Crash Barrier Roll Forming Machine Data Sheet | Technical Specifications
Crash Barrier Roll Forming Machine Technical Data Sheet
Machine Overview
Parameter Specification
Machine Name Crash Barrier Roll Forming Machine
Profile Produced Highway crash barrier profiles (W beam / Thrie beam)
Machine Type Single profile / dual profile roll forming machine
Production Application Road safety barriers, highway crash barriers, bridge protection systems
Manufacturing Process Continuous cold roll forming with inline punching
Production Environment Infrastructure steel manufacturing facility / heavy industrial production line
The crash barrier roll forming machine produces steel safety barrier profiles used along highways and roads to protect vehicles from leaving the roadway and reduce accident severity.
Crash barriers are widely installed on highways, bridges, medians, road edges, and high-risk roadway sections.
Production Specifications
Specification Typical Value
Production Speed 8–18 m/min
Forming Stations 16–24 stations
Material Thickness Range 2.5–4.5 mm
Coil Width 480–850 mm
Coil Weight Capacity 8–15 tons
Cut Length Tolerance ±2 mm
Minimum Barrier Length 2000 mm
Maximum Barrier Length 4320 mm (standard crash barrier section)
Crash barrier machines are designed to process heavy gauge structural steel used in safety barrier systems.
Material Compatibility
Material Type Supported
Hot Rolled Steel Yes
Galvanized Steel Yes
High Strength Steel Yes
Weathering Steel Optional
Stainless Steel Limited
Crash barriers are typically produced from hot dip galvanized steel for long-term outdoor durability.
Material Strength
Property Typical Range
Yield Strength G350 – G550
Tensile Strength Up to 600 MPa
Coating Types Hot dip galvanized
Galvanized coatings protect crash barriers from corrosion in harsh outdoor environments.
Machine Frame Construction
Component Specification
Frame Type Heavy duty welded structural steel frame
Frame Plate Thickness 25–35 mm
Machine Base Reinforced industrial steel base
Frame Alignment Precision machined mounting surfaces
Machine Weight 20–36 tons
Heavy structural frames ensure stable forming of thick crash barrier steel.
Roll Tooling Specifications
Specification Typical Value
Roller Material GCr15 bearing steel
Heat Treatment HRC 58–62
Roller Diameter 120–170 mm
Shaft Diameter 100–140 mm
Shaft Material 40Cr alloy steel
Surface Finish Hard chrome plating
Roll Pass Design Crash barrier forming system
Forming Stages 16–24 stations
Roll tooling gradually forms flat steel strip into highway crash barrier profiles.
Drive System
Component Specification
Drive Type Gearbox drive system
Main Motor 30–55 kW
Drive Ratio 1:20
Transmission Heavy duty industrial gearbox
Lubrication Oil bath gearbox
High torque drive systems are required for heavy steel forming.
Hydraulic Cutting System
Component Specification
Cutting Type Hydraulic flying cut
Blade Material Cr12 tool steel
Cutting Accuracy ±2 mm
Hydraulic Pressure 16–22 MPa
Hydraulic Motor 7.5–11 kW
Hydraulic cutting systems cut crash barrier sections to installation lengths.
Punching System
Component Specification
Punch Type Hydraulic punching system
Application Mounting holes and bolt slots
Punch Capacity 80–120 tons
Punching Speed Synchronized with forming line
Punching systems produce connection holes used for crash barrier installation.
Control System
Component Specification
PLC Siemens / Mitsubishi / Delta
HMI Touch screen control interface
Length Measurement Rotary encoder measurement system
Control Accuracy ±2 mm
Automation Fully automatic production line
Control functions include:
Automatic length control
Punching position control
Batch production programming
Production monitoring
Fault diagnostics
Emergency stop system
Electrical Specifications
Parameter Value
Voltage 380V / 415V / 480V
Frequency 50 Hz / 60 Hz
Control Voltage 24V
Electrical Cabinet IP54 industrial enclosure
Protection Overload protection and circuit breakers
Machine Layout Dimensions
Parameter Value
Machine Length 22–30 m
Machine Width 2.5–3.5 m
Machine Height 2–2.5 m
Total Production Line Length 35–50 m
Typical production line layout:
Uncoiler → Leveling System → Punching System → Roll Forming Machine → Hydraulic Cutting → Run-out Table
Coil Handling Equipment
Specification Value
Uncoiler Type Hydraulic decoiler
Coil Capacity 8–15 tons
Coil Inner Diameter 450–550 mm
Coil Outer Diameter Up to 1600 mm
Expansion Type Hydraulic expansion system
Heavy coil handling equipment is required for thick crash barrier steel coils.
Optional Equipment
Equipment Description
Automatic Stacker Barrier stacking system
Servo Feeder Precision feeding system
Coil Car Automatic coil loading system
Dual Profile System W beam and thrie beam production
Remote PLC Monitoring Remote diagnostics and monitoring
Automation systems improve production efficiency and reduce manual handling.
Installation Requirements
Requirement Typical
Foundation Heavy reinforced concrete foundation
Floor Load Capacity 20–36 tons
Electrical Connection Three phase industrial power supply
Air Supply Optional
Installation Time 3–5 days
Maintenance Requirements
Component Maintenance Interval
Gearbox Oil 6 months
Bearings 6 months
Hydraulic Oil 12 months
Punch Tool Inspection Monthly
Roll Tooling Inspection Monthly
Routine maintenance ensures reliable crash barrier production.
Production Capacity Example
Production Speed Output
8 m/min 480 m/hour
12 m/min 720 m/hour
18 m/min 1080 m/hour
Production output depends on barrier thickness and section length.
Crash Barrier Profile Information
Specification Value
Profile Type W beam / Thrie beam crash barrier
Typical Width 310–500 mm
Material Thickness 2.5–4.5 mm
Standard Length 4320 mm
Crash barriers are designed to absorb vehicle impact and prevent vehicles from leaving the roadway.
Machine Standards
Standard Description
CE Certification European machinery safety standards
ISO 9001 Manufacturing quality management
Road Safety Standards AASHTO / EN highway safety standards
Crash barrier machines are designed to produce profiles compliant with international road safety standards.
Shipping Information
Specification Value
Container Size 40 ft containers (multiple containers)
Shipping Weight 24–38 tons
Packaging Industrial export packing
Typical Machine Price Range
Machine Type Price Range
Basic Line $200,000 – $300,000
Automatic Punching Line $300,000 – $420,000
High Speed Automated Line $450,000+
Pricing depends on automation level, punching systems, and production capacity.
Applications
Industry Use
Road Construction Highway crash barrier systems
Bridge Infrastructure Bridge guardrail protection
Government Road Projects Traffic safety systems
Transportation Infrastructure Roadside protection systems
Crash barrier roll forming machines are widely used by infrastructure steel manufacturers producing highway safety barriers installed along roads, bridges, and highways to improve vehicle safety and road protection.