When investing in a new roll forming machine, the journey doesn’t end when it arrives at your facility. One of the most critical stages comes right at the start: unloading the machine from its shipping container and positioning it correctly on-site.

This step is often underestimated, yet it’s where many costly mistakes happen. Roll forming machines are not like typical shop equipment. They are long, heavy, and precision-built. A wrong lift or poor handling can cause misalignment, damage, or even create dangerous working conditions.

That’s why the best practice is clear: hire professional machine movers or riggers to unload and position your new equipment. In this guide, we’ll explain why, break down the unloading process, cover common mistakes to avoid, and help you make the right decision when choosing a rigging company.

Why Professional Movers Are the Best Choice

1. Roll Forming Machines Are Heavy and Awkward

Most roll forming lines weigh between 5 to 20 tons, depending on the length, width, and accessories. Unlike compact machines, they are long and unevenly balanced — which makes them extremely difficult to lift and maneuver with standard forklifts.

Professional riggers use:

• Heavy-duty forklifts rated for the load.

• Cranes with spreader bars to distribute weight evenly.

• Air skates or dollies to maneuver through tight spaces.

This specialized equipment ensures your machine is handled safely.

2. Avoiding Damage to Precision Components

Roll formers are built with highly precise roller tooling. Even a slight knock can throw the tooling out of alignment, leading to production defects. Hydraulic lines, electrical cabinets, and guard systems are also vulnerable during unloading.

With professionals, you get a crew that knows where to lift, how to brace, and what parts to avoid stressing. Their expertise helps preserve the machine’s accuracy and ensures it’s production-ready.

3. Protecting Worker Safety

Attempting to unload a 20-ton machine without training is a serious hazard. Machines can shift inside containers, forks can slip, and uneven loads can tip equipment.

Professional movers follow strict safety procedures and comply with OSHA (or local equivalents). They know how to:

• Stabilize loads during lifts.

• Manage confined container spaces.

• Spot potential hazards before they become accidents.

Keeping your team safe should be the top priority — and riggers are trained to do just that.

4. Insurance and Liability Coverage

Professional rigging companies carry insurance that covers damage to machinery and property during the move. If you attempt unloading in-house and something goes wrong, you could be left with:

• Costly machine repairs.

• Damaged floors, doors, or infrastructure.

• Worker injury claims.

With insured professionals, you transfer that risk away from your company.

5. Efficient Placement and Setup

Unloading is only half the job. The machine also needs to be:

• Placed in the correct position on the shop floor.

• Aligned with floor markings or anchor bolts.

• Oriented properly for material infeed and outfeed flow.

Riggers can move the machine into place with precision, saving hours — or even days — compared to in-house attempts. That efficiency reduces downtime and helps your commissioning team start faster.

Step-by-Step: How Professionals Unload and Position a Roll Forming Machine

Hiring riggers doesn’t just give you muscle — it gives you a process. Here’s how professionals typically handle the job:

1. Pre-Site Assessment

Before the machine arrives, the rigging team inspects the site:

• Container location and access.

• Doorway widths and ceiling heights.

• Floor load capacity.

• Placement area for the machine.

This assessment ensures they bring the right lifting equipment.

2. Securing the Container

The shipping container is set on a stable, level surface. The crew inspects how the machine was braced and blocked inside. Safety braces or transport locks are removed only when lifting begins.

3. Rigging and Lifting

Using manufacturer-recommended lifting points, riggers attach:

• Slings, chains, or spreader bars to distribute weight evenly.

• Protective padding to prevent scratches and frame stress.

This step prevents frame twisting or roller misalignment.

4. Unloading from the Container

The machine is carefully lifted out using cranes or forklifts. Balance is critical here — a sudden shift could cause tipping. Professionals constantly monitor the load to maintain control.

5. Transport to the Foundation

Once on the ground, the machine is moved into the building. Depending on the facility layout, this may involve:

• Forklifts with low clearance.

• Rollers or skates to move through tight spaces.

• Air skates to glide the machine across smooth floors.

6. Positioning and Leveling

The machine is placed exactly where it belongs, aligned with pre-marked spots. Leveling is performed to ensure a stable foundation. If anchors are used, the machine is aligned for bolting.

7. Handover to Your Team

At this stage, the riggers step back, and your installation crew can begin:

• Electrical connections.

• Hydraulic and pneumatic hookups.

• Control system setup.

• Test runs and commissioning.

Common Mistakes to Avoid When Self-Unloading

Many companies think they can save money by unloading machines themselves. Unfortunately, this often leads to bigger costs down the line. Here are the most common mistakes:

• Using undersized forklifts. If the forks aren’t rated for the weight, they can snap or tip.

• Lifting from the wrong points. This bends frames and misaligns rollers.

• Dragging machines across floors. Creates floor damage and machine stress.

• Failing to secure loads. A shifting machine can injure workers or damage property.

• Skipping insurance coverage. If you’re not insured, you’re on the hook for all damages.

Cost Considerations

Hiring riggers may seem expensive upfront, but the costs of not hiring them can be far greater.

Typical costs:

• Small roll forming machines: $2,000–$5,000 for unloading and placement.

• Large or complex machines: $5,000–$15,000 depending on weight and access conditions.

Compare that to:

• A damaged machine: $10,000–$50,000+ in repairs or replacement parts.

• Worker injury claims: hundreds of thousands in liability.

• Production delays: Lost contracts and missed deadlines.

Hiring professionals quickly becomes the more economical choice.

How to Choose the Right Rigging Company

Not all riggers are the same. When selecting a company, look for:

• Experience with industrial machinery. Ask if they’ve handled roll formers, presses, or similar lines.

• Licensed and insured crews. Request proof of coverage.

• Modern equipment. Verify they have forklifts, cranes, and rigging gear suitable for your machine’s size.

• References or case studies. A reputable company will share success stories.

• Clear communication. They should provide a detailed plan and cost estimate before work begins.

Final Thoughts

Unloading and positioning a roll forming machine is not just about moving heavy steel — it’s about protecting a precision investment that your production depends on.

By hiring professional machine movers, you:

• Reduce risk of damage.

• Keep your team safe.

• Ensure accurate placement.

• Save time and money in the long run.

In short, professional riggers are not an expense — they’re an investment in safety, efficiency, and machine longevity.

When your next roll forming machine arrives, plan ahead and bring in the experts. It’s the smartest way to start your new production line off on the right track.