Highway Guardrail Roll Forming Machine Data Sheet | Technical Specifications
Highway Guardrail Roll Forming Machine Technical Data Sheet
Machine Overview
Parameter Specification
Machine Name Highway Guardrail Roll Forming Machine
Profile Produced W-beam guardrail / highway safety barrier profiles
Machine Type Single profile / double profile guardrail roll forming machine
Production Application Road safety barriers, highway guardrails, crash protection systems
Manufacturing Process Continuous cold roll forming with inline punching
Production Environment Heavy industrial manufacturing facility / infrastructure fabrication plant
The highway guardrail roll forming machine produces steel safety barrier profiles used on highways and roadways to prevent vehicles from leaving the road.
Guardrail systems are widely installed along highways, bridges, curves, and road edges to improve road safety.
Production Specifications
Specification Typical Value
Production Speed 10–18 m/min
Forming Stations 16–24 stations
Material Thickness Range 2.5–4.5 mm
Coil Width 480–750 mm
Coil Weight Capacity 8–12 tons
Cut Length Tolerance ±2 mm
Minimum Rail Length 2000 mm
Maximum Rail Length 4320 mm (typical guardrail length)
Guardrail production requires heavy gauge steel forming with high structural accuracy.
Material Compatibility
Material Type Supported
Hot Rolled Steel Yes
Galvanized Steel Yes
High Strength Steel Yes
Weathering Steel Optional
Stainless Steel Limited
Most highway guardrails are produced from galvanized steel for corrosion protection.
Material Strength
Property Typical Range
Yield Strength G350 – G550
Tensile Strength Up to 600 MPa
Coating Types Hot dip galvanized
Galvanized coating protects guardrails from corrosion in 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 20–35 tons
Guardrail machines require heavy structural frames to form thick steel.
Roll Tooling Specifications
Specification Typical Value
Roller Material GCr15 bearing steel
Heat Treatment HRC 58–62
Roller Diameter 120–160 mm
Shaft Diameter 100–130 mm
Shaft Material 40Cr alloy steel
Surface Finish Hard chrome plating
Roll Pass Design Guardrail profile forming system
Forming Stages 16–24 stations
Roll tooling gradually forms flat steel strip into W-beam guardrail profiles.
Drive System
Component Specification
Drive Type Gearbox drive system
Main Motor 30–45 kW
Drive Ratio 1:20
Transmission Heavy duty industrial gearbox
Lubrication Oil bath gearbox
High torque drive systems are required for forming thick guardrail steel.
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 guardrail sections to standard lengths.
Punching System
Component Specification
Punch Type Hydraulic punching system
Application Mounting holes and connection slots
Punch Capacity 80–120 tons
Punching Speed Synchronized with forming line
Punching systems produce bolt holes required for guardrail 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 system functions include:
Automatic length control
Punching position control
Batch production programming
Production monitoring
Fault diagnostics
Emergency stop functions
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 20–28 m
Machine Width 2.5–3.5 m
Machine Height 2–2.5 m
Total Production Line Length 35–50 m
Typical line configuration:
Uncoiler → Leveling System → Punching System → Roll Forming Machine → Hydraulic Cutting → Run-out Table
Coil Handling Equipment
Specification Value
Uncoiler Type Hydraulic decoiler
Coil Capacity 8–12 tons
Coil Inner Diameter 450–550 mm
Coil Outer Diameter Up to 1600 mm
Expansion Type Hydraulic expansion system
Heavy coil handling systems are required for guardrail steel coils.
Optional Equipment
Equipment Description
Automatic Stacker Guardrail stacking system
Servo Feeder Precision feeding system
Coil Car Automatic coil loading system
Post Punching System Additional hole punching system
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 20–35 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 guardrail production.
Production Capacity Example
Production Speed Output
10 m/min 600 m/hour
15 m/min 900 m/hour
18 m/min 1080 m/hour
Production output depends on guardrail length and material thickness.
Guardrail Profile Information
Specification Value
Profile Type W-beam highway guardrail
Typical Width 310 mm
Material Thickness 2.5–4.5 mm
Standard Length 4320 mm
W-beam guardrails are the most widely used highway safety barrier profiles worldwide.
Machine Standards
Standard Description
CE Certification European machinery safety standards
ISO 9001 Manufacturing quality management
Road Safety Standards AASHTO / EN road barrier standards
Guardrail machines are designed to produce profiles compliant with highway safety standards.
Shipping Information
Specification Value
Container Size 40 ft container (multiple containers)
Shipping Weight 22–36 tons
Packaging Industrial export packing
Typical Machine Price Range
Machine Type Price Range
Basic Line $180,000 – $260,000
Automatic Punching Line $260,000 – $380,000
High Speed Automated Line $400,000+
Pricing depends on punching systems, automation level, and production capacity.
Applications
Industry Use
Road Construction Highway safety barriers
Infrastructure Projects Bridge protection systems
Government Road Projects Traffic safety systems
Transportation Infrastructure Roadside protection systems
Highway guardrail roll forming machines are widely used by infrastructure steel manufacturers producing highway safety barriers used in road construction and transportation safety systems.