helen@hbxinnuorollforming.com
Dual 11KW motor heavy-duty metal deck cold roll forming production line
Automatic PLC touchscreen control with batch counting and length presets
Produces trapezoidal open-type steel floor deck panels with dimple bond embossment
26-30 progressive forming stations with 2-inch heavy-duty chain drive system
Five-stage anti-pooling mechanism prevents sheet jamming and surface scratching
Dual-cylinder floor-standing hydraulic shear with Cr12MoV blade for balanced cutoff
Processes 0.8-1.5mm galvanized steel coil at 10-15 m/min forming speed
Heavy Duty Metal Deck Roll Former Cold Roll Forming Machine Automatic Steel Floor Decking Profile Panel Production Line Equipment with Twin Motor Drive Hydraulic Post Cut PLC Digital Control System for Composite Concrete Floor Slab Structural Steel Building Manufacturing
This heavy-duty metal deck roll former is purpose-built for continuous in-line production of open-type trapezoidal steel floor decking panels — the most widely specified deck profile in multi-story steel-frame construction worldwide. Each finished panel functions as permanent formwork during concrete pouring and as bonded tensile reinforcement after the slab cures, enabling faster floor cycles and reduced structural steel tonnage compared to traditional timber formwork methods.
| Component | Specification | Technical Note |
|---|---|---|
| Main Frame | 450H Laisteel I-beam, 10mm wing thickness | Welded monolithic bed resists torsional flex under deep-rib forming loads |
| Mid-Plates | 22mm thickness, CNC bored | Carries twin-motor torque distribution across full shaft span |
| Forming Shafts | Φ95–115mm, 100mm round bar stock | Rough turned → precision ground → chrome plated → polished |
| Forming Rollers | 45# forged steel, HRC 45–50 quenched | 7-step process: forge → rough turn → quench → finish turn → keyway → polish → chrome |
| Drive Chain | 2-inch pitch, external guard type | Upgradeable to 2.5-inch for 915/1025 heavy-gauge profiles |
| Motor Power | 2 × 11KW (8# motor), 380V 50Hz 3-phase | Balanced twin-drive; optional 2 × 15KW for ≥1.2mm gauge |
| Forming Stations | 26–30 rows (configurable by rib depth) | Progressive reduction; each row reduces profile depth incrementally |
| Cutoff System | Dual-cylinder floor-standing hydraulic shear | Cr12MoV blade steel, balanced cut, gravity-assisted panel drop |
| Control System | PLC with 7-inch color touchscreen | Batch counter, length presets, auto-shear trigger, fault diagnostics |
| Decoiler | 5-ton hydraulic expanding mandrel type | Manual expansion, passive pay-off with drag brake |
| Model | Effective Width | Rib Count | Rib Height | Feed Width | Gauge Range |
|---|---|---|---|---|---|
| 600 Type | 600mm | 3 ribs | 50mm | 1000mm | 0.8–1.2mm |
| 688 Type | 688mm | 2 ribs | 76mm | 1000mm | 0.8–1.5mm |
| 750 Type | 750mm | 3 ribs | 53mm | 1000mm | 0.8–1.5mm |
| 870 Type | 870mm | 3 ribs | 60mm | 1250mm | 0.8–1.5mm |
| 915 Type | 915mm | 3 ribs | 76mm | 1250mm | 0.8–1.5mm |
| 1000 Type | 1000mm | 3 ribs | 50mm | 1250mm | 0.8–1.2mm |
| 1025 Type | 1025mm | 3 ribs | 51mm | 1250mm | 0.8–1.5mm |
Deep-rib floor deck forming generates extreme friction between the steel strip and roller surfaces. Without active anti-pooling measures, material bunches inside the forming zone — scratching panels and halting production. This machine integrates five synchronized devices to prevent that:
| Stage | Device | Location | Function |
|---|---|---|---|
| 1 | Clutch-Controlled Dimple Wheel | Immediately after dimple embossment station | Disengages dimple wheel drive after material entry; downstream rollers carry the sheet forward at correct linear speed, preventing overspeed jamming |
| 2 | Bearing-Mounted Oversized Rear Rollers | Final 10 forming stations | Internal-bearing design converts roller action from pulling to pushing; eliminates surface scratching on finished rib flanks |
| 3 | Pressure Reinforcement Bars | At dimple station, main drive row, rib-forming rows, and sizing rows | Increases effective shaft leverage force — Φ95 shaft performs equivalent to Φ100 under load; ensures flat, unwarped panel surface |
| 4 | Gear Drive Boosters | Dimple row entry, front of oversized wheel section, exit sizing rows | Boosts material feeding and pulling torque at the highest-resistance points in the forming sequence |
| 5 | Dual-Cylinder Floor Shear | End of forming line, floor-mounted | Balanced hydraulic cutting force across full panel width; floor-level positioning allows finished panels to stack by gravity without manual handling |
| Step | Station | Operation |
|---|---|---|
| 1 | Decoiler Pay-Off | 5-ton hydraulic mandrel feeds galvanized coil strip into leveling guide |
| 2 | Entry Guide & Leveling | Side rollers center the strip; leveling rollers remove coil set curvature |
| 3 | Dimple Embossment | Clutch-controlled embossing wheel stamps bond pattern into rib surfaces |
| 4 | Progressive Forming (Rows 1–12) | Gradual trapezoidal rib shaping — each row deepens the profile incrementally |
| 5 | Deep Rib Forming (Rows 13–22) | Final rib depth achieved; oversized bearing-mounted rollers push material through |
| 6 | Sizing & Straightening (Rows 23–30) | Precision sizing rollers lock final profile geometry; straightening pass corrects camber |
| 7 | Hydraulic Cutoff | PLC triggers dual-cylinder floor shear at preset length; Cr12MoV blades cut clean |
| 8 | Output & Stacking | Finished panels gravity-drop onto run-out table; ready for bundling |
| Item | Specification |
|---|---|
| Controller | Programmable Logic Controller with industrial-grade processor |
| HMI Panel | 7-inch color LCD touchscreen, multilingual interface |
| Length Control | Rotary encoder feedback, precision ±1.5mm per cut |
| Batch Mode | Preset piece count with auto-stop; production log storage |
| Motor Drives | Variable frequency drive, soft-start ramp, overload protection |
| Hydraulic Station | Independent power unit, 4KW pump motor, oil temp monitoring |
| Safety | Emergency stop loop, safety guards, phase-sequence protection relay |
| Parameter | Value |
|---|---|
| Total Line Length | 22,000mm (22m) |
| Forming Unit Footprint | 14,500mm × 2,750mm |
| Full Installation Area | 22m × 6.5m (including decoiler clearance) |
| Power Supply | 380V / 50Hz / 3-phase (custom voltage available) |
| Total Installed Power | Approx. 30–35 KVA |
| Foundation | Flat reinforced concrete floor, no anchor bolts required |
| Operator Requirement | 2 persons per shift (1 feeder + 1 stacker) |
| Option | Benefit |
|---|---|
| Servo motor drive system | Higher precision, energy saving, faster response |
| Automatic stacker | Reduces labor; panels auto-stacked at line exit |
| Closed deck (dovetail) roller set | Switch between open and closed deck on same machine |
| Online embossing pattern change | Quick-swap dimple wheel cassette for different bond patterns |
| Remote diagnostics module | Online troubleshooting and parameter adjustment support |
| Coil car with hydraulic lift | Faster coil changeover, reduced crane dependency |
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.
