helen@hbxinnuorollforming.com
Makes corrugated and IBR roof sheets from one compact production machine
Lower deck produces sinusoidal wave sheets upper deck forms ribbed sheets
Progressive roller sequence gradually bends flat coil into roof sheet profile
PLC digital panel sets sheet making length batch quantity and line speed
Hydraulic flying shear cuts the running roof sheet at programmed target length
Chrome roller coating protects galvanized steel surface during sheet making
Complete roof sheet line includes uncoiler entry guide shear and runout table
This double layer steel roofing machine is engineered to process galvanized, pre-painted, and coated steel coil into two types of finished steel roofing panels from a single integrated production station. The lower forming deck produces traditional corrugated wave steel roofing — the classic sinusoidal profile that serves as affordable steel roofing for residential housing, farm structures, and community buildings worldwide. The upper forming deck produces IBR (Inverted Box Rib) trapezoidal steel roofing — a structural steel roof panel with deep stiffening ribs that delivers the span strength and weather resistance demanded by industrial warehouses, commercial building envelopes, and cyclone-prone construction zones. Both steel roofing production capabilities operate from one machine frame, giving manufacturers the ability to supply every segment of their local steel roofing market from budget residential to premium commercial.
| Steel Roofing Attribute | Corrugated Wave Steel Roofing | IBR Trapezoidal Steel Roofing |
|---|---|---|
| Profile Cross-Section | Continuous sinusoidal wave with uniform radius curvature | Deep trapezoidal ribs separated by flat valley floor pans |
| Effective Cover Width | 660mm to 1000mm per steel roofing panel | 762mm to 1100mm per steel roofing panel |
| Profile Height | 12–18mm wave crest-to-trough amplitude | 28–43mm rib crown elevation above valley plane |
| Waves or Ribs per Panel | 5, 7, 9, or 11 sinusoidal wave repetitions | 4, 5, or 6 trapezoidal structural ribs |
| Panel Length Range | 1.0m to 14.0m per steel roofing panel | 1.0m to 14.0m per steel roofing panel |
| Span Between Purlins | Up to 2.5m standard spacing | Up to 4.5m standard spacing |
| Side Lap Joint | Minimum 1.5-wave weathertight overlap | Single overlap with optional anti-capillary groove detail |
| Processing Stage | Station Position | Steel Transformation Description |
|---|---|---|
| Strip Reception | Station 1 | Flat steel strip feeds from the hydraulic decoiler at controlled tension into the first roller pair. Entry rollers guide and laterally constrain the strip to establish the roofing panel centerline. Initial edge flange turning begins as steel enters the roller deck sequence |
| Bend Initiation | Stations 2–5 | Contoured rollers apply precise bending pressure at the positions where wave crests or ribs will develop — approximately 5–10 degrees of angular change per station. Steel deforms within safe forming limits, protecting the galvanized zinc coating from micro-cracking |
| Progressive Shaping | Stations 6–12 | Wave troughs deepen and crests tighten for corrugated steel roofing; rib side walls steepen and valleys flatten for IBR steel roofing. Seven consecutive stations distribute total plastic deformation evenly, maintaining consistent steel gauge thickness throughout all formed areas |
| Final Profile Setting | Stations 13–16 | Last active forming rollers establish the finished steel roofing dimensions — wave amplitude and pitch for corrugated; rib height, valley width, and side lap geometry for IBR. Springback compensation is engineered into the roller profiles |
| Calibration Verification | Stations 17–18 | Final sizing roller pair eliminates residual dimensional variation. The steel roofing panel achieves its complete engineered cross-section, verified to ±0.5mm of the profile specification drawing across the full panel width |
| Tooling Specification | Corrugated Steel Roofing Deck | IBR Steel Roofing Deck |
|---|---|---|
| Forming Station Quantity | 13–16 roller pairs | 14–18 roller pairs |
| Roller Material | 45# forged medium carbon steel, ultrasonically tested | 45# forged medium carbon steel, ultrasonically tested |
| CNC Machining Accuracy | Sinusoidal wave contour turning, ±0.05mm tolerance | Trapezoidal rib contour turning, ±0.05mm tolerance |
| Hardening Treatment | Gas carburizing furnace, oil quench, HRC 58–62 surface | Gas carburizing furnace, oil quench, HRC 58–62 surface |
| Chrome Surface Finish | Industrial hard chrome, 0.05mm minimum, mirror polish | Industrial hard chrome, 0.05mm minimum, mirror polish |
| Drive Shaft Spec | Φ75–Φ80mm 40Cr alloy, h7 tolerance, sprocket keyway | Φ75–Φ80mm 40Cr alloy, h7 tolerance, sprocket keyway |
| Bearing Assembly | Split pillow block, spherical roller, Zerk grease fitting | Split pillow block, spherical roller, Zerk grease fitting |
| Machine System | Build Specification |
|---|---|
| Welded Steel Frame | Heavy channel steel beams with cross-braced 300H–400H H-beam columns. Post-weld thermal stress-relief annealing eliminates residual fabrication stress. Bearing mounting pads precision machined after heat treatment for exact shaft parallelism through all roller stations in both steel roofing decks |
| Motor and Gear Reduction | 5.5kW or 7.5kW AC induction motor (4-pole, IP54 rated) coupled to worm-type dual-output speed reducer with oil-bath lubrication. Ratios 1:40 or 1:59. Each output shaft independently drives one steel roofing deck through dedicated heavy-duty double-row roller chain circuits with hardened alloy sprockets and individual chain tension adjustment |
| Hydraulic Cutting System | 4.0kW gear pump motor, 80L reservoir with filtration and temperature gauge. Flying shear carriage on linear guide rails with pneumatic steel panel clamp. Cr12MoV die steel blade set, vacuum heat treated to HRC 60–64, profile-ground to match the steel roofing cross-section for clean, burr-free cuts |
| PLC Digital Control | Siemens S7-1200, Delta DVP, or Mitsubishi FX3U PLC with VFD inverter for stepless speed control. 7-inch or 10-inch color touchscreen HMI with multi-language interface 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 |
| No. | Equipment | Function |
|---|---|---|
| 1 | Hydraulic Mandrel Uncoiler | Holds steel coil on expanding hydraulic jaws, 5-ton or 8-ton capacity. Adjustable brake system ensures uniform strip tension for consistent steel roofing panel quality from coil start to finish |
| 2 | Entry Guide and Pre-Shear | Side guide rollers center the steel strip on the machine axis. Integrated manual guillotine squares the coil leading edge before the strip enters the selected roller deck |
| 3 | Double Layer Steel Roofing Main Unit | Lower corrugated steel roofing deck and upper IBR steel roofing deck in one welded frame. Pivoting diverter plate directs the steel strip into the active deck. Shared motor, gearbox, chain circuits, hydraulic shear, and PLC |
| 4 | Flying Hydraulic Post-Cut Shear | On PLC cut command: pneumatic clamp grips formed steel roofing panel → shear carriage matches line speed → hydraulic cylinder drives profiled blade through panel → blade and carriage return to home — complete cycle without production interruption |
| 5 | Digital Control Cabinet | IP54 steel enclosure with PLC processor, VFD inverter, motor contactors, overload protectors, circuit breakers, and terminal blocks. External touchscreen HMI for panel length, batch count, speed, and fault diagnostics |
| 6 | Steel Roofing Discharge Conveyor | 3m–5m free-roller receiving table with adjustable legs. Supports finished steel roofing panels for manual stacking, steel strapping, and warehouse transport |
| Specification | Data |
|---|---|
| Steel Coil Types Processed | Hot-dip galvanized (Z60–Z275 g/m²), pre-painted GI (PPGI PE/SMP/PVDF), aluzinc/Galvalume (AZ150–AZ200), cold-rolled steel, aluminum alloy (1100/3003) |
| Steel Gauge Range | 0.25mm to 0.80mm (gauge 30 through gauge 20) |
| Steel Yield Strength Limit | 200 MPa to 400 MPa (mild through structural grades) |
| Steel Roofing Production Speed | 10–18 linear meters per minute, infinitely variable via VFD |
| Panel Length Accuracy | ±1.0mm via rotary encoder feedback to PLC auto-correction |
| Profile Switch Method | Manual diverter plate; corrugated to IBR in 10–15 minutes |
| Power Supply | 380V 50Hz 3-phase standard; custom voltage/frequency per country |
| Total Installed Power | Approximately 10–12 kW (drive 5.5/7.5kW + pump 4.0kW) |
| Machine Dimensions (L×W×H) | Approximately 7.0–8.0m × 1.4–1.6m × 1.7–2.0m per configuration |
| Machine Net Weight | 5.0–7.5 metric tons per profile and frame specification |
| Uncoiler Rating | 5 metric tons standard, 8 metric tons heavy duty |
| Coil Bore Diameter | Φ508mm standard; Φ610mm with adapter |
| Step | Operation | Description |
|---|---|---|
| 1 | Coil Installation | Steel coil lifted onto the hydraulic uncoiler mandrel via crane or coil cart. Expansion jaws lock the coil bore securely. Brake resistance set for uniform strip feed tension through the entire steel roofing production run |
| 2 | Strip Entry | Steel coil leading edge guided through adjustable side rollers for centerline alignment. Manual pre-shear squares the coil head before entering the selected roller deck for steel roofing production |
| 3 | Deck Activation | Operator positions the pivoting diverter — downward for corrugated steel roofing on the lower deck; upward for IBR steel roofing on the upper deck. Profile changeover takes about 10 minutes |
| 4 | Sequential Roll Forming | Steel strip advances through each roller station pair in order. At every station the steel receives incremental bending until the final station delivers complete corrugated wave steel roofing or fully formed IBR trapezoidal steel roofing ready for cutting |
| 5 | Length Tracking | Rotary encoder on the final shaft sends continuous digital pulses to PLC. Controller compares real-time accumulated count against the operator-programmed target steel roofing panel length |
| 6 | Automated Cut Cycle | At target length: PLC triggers cut — pneumatic clamp grips steel roofing panel → shear carriage accelerates to line speed → hydraulic cylinder drives Cr12MoV blade through panel → blade and carriage return to home — no stoppage of steel roofing production |
| 7 | Panel Stacking | Finished steel roofing panel slides onto the discharge conveyor. Operator lifts each panel and stacks onto the product pallet for steel strapping, warehousing, and delivery to construction customers |
| Cost Factor | Two Separate Steel Roofing Machines | One Double Layer Steel Roofing Machine |
|---|---|---|
| Equipment Investment | 100% — total cost of two machines plus two uncoilers | Approximately 65–75% of the two-machine total |
| Workshop Floor Space | 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, one freight invoice |
| Foundation and Power | 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 | 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 steel roofing decks |
Each completed steel roofing machine passes a rigorous three-phase inspection before export crating. Phase one — dimensional verification: every roller gap measured with calibrated feeler gauges against engineering tolerances; shaft runout checked 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 steel for a minimum of four hours; bearing temperatures logged every 30 minutes with infrared thermometers; chain drive inspected visually and audibly for smooth sprocket meshing; all PLC functions validated — power-up, start-stop, speed regulation, length programming, batch counting, recipe recall, emergency stop, and restart. Phase three — live steel roofing production trial: factory technicians load genuine galvanized steel coil and produce 50 corrugated steel roofing panels plus 50 IBR steel 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 receive export packaging authorization.
The main steel roofing machine receives three-layer protective export packaging: VCI anti-rust film inner wrap, high-density closed-cell 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. The 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 operator tool kit, spare wearing parts starter pack, and complete printed technical documentation: mechanical assembly drawings, electrical schematic, PLC parameter guide, lubrication chart, and English operation manual. Standard manufacturing lead time is 25–35 working days from deposit receipt and signed profile approval drawings. Standard warranty coverage is 12 months from the bill of lading date.
| Option | Description and Benefit |
|---|---|
| Servo Motor Drive | Programmable servo replaces standard AC motor for controlled acceleration, improved panel length accuracy, and reduced power consumption during intermittent steel roofing production |
| Automatic Panel Stacker | Motorized stacking arm transfers finished steel roofing panels from discharge conveyor to aligned pallet bundles, eliminating manual sheet handling labor |
| Electric Coil Loading Cart | Battery-powered trolley on floor rails with hydraulic lift; transports steel coils up to 10 tons from storage to the uncoiler mandrel without crane dependency |
| IoT Remote Monitor | 4G cellular module sends real-time steel roofing 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 steel roofing panel during production for identification and marketing |
| Stainless Roller Upgrade | Complete 304 or 316L stainless steel roller set for steel roofing production in food-grade, pharmaceutical, chemical processing, or high-salinity coastal 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.
