Scaffolding Plank & Catwalk Roll Forming Line | Ben Thomas

Scaffolding Plank and Catwalk Roll Forming Line by Ben Thomas

The Ben Thomas scaffolding plank roll forming line is an automated production line that turns metal coil into finished steel scaffolding planks, also called catwalks or scaffold boards. The line decoils, punches, roll forms, cuts, and stacks planks in one continuous process, with hole patterns punched to the customer's drawing so planks can be made for ringlock, cuplock, and other scaffolding systems.

Typical Specifications

The figures below show a standard configuration for this type of scaffolding plank roll forming line. Final specifications are built to each customer's plank drawing, so confirm exact figures with Ben Thomas when requesting a quote.

Material
Material type: Pre-galvanized steel, hot-dip galvanized steel, high-tensile steel (Q235 or Q345), or aluminum
Material thickness: 1.2 to 2.0 mm
Coil width: 300 to 500 mm, depending on plank size

Finished Plank
Plank widths: 210, 225, 240, 250, 300, or 320 mm, or to customer drawing
Profile height: 45 to 65 mm
Plank length: 0.5 to 4 m, set on the control panel
Length tolerance: ±1 mm

Decoiler
Capacity: 3 to 5 tons
Coil inner diameter: 480 to 520 mm
Coil outer diameter: Up to 1500 mm
Type: Manual or hydraulic expansion

Punching
Punching type: Hydraulic punching or a 63 to 125 ton mechanical press with servo feeder
Patterns: Anti-slip embossed holes, drainage holes, and connection slots to customer drawing
Die material: Cr12MoV, hardened to HRC 58 to 62

Roll Former
Forming stations: 14 to 22
Shaft diameter: 70 to 90 mm
Roller material: GCr15 or Cr12 steel, hardened and chrome plated
Drive: Gearbox or chain
Main motor power: 11 to 22 kW
Forming speed: 8 to 15 m/min

Cutting
Cutting type: Hydraulic, stop-to-cut or flying cut
Blade material: Cr12MoV, hardened to HRC 58 to 62

Control System
PLC: Siemens, Mitsubishi, or Delta
Touch screen: English interface with length and batch quantity input
Inverter: Yaskawa or equivalent
Encoder: Omron or equivalent
Power supply: 380 V, 50 Hz, 3-phase, customizable to local voltage

Stacking and Options
Stacker: Automatic stacking of finished planks
Optional: End cap or hook welding station for ringlock catwalks, automatic packing, and a leveling unit

Line Layout
Total line length: About 30 to 45 m, depending on configuration

What Is a Scaffolding Plank?

A scaffolding plank, or catwalk, is the metal walking platform that sits across a scaffold frame. It supports workers, tools, and materials during high-rise construction, maintenance, and infrastructure work. Steel planks are punched with holes or slots for drainage, slip resistance, and connection to the scaffold system, and they have to carry heavy loads safely every time.

How the Line Works

1. Decoiler. The decoiler holds the coil and unwinds it at steady tension and alignment, so the strip feeds smoothly without jams. The line can run high-tensile steel, galvanized steel, or aluminum coil.

2. Hole punching. The punching unit cuts holes, slots, and notches to the customer's drawing. This is where anti-slip patterns and the connection holes for ringlock, cuplock, or other scaffold systems are made.

3. Roll former. Multiple sets of precision rollers bend the strip step by step into the plank profile. Forming gradually keeps the cross-section uniform and preserves the steel's strength, so finished planks can carry heavy site loads.

4. Hydraulic cutting. A hydraulic cutter cuts the continuous plank to preset lengths with clean, square ends, without deforming the profile.

5. Auto stacker. Finished planks are collected and stacked automatically, cutting manual handling and the risk of damage.

Key Features

High automation. One line runs from coil to stacked planks, replacing labor-intensive manual or semi-automatic methods.

Custom punching patterns. Holes and slots are made to the customer's drawing, so the line can serve different scaffolding systems and markets.

Programmable production. The line can run long batches of identical planks or switch between specifications according to a preset program.

Consistent quality. Stable, continuous operation keeps dimensions and hole positions consistent from plank to plank.

Lower labor costs. Automated cutting and stacking reduce the number of operators needed.

Applications

This line is built for scaffolding manufacturers, scaffold rental companies with in-house production, and construction groups that make their own access equipment. Typical products include steel scaffold boards, ringlock catwalks, cuplock planks, and custom walkway planks.

About the Manufacturer

Ben Thomas builds roll forming lines in the Botou Economic Development Zone, Cangzhou, Hebei Province, China. Its range also includes purlin, cable tray, solar bracket, rack upright, guardrail, and sheet pile lines.

Frequently Asked Questions

What does a scaffolding plank roll forming machine do?
It automatically turns metal coil into finished scaffolding planks by decoiling, punching, roll forming, cutting to length, and stacking.

What is the difference between a scaffolding plank and a catwalk?
They are the same product. "Catwalk" is the common term for steel planks used with ringlock and similar system scaffolding, and "scaffold plank" or "scaffold board" is the general term.

Can the line make planks for ringlock and cuplock scaffolding?
Yes. The hole punching is done to the customer's drawing, so the line can produce planks for ringlock, cuplock, and other scaffold systems.

What materials can it run?
The line can process high-tensile steel, galvanized steel, and aluminum coil.

How are finished planks handled?
An automatic stacker collects and stacks planks at the end of the line.

Can it switch between plank sizes?
Yes. The line can switch between specifications according to a preset program.