helen@hbxinnuorollforming.com
Continuous cold roll forming line for metal decking panel production
Dual motor drive, PLC auto length cutting with encoder feedback
Five-stage anti-pooling system prevents material jamming and scratch
22-30 stations, hardened chrome rollers, dual-cylinder floor shear
This metal decking roll former transforms galvanized steel coil into finished structural decking panels through a single-pass continuous cold roll forming process. Every panel exiting the line is ready for immediate construction use — no secondary cutting, punching, or finishing required. The machine is designed for round-the-clock production in high-output decking manufacturing facilities, with a target annual capacity of 150,000–200,000 linear meters per single-shift operation. Built on a rigid welded 450H I-beam frame with dual 11KW motor drive, it handles the deep-rib forming loads that lighter roof panel machines cannot sustain.
| If Your Market Is... | Recommended Profile | Recommended Spec | Why |
|---|---|---|---|
| Residential mezzanine & light commercial renovation | 510, 600 Type | 2 × 11KW, 22 rows, 0.8–1.0mm gauge | Shorter spans, lighter concrete loads — standard duty sufficient |
| Industrial warehouse & factory floor construction | 688, 750 Type | 2 × 11KW, 26 rows, 0.8–1.2mm gauge | Medium spans with forklift traffic — moderate forming depth needed |
| Multi-story steel-frame commercial buildings | 870, 915 Type | 2 × 15KW, 30 rows, 0.8–1.5mm gauge | Long spans, heavy concrete, fire rating requirements — maximum rigidity |
| Parking structures & long-span applications | 820 Closed, 900 Type | 2 × 15KW, 34–36 rows, 1.0–1.5mm gauge | Unpropped spans up to 6m — heaviest frame and deepest rib needed |
| Mixed general-purpose decking supply | 750 + 1000 Type combo | 2 × 11KW, 26 rows with interchangeable roller cassettes | Two most popular global profiles on one machine — maximum ROI |
| Export-oriented decking production | 688 + 750 + 915 Type | 2 × 15KW, 30 rows with quick-change tooling system | Wide market coverage for different regional standards |
| Region | Common Profile | Key Standard | Special Requirements |
|---|---|---|---|
| North America (USA, Canada, Mexico) | 1.5B, 2B, 3N, 750, 915 | SDI (Steel Deck Institute) ANSI/SDI-C, IBC | UL fire rating listing, embossment pattern certified test data, stud shear values per SDI table |
| Europe (UK, Germany, France) | 600, 688, 750, 870 | EN 1994-1-1 (Eurocode 4), CE Marking | CE Declaration of Performance, harmonized standard EN 1090 compliance |
| Middle East (UAE, Saudi Arabia, Qatar) | 688, 750, 870, 915 | BS 5950 / Eurocode, Dubai Civil Defence | Fire resistance certificate, galvanized coating minimum Z275 (G90 equivalent) |
| Southeast Asia (Philippines, Indonesia, Vietnam) | 510, 600, 688, 750 | NSCP (Philippines), SNI (Indonesia) | Seismic compliance documentation, lighter gauge acceptable for low-rise |
| South Asia (India, Pakistan, Bangladesh) | 600, 688, 750, 1000 | IS 456, IS 800, IS 11384 | High-strength G550 option for weight optimization, competitive cost expectation |
| Africa (Nigeria, Kenya, South Africa) | 510, 600, 688, 750 | SANS 10162 (South Africa) | Robust simple design preferred, minimal electronics dependency, local steel availability compatibility |
| Latin America (Brazil, Peru, Chile) | 688, 750, 870, 915 | NBR 8800 (Brazil), AISC-based local codes | Seismic zone classification, Portuguese/Spanish documentation package |
| Australia & New Zealand | 510, 600, 750, 870 | AS 2327.1, AS/NZS 4600 | Cyclonic region wind loading, AS/NZS compliant structural certification |
Most metal decking roll former buyers require at least one custom profile to match their local market standard. Below is the engineering workflow from customer drawing to production-ready machine configuration:
| Phase | Duration | Deliverable | Customer Action Required |
|---|---|---|---|
| Profile Drawing Submission | Day 1 | — | Provide CAD or dimensioned sketch of deck profile with width, rib count, rib depth, and material gauge |
| Feasibility Analysis | Day 1–2 | Forming feasibility report | None — engineering team reviews bend radii, forming angles, and material compatibility |
| Roll Forming Simulation | Day 2–4 | COPRA or similar FEA simulation showing progressive forming stages | Review and confirm flower pattern diagram shows correct rib geometry development |
| Roller Set Design | Day 3–7 | Complete roller set CAD drawings with station-by-station profile geometry | Approve roller design or request adjustments to specific station profiles |
| Costing & Quotation | Day 5–8 | Final machine quotation with custom tooling cost line item | Confirm order with purchase order or deposit |
| Roller Manufacturing | Week 2–5 | 45# forged steel rollers per approved drawings, quenched and chrome plated | None — in-house CNC turning and heat treatment |
| Machine Assembly & Testing | Week 5–7 | Assembled machine with custom roller set installed, factory trial video | Review trial run video; request sample panels shipped for dimensional verification |
| Component | Entry-Level Competitor | This Machine | Impact on Service Life |
|---|---|---|---|
| Shaft Material | Φ75–85mm, 45# steel, no chrome | Φ95–115mm, 100mm round bar, hard chrome plated | 3× longer shaft life; chrome resists corrosion in humid factory conditions |
| Shaft Processing | Single-pass turning, no grinding | Rough turn → precision grind → chrome → polish (4 stages) | Eliminates bearing seat runout; roller runout reduced from ±0.15mm to ±0.03mm |
| Frame Welding | MIG welded, no stress relief | MIG welded → vibratory stress relief → machined mounting surfaces | No frame warping over 10+ years; bearing alignment stays true |
| Mid-Plate | 16mm, flame-cut bores | 22–25mm, CNC line-bored, ±0.02mm position accuracy | Perfect shaft parallelism across 14+ meters — eliminates chain wear from misalignment |
| Chain Tensioner | Fixed position, manual only | Spring-loaded auto-tensioner with manual override on each station pair | Constant chain tension prevents elongation; reduces maintenance downtime by 60% |
| Shear Blade | Standard HSS, re-grind every 50K cuts | Cr12MoV tool steel, HRC 58–62, re-grind every 500K cuts | 10× longer blade life; cleaner cut edge without burrs |
| Hydraulic Cylinder Seals | Nitrile rubber, 80°C max | Viton fluoroelastomer, 200°C max | No seal degradation in tropical factory heat; zero oil leaks over machine life |
| Electrical Enclosure | IP54 painted steel | IP65 stainless steel, integrated cooling fan with dust filter | Survives dusty factory environments without PLC failure from contamination |
| Parameter | Single Shift (8h) | Double Shift (16h) | Triple Shift (24h) |
|---|---|---|---|
| Daily Output (linear meters) | 3,600–4,800m | 7,200–9,600m | 10,800–14,400m |
| Daily Output (m², 750 type) | 2,700–3,600m² | 5,400–7,200m² | 8,100–10,800m² |
| Monthly Output (25 working days) | 67,500–90,000m² | 135,000–180,000m² | 202,500–270,000m² |
| Coil Consumption (tons/month) | 600–800 tons | 1,200–1,600 tons | 1,800–2,400 tons |
| Operators Required | 2–3 persons | 4–6 persons (2 teams) | 6–9 persons (3 teams) |
| Typical Payback Period | 10–14 months | 6–8 months | 4–5 months |
| Profit per m² (market average) | Machine pays for itself through the material conversion margin — typically $1.50–3.00/m² premium over raw coil cost in most markets | ||
| Service Item | Standard Package | Premium Package |
|---|---|---|
| Installation Supervision | 1 engineer, 5 working days on-site | 1 engineer, full installation + commissioning, up to 10 days |
| Operator Training | 2 operators trained during commissioning | 4 operators + 1 maintenance technician, with certificate |
| Spare Parts Included | 1 set shear blades, 2 drive chains, bearing set, PLC backup module | 2 sets shear blades, 4 drive chains, full bearing set, PLC backup, HMI backup, hydraulic seal kit, dimple insert set |
| Remote Support | WhatsApp/WeChat video call during working hours | 24/7 hotline + remote desktop PLC diagnostic access + quarterly video check-in |
| Warranty | 12 months from shipment date | 24 months from shipment date, extended to 36 months for frame and shafts |
| On-Site Repair | Engineer dispatched within 14 days, customer pays travel | Engineer dispatched within 7 days, travel included for first 2 years |
| Software Updates | PLC firmware updates on request | Automatic notification + remote update support for life of machine |
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.
