Double Layer Floor Decking Machine

This double layer floor decking machine carries two complete deck roller sets inside one frame, stacked one above the other. The material path is switched by hand at the entry guide, so the same line rolls one deck profile or the other without moving a second machine onto the floor. Only one profile runs at a time; the value is in the space and the investment, not in running both together.

How a Double Layer Machine Works

Element	Arrangement
Roller sets	Two independent forming trains, mounted top and bottom in the same frame
Drive	One drive system, shared between the two layers
Profile selection	The entry guide and baffle are reset so the strip enters the upper or lower train
Changeover time	Roughly 5-15 minutes
Simultaneous production	Not possible; the machine produces one panel type at a time
Shared equipment	Decoiler, control cabinet, shear and output table serve both layers

Combining Two Deck Profiles: The Rules That Matter

Floor deck profiles are deeper and heavier than roof or wall sheets, so a double layer deck machine is engineered around the heavier layer rather than being a simple two-for-one.

Rule	Why it matters on a deck machine
Keep the row counts close	A difference of about six rows or fewer keeps both layers forming correctly. A large gap means the shorter layer forms too abruptly, which shows up as rib distortion and surface marking.
Match the feed width	Identical feed widths let both layers share one decoiler and one entry guide. Different widths need a second guide set and a manual changeover.
Frame one class heavier	A 750 mm deck machine normally runs on a 450H frame. Stacking a second deck train on the same body takes the frame, mid plate and base into the heavy class.
Size the chain for the harder layer	Both layers share one transmission, so the chain and sprockets are chosen for the higher torque of the two, not the average.
Check the machine height	Two deep-rib roller stacks make the body noticeably taller than a single deck machine. Confirm the available headroom and crane access before ordering.
Plan for two anti-pooling arrangements	Deep ribs need the bearing wheel and reinforcement bar layout on each layer, so the design is prepared per profile rather than copied.

Recommended Deck Combinations

Combination	Layer rows	Feed width	Note
750 mm deck and 1000 mm deck	20 and 24	1000 mm and 1220 mm	Both ribs are about 50-51 mm, the closest match available. Two feed widths, so a second entry guide is needed.
688 mm deck and 810/830 profile	688 layer plus 18 rows	1000 mm shared	Proven in production: an 18-row 810/830 layer paired with a 688 deck layer on a 450H frame, 20 mm mid plate, 95 mm shaft, 18.5 kW drive and 2-inch chain.
Same profile, two widths	Matched	Shared	The easiest and cheapest pairing, and the smoothest to commission.
Deep deck plus shallow deck	Reviewed per project	Shared where possible	A 50 mm rib stacked with a 150 mm rib is a large gap in both rib depth and row count, so it is engineered case by case and is rarely the economical choice.

Frame and Drive Requirements

Item	Typical requirement
Main frame	Heavy class H-beam, one step above the single layer equivalent for the harder profile
Mid plate	20 mm and above, set by the heavier layer
Shafts	95 mm and above, ground and chrome plated
Motors	Dual drive sized for the heavier layer
Transmission	2-inch chain class, chosen for the higher torque layer
Shear	Hydraulic, cut to length, shared by both layers
Control	PLC with length and quantity setting, with a stored setting for each profile

Double Layer Compared with Two Single Machines

Item	Double layer machine	Two single machines
Machines on the floor	One	Two
Floor space	Roughly 40-60 percent less	Full footprint for both lines
Purchase cost	About 65-75 percent of the two-machine total	Full price for both
Simultaneous output	One profile at a time	Both profiles can run at once
Commissioning	Longer, because both trains are aligned in one body	Independent and quicker per machine
Best fit	Two deck widths, moderate volumes, limited floor space	High volume on both profiles at the same time

Commissioning and Changeover

Both forming trains are aligned and gauge checked before dispatch, with a sample panel from each layer
Commissioning on site typically runs longer than a single layer machine, because two trains are set up in one body
Changeover between profiles is a guide and baffle reset, not a roller change
A written changeover sheet and a video walkthrough are supplied for each profile
Each profile has stored length and quantity settings in the control cabinet

Questions Buyers Ask

Question	Answer
Can both decks be produced at the same time?	No. One layer is active at a time. If you need both profiles running continuously, two single machines are the correct answer and we will say so.
What if my two deck profiles have very different row counts?	We review the gap before quoting. Around six rows is comfortable; a much larger gap needs engineering assessment and may push you towards two single machines.
Will the frame be the same as a single deck machine?	No. Stacking a second deck train takes the frame, mid plate and drive up one class to keep rigidity and surface quality.
How long does switching take?	About 5-15 minutes for the guide and baffle reset. Rollers stay in place.
Is it harder to commission than a roof double layer?	Yes. Deep deck ribs are less forgiving than shallow roof ribs, so commissioning takes longer and we send an experienced engineer.