helen@hbxinnuorollforming.com
- Complete IBR and corrugated sheeting production line ready for immediate factory deployment
- Two fully independent roller carriages housed in one 350H welded steel main frame
- IBR trapezoidal roof sheets spanning 686 mm to 1050 mm effective coverage width
- Corrugated wave sheeting covering 665 mm to 990 mm effective coverage width
- 5 to 15 minute profile switch via mechanical diverter guide without roller removal
- Each machine undergoes full-load test run with customer-specified coil before packing
- Comprehensive 12-month warranty with remote diagnostics and spare parts support
Buying a roll forming machine is a significant capital decision, and understanding exactly what arrives at your factory gate — and what it takes to go from unboxing to full-capacity production — is critical to making an informed purchase. This double layer IBR and corrugated roof sheeting machine for sale is a complete, factory-tested, container-ready production line that produces the two highest-demand metal roofing profiles from a single machine footprint. Below is a transparent breakdown of what the purchase includes, how the machine is built and tested, what preparation your facility requires, and what ongoing support you receive after delivery.
| # | Included Item | Quantity | Description and Specification |
|---|---|---|---|
| 1 | Main Double Layer Forming Machine Body | 1 unit | 350H/400H H-steel welded frame housing both IBR and corrugated roller carriages; includes diverter assembly, drive system, and protective guards |
| 2 | Hydraulic Decoiler / Uncoiler | 1 unit | 5-ton or 8-ton load capacity; expanding mandrel type; manual, pneumatic, or hydraulic mandrel expansion per selection |
| 3 | PLC Control Cabinet with HMI | 1 unit | Industrial-grade PLC; 7-inch color touchscreen; preloaded with IBR and corrugated production recipes; multi-language interface |
| 4 | Hydraulic Power Station | 1 unit | 4.0 kW motor, gear pump, 60-80 L oil reservoir, pressure gauge, relief valve, air-cooled radiator, hydraulic hoses with quick-connect fittings |
| 5 | Run-Out Roller Conveyor Table | 1 unit | 3-meter or 4-meter powered roller conveyor with side alignment rails; height-adjustable support legs |
| 6 | Spare Shear Blade Set | 1 set (2 pcs) | Upper and lower Cr12MoV blades, HRC 60-62, identical to factory-installed blades; individually wrapped in anti-corrosion paper |
| 7 | Standard Maintenance Toolkit | 1 kit | Combination wrenches (8-32 mm), hex key set, adjustable wrench, grease gun with lithium grease cartridge, feeler gauge set, steel ruler, spirit level |
| 8 | Printed Documentation Package | 1 set | Installation manual (English), operation manual, maintenance schedule chart, electrical wiring schematic (A2 size), hydraulic circuit diagram (A2 size), foundation bolt layout drawing |
| 9 | Digital Documentation USB Drive | 1 unit | All printed documents in PDF format; step-by-step commissioning video (approx. 45 minutes); PLC parameter backup files; spare parts catalog with part numbers; machine general arrangement CAD drawing |
| 10 | Foundation Anchor Bolts | 1 set | High-tensile steel anchor bolts with nuts and washers; quantity and size matched to machine frame bolt-hole pattern |
| 11 | Anti-Rust Protective Coating | Applied to all machined surfaces | All roller surfaces, shaft ends, chain and sprocket assemblies, shear blade edges, and exposed machined surfaces coated with removable anti-corrosion grease before container packing |
| 12 | Fumigated Wooden Crating | As required | ISPM-15 compliant fumigated solid wood crates and pallets; moisture-barrier plastic wrapping inside crates; steel banding for container securing |
Every double layer IBR and corrugated roof sheeting machine manufactured for sale undergoes a systematic pre-delivery inspection and test protocol. This is not a spot-check on a sample unit — it is a full functional test performed on the exact machine that will be packed into your container. The testing sequence is as follows:
| Stage | Inspection Item | What Is Checked | Acceptance Standard |
|---|---|---|---|
| 1 | Frame Dimensional Verification | Laser measurement of wall plate parallelism, bearing seat bore alignment, frame diagonal squareness, base flatness | Parallelism deviation ≤ 0.10 mm/m; diagonal difference ≤ 1.0 mm; base flatness ≤ 0.50 mm/m² |
| 2 | Roller Contour Inspection | Each roller measured against its CAD profile template using profile projector or CMM; chrome thickness verified with coating gauge | Profile deviation ≤ 0.05 mm at any point; chrome layer thickness 0.03-0.05 mm; no pits, cracks, or peeling |
| 3 | Shaft Run-Out Measurement | Each installed shaft checked with dial indicator for radial run-out at bearing journals and roller-mounting sections | Bearing journal run-out ≤ 0.02 mm; roller section run-out ≤ 0.03 mm |
| 4 | Chain Drive Dry Run | Main motor engaged without material load; IBR and corrugated drive chains each run for minimum 30 minutes; visual and thermal inspection | Smooth chain movement without binding or skipping; sprocket temperature rise ≤ 15°C above ambient; no abnormal noise |
| 5 | Hydraulic System Pressure Test | Hydraulic power pack operated; system pressurized to 21 MPa working pressure; hold for 15 minutes; inspect all fittings | Zero pressure drop over hold period; zero fluid leakage at any fitting, hose, or cylinder seal |
| 6 | IBR Profile Load Test | Actual customer-specified PPGI coil (or equivalent) loaded; machine run at 8, 12, and 16 m/min; minimum 10 sheets produced | Profile dimensions match drawing within ±0.5 mm; no surface scratches on paint; sheet straightness deviation ≤ 2 mm per meter |
| 7 | Corrugated Profile Load Test | Same coil material; diverter switched to corrugated path; machine run at 8, 12, and 16 m/min; minimum 10 sheets produced | Wave height and pitch match drawing within ±0.3 mm; uniform wave pattern; no coil surface damage |
| 8 | Shear Accuracy Verification | 10 sheets cut at three different programmed lengths (2.0 m, 3.5 m, 6.0 m); each sheet measured with calibrated steel tape | Actual length within ±1.5 mm of programmed value for all 30 test sheets; cut edge square and burr-free |
| 9 | PLC Function Check | All HMI functions tested: length input, batch count, auto-stop, emergency stop, recipe save/load, language switching, speed adjustment | Every function operates as specified; emergency stop halts machine within 0.5 seconds; encoder pulse count verified against measured length |
| 10 | Final Visual & Documentation Review | Paint finish, weld quality, label affixing, tool kit completeness, document package contents checked against packing list | Zero paint defects, weld porosity, or missing labels; all documentation and tools present per packing list |
Upon completion of all 10 inspection stages, the machine receives a signed Factory Acceptance Test (FAT) certificate. A copy of this certificate, along with photos of your specific machine during each test stage, is included in the documentation package. Video recordings of the IBR and corrugated profile load tests are saved to the USB drive. You are welcome to visit the factory in person to witness the testing of your machine, or to receive a live video-streamed demonstration upon request.
| Preparation Item | Requirement and Guidance |
|---|---|
| Floor Space Allocation | Minimum clear area: 22 meters length × 3.5 meters width (approximately 77 m²). Include additional space at coil-loading end for forklift access and at discharge end for finished sheet stacking and handling. Recommended total dedicated zone: 10 m × 5 m (50 m²) plus material staging area. |
| Reinforced Concrete Foundation | Concrete pad minimum thickness 200 mm, C25 grade or higher, with embedded steel reinforcement mesh. Machine anchor bolt positions per supplied foundation layout drawing. Pad surface must be level within ±3 mm across the full machine footprint. Allow minimum 7 days concrete curing before machine installation. |
| Electrical Power Supply | 3-phase power connection rated for minimum 20 kW total load (11 kW main motor + 4 kW hydraulic + control system + lighting margin). Supply cable terminated in a lockable industrial isolator switch within 5 meters of the planned PLC control cabinet location. Voltage must match machine specification (standard: 380V/50Hz; confirm custom voltage if ordered). |
| Overhead Crane or Forklift | Lifting equipment with minimum 5-ton safe working load for unloading the main machine body from the container and positioning it on the foundation. The main frame weighs approximately 3.5-5.5 tons depending on grade and roller count. Spreader bar and slings rated for the load are required. |
| Compressed Air (Optional) | If pneumatic decoiler expansion or optional automatic stacking arm is ordered: compressed air supply at 0.6-0.8 MPa with minimum 200 L/min flow rate. Air must be filtered and lubricated. 1/2-inch BSP quick-connect coupling at machine location. |
| Raw Material Inventory | At minimum 5-10 tons of PPGI or galvanized coil in the gauge and width required for your target IBR and corrugated profiles. Having test material on-site enables immediate commissioning without waiting for coil delivery after machine installation. |
| Operator Selection | Designate one primary operator before machine arrival. Operator should have basic mechanical aptitude and English literacy sufficient to navigate the HMI touchscreen and read the operation manual. No prior roll forming experience is necessary — all essential skills are covered in the commissioning process. |
Understanding the commercial specifications of the roof sheeting products your machine will produce helps you plan your product catalog, pricing structure, and marketing strategy. The following tables present the standard IBR and corrugated sheeting specifications from the end-customer's perspective — the information your sales team will use to quote projects and write invoices.
| IBR Trapezoidal Roof Sheeting — Commercial Product Range (Upper Machine Tier) | ||||||
|---|---|---|---|---|---|---|
| Product Code | Cover Width | Rib Height | Ribs / Sheet | Standard Lengths | Weight per m² (0.4 mm) | Typical Retail Market |
| IBR-686 | 686 mm | 43 mm | 5 | 1.8 – 8.0 m | ~4.6 kg | South Africa, Botswana, Namibia, Zimbabwe — SANS-compliant residential |
| IBR-762 | 762 mm | 43 mm | 5 | 2.0 – 10.0 m | ~4.1 kg | Kenya, Tanzania, Uganda, Yemen — industrial warehouse standard |
| IBR-840 | 840 mm | 35 mm | 4-5 | 2.0 – 12.0 m | ~3.7 kg | Nigeria, Ghana, Philippines, Indonesia — commercial and institutional |
| IBR-925 | 925 mm | 38 mm | 5 | 2.5 – 14.0 m | ~3.4 kg | UAE, Saudi Arabia, Qatar — large-span factory and hangar roofing |
| IBR-1050 | 1050 mm | 28 mm | 6-7 | 2.0 – 13.0 m | ~3.0 kg | Australia, NZ, Pacific — cyclone-rated wall and roof cladding |
| Corrugated Wave Roof Sheeting — Commercial Product Range (Lower Machine Tier) | ||||||
|---|---|---|---|---|---|---|
| Product Code | Cover Width | Wave Height | Waves / Sheet | Standard Lengths | Weight per m² (0.4 mm) | Typical Retail Market |
| CR-665 | 665 mm | 17 mm | 11 | 1.5 – 6.0 m | ~4.7 kg | El Salvador, Guatemala, Honduras — agricultural and fencing |
| CR-715 | 715 mm | 17 mm | 11 | 1.5 – 7.0 m | ~4.4 kg | Ghana, Burkina Faso, Senegal — rural housing and school projects |
| CR-762 | 762 mm | 17 mm | 12 | 2.0 – 9.0 m | ~4.1 kg | Chile, Peru, Bolivia — mining infrastructure and warehouse siding |
| CR-836 | 836 mm | 17 mm | 11 | 2.0 – 8.0 m | ~3.7 kg | Kenya, Tanzania, Rwanda — mass housing and humanitarian shelter |
| CR-990 | 990 mm | 17 mm | 13 | 2.5 – 10.0 m | ~3.2 kg | Mauritius, Seychelles, Maldives — resort and coastal construction |
| Technical Parameter | Specification Data |
|---|---|
| Machine Type & Configuration | Double layer cold roll forming machine; upper carriage: IBR trapezoidal profile; lower carriage: corrugated sinusoidal wave profile; vertically stacked architecture with shared drive and shear |
| Structural Frame Grade | 350H welded H-section structural steel (standard); 400H (heavy-duty option for deep-rib IBR ≥ 43 mm or machine weight > 7 tons) |
| Side Panel / Wall Plate | 16-20 mm CNC laser-cut steel plate; precision-bored bearing housing bores with tolerance H7 for accurate shaft alignment |
| IBR Roller Stations | 14 to 18 rows; each station: one pair hardened chrome rollers mounted on keyed shafts with dual self-aligning bearings |
| Corrugated Roller Stations | 12 to 16 rows; same bearing, shaft, and chrome specification as IBR carriage |
| Roller Core Material | 45# medium-carbon steel forging (equivalent to AISI/SAE 1045); CNC contour-turned to ±0.03 mm profile tolerance |
| Roller Surface Finish | Industrial hard chrome electroplate, 0.03-0.05 mm thickness, HRC 58-62 hardness; mirror-polished forming contact surfaces |
| Shaft Specification | Φ75 mm or Φ80 mm diameter solid alloy steel, centerless precision ground; keyway per GB/T 1095 standard for sprocket mounting |
| Bearing Type | Double-row self-aligning spherical roller bearing (22xxx or 23xxx series); split pillow block housing; Zerk-type grease nipple |
| Drive Transmission | Duplex roller chain, 6-fen (19.05 mm) pitch standard or 1-inch (25.4 mm) pitch heavy-duty; hardened and precision-ground sprockets |
| Tier Selector | Manual lever-operated diverter plate with spring-loaded positive-lock detent; upper position = IBR path, lower = corrugated path |
| Main Drive Motor | 3-phase AC squirrel-cage induction motor; 7.5 kW (standard) or 11 kW (heavy-duty); 4-pole (approx. 1450 rpm at 50 Hz) |
| Speed Regulation | Variable frequency drive (VFD) with digital keypad; 0-50 Hz output range; stepless speed 0-18 m/min; acceleration/deceleration ramp programmable |
| Gearbox Ratio | Cycloidal pinwheel or helical-bevel reduction gearbox; ratio selected to match motor speed to target forming speed range |
| Hydraulic Power Pack | 4.0 kW motor; gear-type pump (8-12 cc/rev displacement); 60-80 L reservoir; air-cooled radiator; pressure gauge 0-40 MPa; relief valve set at 25 MPa |
| Shear Mechanism | Guillotine-type flying post-cut; shear carriage on linear bearing rails with spring-return cylinder; blade set: Cr12MoV die steel |
| Blade Heat Treatment | Vacuum quench 1020-1040°C; triple temper 180-200°C; final hardness HRC 60-62; edge ground to 0.01-0.02 mm sharpness |
| Length Measurement System | Rotary incremental encoder (1000-2500 PPR) on friction measuring wheel; quadrature output to PLC high-speed counter input |
| Length Accuracy | ±1.5 mm at all rated forming speeds; verified by calibrated tape measurement on 30-sample test run per FAT protocol |
| PLC Controller Platform | Siemens SIMATIC S7-200/S7-1200, Delta DVP-SS2/DVP-SE, or Mitsubishi MELSEC FX3U/FX5U series — per customer brand preference |
| HMI Display | 7-inch TFT-LCD color touchscreen; 800×480 pixel resolution; resistive touch (glove-operable); RS-485/RS-232 communication to PLC |
| Electrical Enclosure Rating | IP54 dust and splash-proof control cabinet; forced-ventilation cooling fan with filter; cable entry via bottom gland plates |
| Acceptable Coil Material | PPGI (pre-painted galvanized iron), PPGL (pre-painted galvalume/Zincalume), HDGI (hot-dip galvanized iron), Al-Zn alloy coated (AZ50-AZ150), pre-painted aluminum strip |
| Material Gauge Range | 0.30 mm to 0.80 mm standard; 0.25 mm minimum and 1.00 mm maximum with engineering confirmation |
| Coil ID / OD Limits | Inner diameter: Φ450-520 mm; outer diameter: up to Φ1250 mm maximum; coil width: up to 1250 mm (IBR) / 1250 mm (corrugated) |
| Decoiler Load Rating | 5 metric tons (standard); 8 metric tons (heavy-duty); hydraulic or manual mandrel expansion; loop control sensor for tension regulation |
| Production Line Dimensions | Approximately 18-22 m total length × 2.5 m width × 2.5 m height (varies by frame grade and roller station count) |
| Machine Net Weight | 6.5 to 9.0 metric tons depending on frame grade (350H/400H), roller station count (14-18+12-16), motor power (7.5/11 kW), and optional attachments |
| Power Supply Standard | AC 380V ±10%, 50 Hz, 3-phase + neutral + earth (5-wire); customizable to 220V/440V/480V at 50 or 60 Hz |
| Profile Changeover Time | 5-15 minutes; operational steps: stop machine → move diverter lever → verify strip centering → select recipe on HMI → confirm length → restart |
| Noise Level | ≤ 85 dB(A) at 1 meter from machine at rated forming speed with 0.5 mm PPGI material |
| Design Service Life | ≥ 15 years under normal operating conditions (8-10 hours/day, 250-300 days/year) with recommended preventive maintenance |
| Support Item | Coverage Details | Duration / Conditions |
|---|---|---|
| Comprehensive Machine Warranty | Covers all manufacturing defects in materials and workmanship: frame weld failures, roller delamination, shaft breakage, bearing seizure, gearbox failure, motor winding faults, PLC/HMI malfunction, hydraulic pump failure, cylinder seal leakage | 12 months from date of shipment (bill of lading date); extended warranty available at additional cost |
| Wear Parts Coverage | Shear blades, drive chains, sprockets, bearings, hydraulic seals, V-belts (if equipped) covered for premature failure attributable to manufacturing defect | 6 months from date of shipment; normal wear-and-tear excluded |
| Remote Technical Support | Video-call diagnostics via WhatsApp, WeChat, Zoom, or Skype; technician visually inspects machine status, guides operator through troubleshooting, adjusts PLC parameters remotely if internet-connected HMI option purchased | Unlimited during warranty period; available after warranty on per-incident or annual contract basis |
| Spare Parts Supply | All machine components available as spare parts with factory part numbers; express air freight shipment for urgent breakdown parts (2-7 business days worldwide); sea freight for planned maintenance stock orders | Lifetime parts availability commitment; prices quoted per inquiry |
| On-Site Service Technician | Factory-trained technician dispatched to customer facility for commissioning, major repair, roller changeover, or profile addition; technician handles airfare, accommodation, meals; customer provides local transportation and translator if needed | Available upon request; daily service rate applied; typical dispatch within 14 business days after visa processing |
| Operator Refresher Training | Remote video training session for new operators joining after initial commissioning; covers machine startup/shutdown, profile switching, HMI operation, basic troubleshooting, daily maintenance routine | 2 sessions included free within first 12 months; additional sessions available at nominal cost |
| Frequency | Maintenance Task | Procedure | Estimated Time |
|---|---|---|---|
| Daily | Clean roller surfaces and machine bed of metal debris | Use compressed air or soft brush to remove zinc and paint particles; wipe rollers with clean dry cloth; inspect for embedded debris | 10 minutes |
| Daily | Check hydraulic oil level and temperature | Read sight glass on reservoir; oil level between MIN and MAX marks; temperature gauge should not exceed 60°C after 1 hour operation | 2 minutes |
| Weekly | Lubricate drive chains | Apply chain lubricant spray to both IBR and corrugated drive chains while rotating slowly; wipe excess to prevent dirt accumulation | 15 minutes |
| Weekly | Grease all bearing housings | Pump lithium-based grease (NLGI #2) through Zerk fittings until fresh grease appears at seal; approximately 3-5 pumps per bearing | 20 minutes |
| Weekly | Inspect shear blade edge condition | Visually examine both upper and lower blade edges for chips, rounding, or uneven wear; test-cut one sheet and inspect cut quality | 10 minutes |
| Monthly | Check and adjust chain tension | Measure chain sag at midpoint of longest unsupported span; adjust idler sprocket position if sag exceeds 2% of span length | 15 minutes |
| Monthly | Tighten all accessible fasteners | Torque-check bearing housing bolts, sprocket set screws, motor mount bolts, guard panel screws; retighten to specification if loosened by vibration | 30 minutes |
| Monthly | Verify encoder measurement accuracy | Run machine to produce one sheet at 3.0 m programmed length; measure with calibrated tape; adjust encoder pulse-per-meter parameter if deviation exceeds ±1.5 mm | 15 minutes |
| Quarterly | Replace hydraulic oil filter element | Isolate hydraulic power pack; remove filter housing; replace disposable filter element with OEM-specification equivalent; check housing O-ring and replace if hardened | 20 minutes |
| Annually | Complete hydraulic oil change | Drain reservoir completely; flush with flushing oil if contaminated; refill with ISO VG 46 hydraulic oil (approximately 60-80 liters); replace suction strainer and return filter | 2 hours |
| Annually | Inspect all roller chrome surfaces | Examine each roller under good lighting for chrome peeling, pitting, or abnormal wear patterns; measure roller diameter at multiple points with micrometer; record in maintenance log | 2 hours |
| Annually | Check electrical connections and insulation | Tighten all terminal screws in control cabinet; megohmmeter test motor winding insulation (should exceed 1 MΩ at 500V DC); inspect cable glands for tightness | 1 hour |
| Quality Factor | Lower-Cost / Entry-Level Machines | This Double Layer IBR + Corrugated Machine |
|---|---|---|
| Frame Structure | Channel steel (C-section) or lighter H-beam; fewer cross ribs; thinner side plates (12-14 mm) | 350H/400H H-section steel with full cross-ribbed gusset plates; 16-20 mm CNC laser-cut side plates with precision-bored bearing seats |
| Roller Material | 45# steel without forging; CNC turned only, may skip surface grinding; decorative chrome or thin flash chrome | 45# hot-forged billet → CNC turned → surface ground → industrial hard chrome 0.03-0.05 mm → HRC 58-62 verified |
| Shaft Quality | Cold-drawn shaft without grinding; standard bearings without self-alignment; possible undersized diameter | Φ75-80 mm solid alloy steel, centerless precision ground; dual-row self-aligning spherical roller bearings throughout |
| Drive Chain | Single-row chain; unhardened sprockets; no idler tensioners; chain stretch within months | Duplex roller chain; hardened precision sprockets; adjustable idler tensioners at multiple points; chain sized for peak torque with safety margin |
| Shear Blades | Standard tool steel or even carbon steel; basic heat treatment; rapid edge dulling; burr formation on cuts | Cr12MoV / SKD11 die steel; vacuum quenched + triple tempered; HRC 60-62; 500,000+ cuts between sharpening |
| PLC / Electronics | Generic or unbranded controller; monochrome text display; limited functions; no recipe storage | Siemens / Delta / Mitsubishi PLC; 7-inch color touchscreen; 50 recipes; fault diagnostics; multi-language; encoder closed-loop |
| Pre-Delivery Testing | Dry run only or minimal test; no load test with actual material; no FAT documentation | 10-stage FAT protocol; load test with real coil material at three speeds; documented results with photos and video; FAT certificate issued |
| Documentation | Generic manual; no wiring schematic; no video guide; Chinese language only | Printed English manual set + USB with PDFs, CAD drawings, wiring/hydraulic schematics, commissioning video, PLC backup, spare parts catalog |
| After-Sales Support | Minimal or no post-delivery contact; parts difficult to obtain; no remote diagnostics capability | 12-month warranty; unlimited remote video support; lifetime spare parts; on-site technician available; operator refresher training included |
