pre-painted galvanized iron coil (PPGI with polyester, SMP, or PVDF paint topcoat system), aluzinc/Galvalume coated steel (AZ150–AZ200), cold-rolled steel strip, aluminum alloy sheet coil (grade 1100 and 3003 series) |
| Sheet Material Thickness Range |
0.25mm to 0.80mm (equivalent to gauge 30 through gauge 20) |
| Material Yield Strength Limit |
200 MPa up to 400 MPa covering mild steel grades through high-tensile structural steel grades |
| Sheet Making Production Speed |
10–18 linear meters of finished sheet per minute; infinitely variable speed control through the VFD inverter digital interface |
| Made Sheet Cut Length Accuracy |
±1.0mm at any operator-programmed sheet length via rotary encoder real-time digital pulse feedback to the PLC auto-correction control algorithm |
| Sheet Type Production Changeover |
Manual pivoting material diverter plate repositioning operation; switch from corrugated sheet making to IBR sheet making completed in approximately 10–15 minutes including the strip re-threading procedure into the alternate roller deck |
| Electrical Power Supply |
380V 50Hz 3-phase standard factory configuration; custom voltage options (220V, 415V, 440V, 480V) and frequency (50Hz or 60Hz) configured to match the destination country electrical grid specifications |
| Total Connected Motor Power |
Approximately 10–12 kW combined total (main drive motor 5.5/7.5kW + hydraulic pump motor 4.0kW) |
| Machine Overall Dimensions |
Approximately L 7.0–8.0m × W 1.4–1.6m × H 1.7–2.0m; final machine dimensions determined by the ordered roller station quantity and frame structural specification grade |
| Machine Net Shipping Weight |
5.0 to 7.5 metric tons depending on the selected profile configuration, roller station count, and frame structural grade specification |
| Uncoiler Coil Weight Capacity |
5 metric tons standard duty rating or 8 metric tons heavy duty rating per customer daily production throughput requirement |
| Coil Inner Bore Diameter |
Φ508mm industry standard bore diameter; Φ610mm bore diameter available with uncoiler mandrel adapter sleeve upon request |
Sheet Making Production Workflow — Coil Loading to Finished Sheet Stacking
| Step |
Workflow Operation |
Operational Detail |
| 1 |
Raw Coil Installation |
Steel coil crane-lifted or coil-cart-delivered onto the hydraulic uncoiler expanding mandrel; hydraulic jaws engage and securely lock the coil inner bore diameter; brake resistance adjusted to deliver uniform strip feed tension throughout the entire sheet making production run |
| 2 |
Strip Alignment and Entry |
Coil leading edge guided through the adjustable entry side roller alignment assembly to achieve precise centerline positioning on the sheet making machine axis; manual guillotine pre-shear squares the coil head before the strip enters the selected roller deck entrance point |
| 3 |
Making Deck Activation |
Operator positions the pivoting material diverter guide plate — downward orientation routes the strip into the lower corrugated sheet making deck; upward orientation routes into the upper IBR sheet making deck. Changing from one sheet product type to the other requires approximately 10 minutes for diverter repositioning and strip re-threading |
| 4 |
Sequential Roll Forming |
The flat steel strip advances progressively through each roller station pair in sequence; at every station the metal receives controlled incremental bending deformation until, emerging from the final forming station, the strip has been fully transformed into a complete corrugated wave sheet or finished IBR trapezoidal profile sheet ready for cutting to the specified length |
| 5 |
Sheet Length Monitoring |
Rotary pulse encoder mounted on the final drive shaft transmits continuous digital pulse signals to the PLC central processor; the controller compares the real-time accumulated pulse count against the operator-entered target sheet length value programmed on the touchscreen HMI display panel |
| 6 |
Automatic Sheet Cutting |
When the target sheet length is reached the PLC initiates the automated cutting sequence: pneumatic sheet clamp engages and secures the formed sheet → shear carriage accelerates to synchronize with the making line speed → hydraulic cylinder drives the profiled Cr12MoV blade through the complete sheet cross-section → blade assembly retracts and carriage returns to the home reference position — the entire cut cycle is executed without stopping or reducing sheet making production speed |
| 7 |
Finished Sheet Handling |
The separated completed sheet slides onto the free-roller discharge conveyor table surface; the operator lifts each finished sheet and stacks it onto the product pallet or sheet bundle for steel strapping, finished goods inventory warehousing, and delivery to building material customers or construction project sites |
Sheet Making Business — Investment and Operating Cost Comparison
| Cost Comparison Factor |
Two Separate Sheet Making Production Lines |
One Double Layer Sheet Making Production Line |
| Initial Equipment Capital Cost |
100% baseline — total purchase price of two complete sheet making machines plus two uncoilers |
Approximately 65–75% of the combined two-machine total expenditure |
| Factory Floor Footprint |
44–70 square meters occupied by both sheet making lines |
20–35 square meters for the single dual-output sheet making line |
| Export Container Freight Charges |
Two 20GP shipping containers, two separate ocean freight invoices |
One 20GP or 40HQ shipping container, single consolidated ocean freight invoice |
| Foundation and Power Infrastructure |
Two concrete machine foundation pads, two electrical power supply drops, two cable installation runs |
Single concrete machine foundation pad, one electrical power supply drop, one cable installation run |
| Production Workforce per Shift |
3–4 operators required across two independent sheet making lines |
1–2 operators sufficient for one dual-deck sheet making line per production shift |
| Monthly Electrical Energy Cost |
Two drive motors and two hydraulic pump motors drawing power simultaneously |
Single drive motor and single hydraulic pump motor operating — approximately 40% reduction in monthly electricity consumption |
| Spare Wearing Parts Inventory |
Two complete sets of wearing components held in warehouse spare parts stock |
One spare parts kit services both sheet making roller decks |
Global Markets for Sheet Making Machine Investment
- Sub-Saharan Africa — Nigeria, Ghana, Ivory Coast, Kenya, Tanzania, Uganda, Zambia, and South Africa represent the world's fastest-growing markets for corrugated sheet making equipment serving mass residential roofing, agricultural building construction, and public infrastructure projects. IBR sheet making capability adds a premium product tier serving government buildings, commercial complexes, warehouse roofing, and industrial facility construction.
- South Asia — India, Pakistan, Bangladesh, and Sri Lanka collectively form the highest-volume market for corrugated metal sheet making on earth. IBR sheet making demand is expanding rapidly across organized industrial construction, modern logistics warehousing, cold chain storage facilities, and retail infrastructure development throughout the subcontinent.
- Southeast Asia — Indonesia, the Philippines, Vietnam, Thailand, and Myanmar sustain robust demand for corrugated sheet making serving rural housing, farm building, and community facility construction markets. IBR sheet making is mandated by typhoon-resistant building code requirements for commercial roof and wall sheeting applications across the entire region.
- Middle East and North Africa — UAE, Saudi Arabia, Qatar, Oman, Iraq, Egypt, and Morocco deploy IBR sheet making production lines for logistics park warehouse roofing, cold storage facility building sheeting, and industrial zone cladding manufacturing. Corrugated sheet making supplies the labor accommodation camp, temporary construction site office, and perimeter security enclosure production sectors.
- Latin America and Caribbean — Brazil, Mexico, Colombia, Peru, Chile, and Caribbean island states require both sheet making capabilities: corrugated sheet making for agricultural building construction and affordable housing development; IBR sheet making for industrial shed roofing and commercial building envelope construction throughout the region.
- Pacific and Oceania — Australia, New Zealand, Fiji, Papua New Guinea, and Pacific island nations specify IBR made sheets in cyclone-rated structural building standards for roof and wall cladding applications. Corrugated made sheets provide cost-effective building enclosure products for community halls, farm structures, and rural housing projects across the island nations.
Pre-Export Factory Quality Verification Protocol
Prior to export crating, every completed sheet making machine is required to pass a rigorous three-phase factory quality verification procedure. Phase one — comprehensive dimensional inspection protocol: all roller gaps at every forming station are measured using calibrated feeler gauges and cross-checked against the engineering tolerance specification table; shaft concentricity runout is verified at every bearing position with dial test indicators; frame structural alignment and squareness are confirmed using precision spirit levels and cross-laser measurement instrumentation. Phase two — extended no-load operational endurance trial: the machine operates continuously at maximum rated sheet making speed without material for a minimum duration of four hours; bearing housing temperatures are monitored and recorded at 30-minute intervals using infrared non-contact thermometers; chain drive sprocket tooth engagement is inspected visually and audibly for smooth, even meshing characteristics; every PLC control function undergoes complete operational validation testing including power-up sequencing, motor start and stop, sheet making speed regulation, sheet length value programming, production batch quantity setting, product recipe storage and recall, emergency stop circuit activation, and full system restart — confirming total control system integration and fault-free operational capability. Phase three — live sheet making production validation trial: factory technicians load genuine galvanized steel coil raw material stock and make 50 consecutive corrugated sheets plus 50 consecutive IBR sheets under actual production conditions; every 10th made sheet is measured for finished length, wave pitch spacing or rib profile geometry, and cut edge quality using calibrated digital measuring instruments. Only machines achieving zero out-of-tolerance measurement results across all three inspection phases receive final approval for export protective packaging and container loading.
Export Packaging Standard, Manufacturing Schedule, and Warranty Coverage
The main sheet making machine body receives comprehensive multi-layer protective export packaging engineered for ocean freight transit conditions: an inner wrap layer of VCI (volatile corrosion inhibitor) anti-rust protective film; a middle layer of high-density closed-cell foam padding applied to all corners, machined surfaces, and protruding mechanical components; an outer wrap layer of heavy-gauge UV-stabilized polyethylene shrink film providing moisture ingress protection, dust contamination prevention, and mechanical handling damage resistance during transit. The fully wrapped assembly is securely bolted through its base frame structure to a fumigated ISPM-15 certified plywood pallet or welded structural steel export skid. The hydraulic uncoiler unit, sheet discharge roller conveyor table, hydraulic power pack assembly, and digital electrical control enclosure are each packed individually in purpose-built marked fumigated wooden crates with internal closed-cell foam bracing and bolted steel tie-downs for secure ocean freight transit. A dedicated accessories crate contains the operator hand tool kit, starter set of spare wearing parts, and one complete printed set of technical documentation: mechanical assembly engineering drawings with exploded component identification views, electrical wiring schematic diagram with terminal block and wire number labeling, PLC parameter programming and configuration reference guide, daily and weekly lubrication maintenance schedule chart with recommended grease type specifications, and the comprehensive English-language operation and maintenance instruction manual. Standard factory manufacturing lead time is 25–35 working days from confirmed deposit payment receipt and customer-signed profile approval engineering drawings. Standard warranty coverage is 12 months from the ocean bill of lading date against defects in materials and factory workmanship quality.
Optional Sheet Making Line Enhancements
| Optional Enhancement |
Description and Operational Benefit |
| Servo Motor Drive System Upgrade |
Replace the standard AC induction drive motor with a programmable precision servo motor drive system for controlled sheet making acceleration and deceleration motion profiles, enhanced finished sheet length accuracy, and reduced electrical energy consumption during intermittent production cycle operation |
| Automatic Sheet Stacking Mechanism |
Motorized stacking arm assembly that transfers finished made sheets from the discharge roller conveyor table to neatly aligned product bundles positioned on a waiting pallet, eliminating manual sheet handling labor requirements and reducing operator physical fatigue during extended production shift operations |
| Electric Coil Loading Transport Cart |
Battery-electric powered trolley operating on floor-mounted steel guide rails with integrated hydraulic scissor lift platform mechanism; safely transports raw steel coils weighing up to 10 metric tons from warehouse coil storage directly to the uncoiler expanding mandrel without requiring overhead crane equipment availability |
| IoT Remote Production Monitoring |
4G cellular network-connected module that transmits real-time sheet making production performance metrics — daily finished sheet output tally count, motor operating hours accumulation, equipment fault diagnostic trouble codes, and scheduled preventive maintenance interval reminder notifications — to a dedicated smartphone mobile application or web-based production management dashboard interface |
| Custom Embossing Roller Station |
Specially engraved forming roller pair integrated into the sheet making roller sequence that permanently imprints a manufacturer brand name, company identification logo, or production date batch code into each sheet during the making process for product traceability identification and market brand recognition purposes |
| Stainless Steel Roller Tooling Option |
Complete sheet making roller set manufactured from grade 304 or 316L austenitic stainless steel material for sheet making production operations in food-grade processing facilities, pharmaceutical manufacturing plants, chemical industry production environments, or high-atmospheric-salinity coastal production locations where standard carbon steel rollers would be vulnerable to accelerated corrosion degradation |
