helen@hbxinnuorollforming.com
Makes corrugated and trapezoidal metal roofs from one production machine
Lower deck produces wave profile roofing upper deck forms ribbed roofing
Fourteen to eighteen roller stations progressively shape flat steel strip
Hydraulic flying shear cuts finished metal roof panel at programmed length
PLC digital controller manages roof making speed length and batch output
Chrome plated forming rollers protect galvanized coating during the process
Entire metal roof production line delivered as single container shipment
This double layer metal roof making machine enables a single factory to manufacture two different metal roof profiles — corrugated wave roofing and IBR trapezoidal roofing — from one integrated production unit. The lower forming deck produces traditional corrugated metal roof panels, the world's most affordable and widely consumed roofing product for residential homes, farm buildings, and community structures. The upper forming deck manufactures IBR (Inverted Box Rib) metal roof panels, engineered with deep stiffening ribs that provide the span strength and weather resistance required for industrial warehouses, commercial complexes, and cyclone-prone regions. By housing both roof making capabilities in a single welded steel frame, roofing manufacturers avoid purchasing two separate machines while gaining the flexibility to serve every segment of their local construction market from budget housing to premium commercial projects.
| Roof Attribute | Corrugated Wave Metal Roof | IBR Trapezoidal Metal Roof |
|---|---|---|
| Profile Appearance | Smooth continuous sinusoidal wave curvature | Sharp trapezoidal ribs with flat valley sections |
| Effective Cover Width | 660mm to 1000mm per panel | 762mm to 1100mm per panel |
| Profile Height | 12–18mm wave crest-to-trough | 28–43mm rib crown above valley |
| Waves or Ribs per Panel | 5, 7, 9, or 11 wave repetitions | 4, 5, or 6 structural ribs |
| Made Length Range | 1.0m to 14.0m per roof panel | 1.0m to 14.0m per roof panel |
| Typical Building Type | Houses, barns, sheds, fences, community halls | Warehouses, factories, shopping centers, schools, hangars |
| Purlin Span Distance | Up to 2.5m between supports | Up to 4.5m between supports |
| Side Overlap Seal | Minimum 1.5-wave weathertight overlap | Single lap with optional anti-capillary groove |
| Making Stage | Station Range | What Happens to the Steel Strip |
|---|---|---|
| Strip Reception | Station 1 | Flat galvanized steel strip feeds from the hydraulic decoiler at regulated tension into the first roller pair. The entry rollers guide the strip laterally and establish the roof panel centerline axis. Edge flange formation begins as the material enters the roof making sequence |
| Bend Initiation | Stations 2–5 | Contoured rollers apply precise bending force at the positions where wave crests or ribs will form — approximately 5–10 degrees per station. Steel remains within safe forming limits to prevent damage to the galvanized zinc protective coating |
| Profile Development | Stations 6–12 | Wave troughs deepen and crests sharpen for corrugated roofs; rib walls steepen and valley sections flatten for IBR roofs. Seven consecutive stations evenly distribute the total deformation to maintain consistent panel thickness throughout all bent profile areas |
| Final Roof Geometry | Stations 13–16 | The last active forming rollers set the exact roof panel dimensions — wave amplitude and spacing for corrugated output; rib height, valley width, and side lap profile for IBR output. Springback compensation is built into the roller design |
| Calibration Pass | Stations 17–18 | A final sizing roller pair eliminates residual dimensional deviation. The metal roof panel achieves its complete engineered cross-section verified to within ±0.5mm of the profile drawing across the full panel width |
| Tooling Parameter | Corrugated Roof Making Deck | IBR Roof Making Deck |
|---|---|---|
| Station Count | 13–16 roller pairs | 14–18 roller pairs |
| Roller Material | 45# medium carbon forged steel, ultrasonically inspected | 45# medium carbon forged steel, ultrasonically inspected |
| CNC Machining | Sinusoidal wave contour turning, ±0.05mm accuracy | Trapezoidal rib contour turning, ±0.05mm accuracy |
| Hardening Method | Gas carburizing furnace, oil quench, HRC 58–62 surface | Gas carburizing furnace, oil quench, HRC 58–62 surface |
| Chrome Plating | Hard chrome electrodeposit, 0.05mm minimum, mirror polish | Hard chrome electrodeposit, 0.05mm minimum, mirror polish |
| Shaft Specification | Φ75–Φ80mm 40Cr alloy, h7 tolerance, keyway for sprocket | Φ75–Φ80mm 40Cr alloy, h7 tolerance, keyway for sprocket |
| Bearing Type | Split pillow block, spherical roller, Zerk grease fitting | Split pillow block, spherical roller, Zerk grease fitting |
| System | Construction Detail |
|---|---|
| Welded Frame Assembly | Heavy channel steel beams cross-braced with 300H–400H H-beam columns. Post-weld thermal stress-relief annealed in industrial furnace. Bearing mounting pads precision machined after heat treatment for exact shaft parallelism through all roller stations in both roof making decks |
| Motor and Gearbox | 5.5kW or 7.5kW AC induction motor, 4-pole, IP54 enclosure. Worm-type dual-output reducer with oil-bath lubrication. Gear ratios 1:40 or 1:59. Each output shaft independently drives one roof making deck through separate heavy-duty double-row roller chain circuits with hardened alloy sprockets and individual tension adjustment |
| Hydraulic Cut-Off | 4.0kW gear pump motor, 80L reservoir with filtration and temperature monitoring. Flying shear carriage on linear guide rails with pneumatic panel clamp. Cr12MoV blade set vacuum heat treated to HRC 60–64, profile-ground to match the roof panel cross-section for clean cuts |
| PLC Control | Siemens S7-1200, Delta DVP, or Mitsubishi FX3U PLC with VFD inverter. 7-inch or 10-inch color touchscreen HMI with multi-language support and recipe memory. Rotary encoder on final shaft for real-time panel length measurement with digital feedback correction. Mechanical limit switches and three emergency stop pushbuttons along the line |
| Pos. | Equipment | Role in Roof Making |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | Holds steel coil on expanding hydraulic jaws, 5-ton or 8-ton capacity. Adjustable brake system delivers uniform strip feed tension for consistent roof panel quality |
| 2 | Entry Guide and Pre-Shear | Side guide rollers center the strip on the machine axis. Manual guillotine squares the coil leading edge before it enters the selected roller deck |
| 3 | Double Layer Main Roof Making Unit | Lower corrugated roof deck and upper IBR roof deck in one frame. Pivoting diverter plate selects which deck receives the strip. Shared motor, gearbox, chain circuits, shear, and PLC controller |
| 4 | Flying Hydraulic Post-Cut Shear | On PLC cut command: pneumatic clamp grips roof panel → carriage matches line speed → hydraulic cylinder drives profiled blade through panel → blade and carriage return to home — cycle completes without stopping production |
| 5 | Digital Electrical Cabinet | IP54 steel enclosure with PLC, VFD, contactors, overload relays, breakers, and terminal blocks. External touchscreen HMI for panel length, batch count, speed, and fault diagnostics |
| 6 | Discharge Roller Conveyor | 3m–5m free-roller receiving table with height-adjustable legs. Supports finished roof panels for manual stacking, bundling, and warehouse transport |
| Specification | Data |
|---|---|
| Accepted Coil Materials | Hot-dip galvanized steel (Z60–Z275 g/m²), pre-painted GI (PPGI PE/SMP/PVDF), aluzinc/Galvalume (AZ150–AZ200), cold-rolled steel, aluminum alloy (1100/3003) |
| Panel Gauge Range | 0.25mm to 0.80mm (gauge 30 through gauge 20) |
| Yield Strength Limit | 200 MPa to 400 MPa (mild through structural grades) |
| Production Speed | 10–18 linear meters per minute, infinitely variable via VFD |
| Length Accuracy | ±1.0mm via rotary encoder feedback to PLC auto-correction |
| Roof Type Switch | Manual diverter plate; corrugated to IBR in 10–15 minutes |
| Power Supply | 380V 50Hz 3-phase standard; custom voltage/frequency per destination |
| Total Motor Power | Approximately 10–12 kW (drive 5.5/7.5kW + pump 4.0kW) |
| Dimensions (L×W×H) | Approximately 7.0–8.0m × 1.4–1.6m × 1.7–2.0m |
| Net Weight | 5.0–7.5 metric tons per configuration |
| Uncoiler Rating | 5 metric tons standard, 8 metric tons heavy duty |
| Coil Bore | Φ508mm standard; Φ610mm with adapter |
| Step | Operation | Description |
|---|---|---|
| 1 | Coil Loading | Steel coil placed onto hydraulic uncoiler mandrel via crane or coil cart. Expansion jaws lock the coil bore. Brake tension set for uniform strip feed through the entire roof making run |
| 2 | Strip Entry | Coil leading edge guided through adjustable side rollers for centerline alignment. Manual pre-shear squares the coil head before entering the selected roller deck |
| 3 | Deck Selection | Operator positions the pivoting diverter — downward for corrugated roof making on the lower deck; upward for IBR roof making on the upper deck. Profile changeover takes about 10 minutes |
| 4 | Sequential Roll Forming | Flat strip advances through all roller station pairs in order. Each station applies incremental bending until the final station delivers a complete corrugated wave roof panel or fully formed IBR trapezoidal roof panel ready for cutting |
| 5 | Length Tracking | Rotary encoder on the final shaft sends continuous digital pulses to the PLC. Controller compares real-time accumulated count against the operator-programmed target roof panel length |
| 6 | Automated Cut | At target length: PLC triggers the cut cycle — pneumatic clamp grips the roof panel → shear carriage accelerates to line speed → hydraulic cylinder drives Cr12MoV blade through the panel → blade and carriage return to home — no production stoppage |
| 7 | Panel Stacking | Finished roof panel slides onto the discharge conveyor. Operator lifts each panel and stacks onto the product pallet for strapping, warehousing, and customer delivery to construction sites |
| Cost Factor | Two Separate Roof Making Machines | One Double Layer Roof Making Machine |
|---|---|---|
| Equipment Purchase | 100% — total price of two machines plus two uncoilers | Approximately 65–75% of the two-machine combined total |
| Workshop Floor Space | 44–70 square meters for two production lines | 20–35 square meters for one dual-output line |
| Ocean Freight | Two 20GP containers, two freight invoices | One 20GP or 40HQ container, one freight invoice |
| Foundation and Power | Two concrete pads, two power drops, two cable runs | One concrete pad, one power drop, one cable run |
| Workers per Shift | 3–4 operators across two lines | 1–2 operators for one line |
| Monthly Electricity | Two motors and two pumps operating | One motor and one pump — about 40% less consumption |
| Spare Parts Stock | Two complete wearing parts sets | One kit covers both roof making decks |
Each completed roof making machine undergoes a strict three-phase inspection before export crating. Phase one — dimensional check: every roller gap measured with calibrated feeler gauges against engineering tolerances; shaft runout verified with dial indicators at all bearing positions; frame alignment confirmed with precision levels and laser instruments. Phase two — extended dry run: machine operates at maximum rated speed without material for a minimum of four hours; bearing temperatures logged every 30 minutes with infrared thermometers; chain drive inspected visually and audibly; all PLC functions validated including power-up, start-stop, speed regulation, length programming, batch counting, recipe recall, emergency stop, and restart. Phase three — live roof production trial: factory personnel load actual galvanized coil and make 50 corrugated roof panels plus 50 IBR roof panels; every 10th panel measured for length, profile geometry, and cut quality with calibrated digital instruments. Only machines passing all three phases with zero defects receive export packaging approval.
The main roof making machine receives three-layer protective export packaging: VCI anti-rust film inner wrap, high-density foam padding at all corners and machined surfaces, and UV-stabilized polyethylene outer shrink wrap. The wrapped unit is bolted to a fumigated ISPM-15 certified plywood pallet or welded steel export skid. Hydraulic uncoiler, discharge conveyor, power pack, and control cabinet are individually packed in marked fumigated wooden crates with internal bracing. An accessories crate holds the tool kit, spare wearing parts starter pack, and full printed technical documentation. Manufacturing lead time is 25–35 working days from deposit and signed profile drawings. Standard warranty is 12 months from the bill of lading date.
| Option | Description and Benefit |
|---|---|
| Servo Motor Drive | Programmable servo replaces standard AC motor for precision acceleration control, improved panel length accuracy, and reduced energy consumption during intermittent roof production |
| Automatic Panel Stacker | Motorized stacking arm transfers finished roof panels from the discharge conveyor to neatly aligned pallet bundles, eliminating manual handling labor |
| Electric Coil Loading Cart | Battery-powered trolley on floor rails with hydraulic lift; moves coils up to 10 tons from storage to the uncoiler mandrel without crane dependency |
| IoT Remote Monitor | 4G cellular module sends real-time production data — daily output, motor hours, fault alerts, and maintenance reminders — to a smartphone app or web dashboard |
| Custom Embossing Roller | Engraved forming roller permanently stamps a brand name, logo, or batch code into each roof panel during the making process for identification and marketing |
| Stainless Roller Option | Full 304 or 316L stainless steel roller set for roof making in food-grade, pharmaceutical, chemical processing, or high-salinity coastal production environments |
Hebei Xinnuo is a professional cold roll forming machinery manufacturer with 20+ years of experience. We specialize in C/Z purlin machines, roof panel roll formers, floor deck machines, and custom profile solutions — exported to 50+ countries worldwide.
