Road Safety Rail Roll Forming Machine Data Sheet | Technical Specifications
Road Safety Rail Roll Forming Machine Technical Data Sheet
Machine Overview
Parameter Specification
Machine Name Road Safety Rail Roll Forming Machine
Profile Produced Road safety rail profiles (W beam / thrie beam barrier rails)
Machine Type Single profile / dual profile roll forming machine
Production Application Highway safety rails, roadside crash protection systems, bridge safety barriers
Manufacturing Process Continuous cold roll forming with inline punching
Production Environment Infrastructure steel manufacturing facility / heavy industrial production line
The road safety rail roll forming machine produces steel safety rail profiles used along highways and roadways to prevent vehicles from leaving the roadway and to reduce crash severity.
Road safety rails are installed on highways, bridges, road medians, and roadside edges to improve transportation safety.
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 Rail Length 2000 mm
Maximum Rail Length 4320 mm (standard safety rail section)
Road safety rail machines are designed to process heavy gauge steel required for highway 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
Road safety rails are normally produced from hot dip galvanized steel to ensure corrosion resistance in outdoor environments.
Material Strength
Property Typical Range
Yield Strength G350 – G550
Tensile Strength Up to 600 MPa
Coating Types Hot dip galvanized
Galvanized coating protects safety rails from long-term weather exposure.
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 structural 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 Road safety rail forming system
Forming Stages 16–24 stations
Roll tooling gradually forms flat steel strip into road safety rail 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 allow forming of heavy steel used in safety barriers.
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 safety rails to installation lengths.
Punching System
Component Specification
Punch Type Hydraulic punching system
Application Bolt holes and connection slots
Punch Capacity 80–120 tons
Punching Speed Synchronized with forming line
Punching systems produce holes required for installing road safety rails.
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 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 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 8–15 tons
Coil Inner Diameter 450–550 mm
Coil Outer Diameter Up to 1600 mm
Expansion Type Hydraulic expansion system
Heavy duty coil handling systems are required for safety rail steel coils.
Optional Equipment
Equipment Description
Automatic Stacker Rail stacking system
Servo Feeder Precision feeding system
Coil Car Automatic coil loading system
Dual Profile System W beam and thrie beam rail production
Remote PLC Monitoring Remote diagnostics and monitoring
Automation systems improve production efficiency and safety.
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 road safety rail 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 capacity depends on rail thickness and section length.
Safety Rail Profile Information
Specification Value
Profile Type W beam / thrie beam safety rail
Typical Width 310–500 mm
Material Thickness 2.5–4.5 mm
Standard Length 4320 mm
Road safety rails absorb vehicle impact energy and redirect vehicles safely back onto 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
Road safety rail machines are designed to produce profiles compliant with international road safety regulations.
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 safety rail systems
Infrastructure Projects Bridge protection systems
Government Road Projects Traffic safety installations
Transportation Infrastructure Roadside crash protection systems
Road safety rail roll forming machines are widely used by infrastructure steel manufacturers producing highway safety rails installed along roads, bridges, and highways to improve transportation safety and vehicle protection.