helen@hbxinnuorollforming.com
One machine produces two metal roofing profiles for building construction
Lower deck forms corrugated wave roofing upper deck forms trapezoidal IBR
Progressive roller stations bend flat coil into finished metal roofing panel
PLC digital touchscreen sets roofing panel length and production batch count
Hydraulic flying shear cuts formed roofing panel at target length on the fly
Hard chrome roller finish preserves galvanized coating during roofing process
Complete metal roofing line with decoiler shear control panel and conveyor
This double layer metal roofing machine is an integrated production system that manufactures two distinct steel roofing panel profiles from a single equipment investment. Two complete roller forming decks are vertically stacked within one welded structural steel chassis — the lower deck configured for traditional corrugated wave metal roofing panels, the upper deck tooled for IBR (Inverted Box Rib) trapezoidal metal roofing panels. By consolidating both roofing production capabilities into one machine body, metal roofing manufacturers gain the ability to supply the full range of roofing products demanded by residential, commercial, agricultural, and industrial construction markets while significantly reducing equipment capital cost, factory floor space requirements, shipping expenses, and ongoing operational overhead compared to operating two independent single-profile production lines.
| Roofing Product Feature | Corrugated Wave Roofing | IBR Trapezoidal Roofing |
|---|---|---|
| Profile Geometry | Continuous sinusoidal wave pattern, uniform curvature throughout | Deep trapezoidal ribs with flat valley pans between stiffening channels |
| Effective Coverage Width | 660mm to 1000mm per panel | 762mm to 1100mm per panel |
| Profile Depth | 12–18mm wave crest-to-trough amplitude | 28–43mm rib crown elevation above valley floor |
| Waves or Ribs per Panel | 5, 7, 9, or 11 sinusoidal wave cycles | 4, 5, or 6 trapezoidal stiffening ribs |
| Panel Length Capability | 1.0m to 14.0m per roofing panel | 1.0m to 14.0m per roofing panel |
| Span Between Supports | Up to 2.5m purlin spacing standard | Up to 4.5m purlin spacing standard |
| Side Lap Weather Seal | 1.5-wave minimum overlap for watertight joint | Single overlap with optional anti-capillary groove detail |
| Process Phase | Stations | Steel Transformation Description |
|---|---|---|
| Strip Reception | Station 1 | Flat galvanized steel strip feeds from the hydraulic decoiler under regulated tension into the first roller pair. The entry rollers guide and constrain the strip laterally, setting the roofing panel centerline reference. Initial edge flange turning begins as material enters the roller deck |
| Bend Initiation | Stations 2–5 | Contoured rollers apply bending pressure at the precise positions where corrugated wave crests or IBR ribs will develop. Approximately 5–10 degrees of angular deformation per station. Metal remains within safe forming parameters, preventing zinc coating micro-fracture on galvanized steel |
| Profile Development | Stations 6–12 | Wave troughs deepen and crests tighten for corrugated roofing; rib walls steepen and valley floors flatten for IBR roofing. Seven stations distribute total deformation evenly, ensuring uniform plastic material flow and consistent panel gauge thickness across all bent profile zones |
| Final Geometry Setting | Stations 13–16 | The last active forming rollers establish finished roofing panel dimensions — wave amplitude and pitch for corrugated output; rib height, valley width, and side lap geometry for IBR output. Springback compensation is built into roller contours so panels retain their design profile after forming |
| Calibration Verification | Stations 17–18 | A final sizing station removes residual dimensional variation. At this point the metal roofing panel has achieved its complete engineered cross-section, measured to within ±0.5mm of the profile drawing across the full cover width |
| Tooling Parameter | Corrugated Roofing Deck | IBR Roofing Deck |
|---|---|---|
| Forming Station Count | 13–16 pairs of upper and lower rollers | 14–18 pairs of upper and lower rollers |
| Roller Base Material | 45# medium carbon forged steel; ultrasonic inspected for internal flaws before CNC machining begins | 45# medium carbon forged steel; ultrasonic inspected for internal flaws before CNC machining begins |
| CNC Profile Accuracy | Contour turning with sinusoidal wave tooling; geometry within ±0.05mm of engineering drawing | Contour turning with trapezoidal rib tooling; geometry within ±0.05mm of engineering drawing |
| Hardening Process | Controlled-atmosphere gas carburizing furnace; oil quench; surface HRC 58–62; ductile core for impact resistance | Controlled-atmosphere gas carburizing furnace; oil quench; surface HRC 58–62; ductile core for impact resistance |
| Chrome Plating Spec | Industrial hard chrome electrodeposit; 0.05mm minimum thickness; mirror-grade polished finish | Industrial hard chrome electrodeposit; 0.05mm minimum thickness; mirror-grade polished finish |
| Shaft Engineering | Φ75–Φ80mm 40Cr alloy steel; precision ground to h7 tolerance; keyway for sprocket | Φ75–Φ80mm 40Cr alloy steel; precision ground to h7 tolerance; keyway for sprocket |
| Bearing Configuration | Split cast iron pillow block; double-row self-aligning spherical roller bearing; Zerk grease fitting | Split cast iron pillow block; double-row self-aligning spherical roller bearing; Zerk grease fitting |
| System | Construction Specification |
|---|---|
| Welded Structural Frame | Heavy channel steel longitudinal beams with cross-braced H-beam columns in 300H–400H structural grade. Complete assembly undergoes post-weld thermal stress-relief annealing to eliminate residual fabrication stress. All bearing mounting pads precision machined after heat treatment for absolute shaft parallelism through every roller station in both roofing decks |
| Motor and Reduction Drive | 5.5kW or 7.5kW AC induction motor (4-pole, IP54 rated) directly coupled to a worm-type dual-output speed reducer with oil-bath lubrication. Gear ratios: 1:40 for faster thin-gauge roofing production or 1:59 for higher-torque thick-gauge processing. Each output shaft independently drives one complete roofing deck through a dedicated heavy-duty double-row roller chain circuit with hardened alloy sprockets and individual chain tension adjustment per loop |
| Hydraulic Cutting Unit | 4.0kW gear pump motor supplying an 80L oil reservoir system with inline filtration, sight glass indicator, and temperature monitor. Flying shear carriage on precision linear guide rails with pneumatic panel clamp. Cr12MoV cold-work die steel blade set vacuum heat treated to HRC 60–64, profile-ground to match the roofing panel cross-section for clean, burr-free cuts that preserve panel geometry |
| PLC Digital Control Architecture | Programmable logic controller (Siemens S7-1200, Delta DVP, or Mitsubishi FX3U per customer order) with VFD inverter providing stepless roofing production speed regulation. 7-inch or 10-inch color touchscreen HMI with multi-language interface and recipe storage. Rotary pulse encoder on final forming shaft for real-time panel length measurement with digital feedback to PLC auto-correction algorithm. Safety: mechanical limit switches at shear positions plus three emergency stop pushbuttons along the line |
| No. | Equipment | Function in Metal Roofing Production |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | Holds steel coil on expanding hydraulic jaws; 5-ton or 8-ton capacity. Adjustable brake system delivers uniform strip tension for consistent roofing panel quality throughout each coil |
| 2 | Entry Guide and Pre-Shear | Adjustable side guide rollers center the strip on the machine axis. Integrated manual guillotine squares the coil leading edge before threading into the selected roller deck |
| 3 | Double Layer Main Roofing Machine | Central unit combining lower corrugated roofing deck and upper IBR roofing deck in one welded frame. Pivoting diverter plate directs strip to the active deck. Both decks share drive motor, gearbox, chain circuits, hydraulic shear, and PLC |
| 4 | Flying Hydraulic Post-Cut Shear | On PLC cut command: pneumatic clamp grips formed roofing panel → shear carriage matches line speed → hydraulic cylinder drives profiled blade through panel → blade and carriage retract to home — entire cycle without interrupting continuous roofing production |
| 5 | Digital Control Cabinet | IP54 steel enclosure housing PLC, VFD, contactors, overload protectors, breakers, and terminal blocks. External touchscreen HMI for panel length, batch count, speed, and fault display |
| 6 | Roofing Panel Discharge Conveyor | 3m–5m free-roller receiving table with height-adjustable legs. Supports finished roofing panels for manual stacking, bundling, and warehouse transport |
| Specification | Data |
|---|---|
| Compatible Coil Materials | Hot-dip galvanized steel (Z60–Z275 g/m²), pre-painted galvanized iron (PPGI PE/SMP/PVDF), aluzinc/Galvalume (AZ150–AZ200), cold-rolled steel, aluminum alloy (1100/3003) |
| Panel Thickness Range | 0.25mm to 0.80mm (gauge 30 through gauge 20) |
| Yield Strength Capability | 200 MPa to 400 MPa (mild through structural steel grades) |
| Production Line Speed | 10–18 linear meters per minute; infinitely variable via VFD inverter |
| Panel Cut Length Accuracy | ±1.0mm via rotary encoder digital pulse feedback to PLC auto-correction |
| Profile Changeover Method | Manual pivoting diverter plate; corrugated to IBR switch in 10–15 minutes |
| Electrical Supply | 380V 50Hz 3-phase standard; custom voltage (220V/415V/440V/480V) and frequency (50/60Hz) per destination |
| Total Motor Power | Approximately 10–12 kW (main drive 5.5/7.5kW + hydraulic pump 4.0kW) |
| Machine Dimensions (L×W×H) | Approximately 7.0–8.0m × 1.4–1.6m × 1.7–2.0m per ordered configuration |
| Machine Net Weight | 5.0 to 7.5 metric tons per profile configuration and frame grade |
| Uncoiler Capacity | 5 metric tons standard duty or 8 metric tons heavy duty |
| Coil Bore Diameter | Φ508mm standard; Φ610mm with adapter sleeve available |
| Step | Operation | Description |
|---|---|---|
| 1 | Coil Installation | Steel coil crane-lifted onto the hydraulic uncoiler mandrel; expansion jaws engage and lock the coil bore; brake resistance adjusted for uniform strip feed tension through the entire production run |
| 2 | Strip Entry | Coil leading edge threaded through adjustable entry guide rollers for centerline alignment; manual pre-shear guillotine squares the coil head before feeding into the selected roller deck |
| 3 | Deck Selection | Operator positions the pivoting diverter plate — downward for corrugated roofing on the lower deck; upward for IBR roofing on the upper deck. Profile changeover completed in approximately 10 minutes |
| 4 | Progressive Roll Forming | Flat strip advances through successive roller station pairs; at each station the metal receives incremental bending until emerging from the final station as a complete corrugated wave or IBR trapezoidal roofing panel ready for cutting |
| 5 | Length Measurement | Rotary pulse encoder on the final drive shaft sends continuous digital pulses to the PLC; controller compares real-time accumulated count against the operator-programmed target panel length |
| 6 | Automated Cut Cycle | At target length PLC triggers the sequence: pneumatic clamp grips the formed roofing panel → shear carriage accelerates to line speed → hydraulic cylinder drives Cr12MoV blade through the cross-section → blade and carriage retract to home — cut cycle completes without interrupting production |
| 7 | Panel Stacking | Separated finished roofing panel slides onto the discharge roller conveyor; operator lifts each panel and stacks onto the product pallet for strapping, warehousing, and customer delivery |
| Cost Factor | Two Separate Roofing Machines | One Double Layer Roofing Machine |
|---|---|---|
| Equipment Purchase Cost | 100% — total cost of two machines plus two uncoilers | Approximately 65–75% of the two-machine combined price |
| Factory Floor Footprint | 44–70 square meters for both lines | 20–35 square meters for one line |
| Ocean Container Freight | Two 20GP containers, two freight invoices | One 20GP or 40HQ container, single freight invoice |
| Foundation and Power Setup | Two concrete pads, two power drops, two cable runs | One concrete pad, one power drop, one cable run |
| Workforce per Shift | 3–4 operators across two lines | 1–2 operators for one line |
| Monthly Electricity Cost | Two motors and two pumps operating simultaneously | One motor and one pump — approximately 40% reduction |
| Spare Parts Inventory | Two complete wearing parts sets | One kit services both roofing decks |
Before export crating, every completed metal roofing machine undergoes a rigorous three-phase quality inspection. Phase one — dimensional verification: all roller gaps measured with calibrated feeler gauges against engineering tolerances; shaft runout checked with dial indicators at all bearing positions; frame alignment confirmed with precision spirit 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 monitored and logged at 30-minute intervals with infrared thermometers; chain engagement inspected visually and audibly; every PLC function validated including power-up, start-stop, speed regulation, length programming, batch counting, recipe recall, emergency stop, and restart. Phase three — live production trial: factory technicians load genuine galvanized coil and produce 50 corrugated roofing panels plus 50 IBR roofing panels; every 10th panel measured for length, profile geometry, and cut edge quality with calibrated digital instruments. Only machines achieving zero out-of-tolerance results across all three phases receive export packaging approval.
The main roofing machine body receives comprehensive multi-layer export packaging: VCI anti-rust film inner wrap, high-density closed-cell foam padding at all corners and machined surfaces, and heavy-gauge UV-stabilized polyethylene outer shrink wrap for moisture and handling protection. The wrapped assembly is bolted to a fumigated ISPM-15 certified plywood pallet or welded steel export skid. The hydraulic uncoiler, discharge conveyor, hydraulic power pack, and electrical control enclosure are individually packed in marked fumigated wooden crates with internal foam bracing and bolted tie-downs. A dedicated accessories crate contains the operator tool kit, spare wearing parts starter pack, and complete printed technical documentation: mechanical assembly drawings, electrical wiring schematic, PLC parameter guide, lubrication schedule, and English-language operation manual. Standard manufacturing lead time is 25–35 working days from deposit receipt and customer-signed profile approval drawings. Standard warranty is 12 months from the bill of lading date against material and workmanship defects.
| Optional Upgrade | Description and Benefit |
|---|---|
| Servo Motor Drive System | Programmable servo drive replaces standard AC motor for precision acceleration control, enhanced panel length accuracy, and reduced energy consumption during intermittent production cycles |
| Automatic Roofing Panel Stacker | Motorized stacking arm transfers finished roofing panels from the discharge conveyor to aligned bundles on a pallet, eliminating manual sheet handling labor |
| Electric Coil Loading Cart | Battery-powered trolley on floor-mounted guide rails with hydraulic scissor lift; transports coils up to 10 tons from storage to the uncoiler mandrel without crane assistance |
| IoT Remote Monitoring System | 4G cellular module transmits real-time production metrics — daily panel output, motor hours, fault codes, and maintenance alerts — to a smartphone app or web dashboard |
| Custom Embossing Roller Station | Engraved forming roller permanently imprints a brand name, logo, or batch code into each roofing panel during the production process |
| Stainless Steel Roller Upgrade | Complete roller set in grade 304 or 316L austenitic stainless steel for roofing production in food-grade, pharmaceutical, chemical, or high-salinity coastal environments |
