Floor deck roll forming machine in Hong Kong

A floor deck roll forming machine is designed to produce high-quality floor decking panels commonly used in the construction industry for floors, roofs, and composite slabs. These machines are essential for creating sturdy and reliable floor deck profiles, ensuring structural integrity and durability in building projects. Floor deck panels produced by these machines often feature grooves or embossments that enhance bonding with concrete, providing enhanced load-bearing capacity and resistance to seismic activity.

Machine Specifications

A typical floor deck roll forming machine includes the following components and specifications:

1. Roller Materials: High-grade steel rollers with a chrome finish for corrosion resistance and durability. Rollers are heat-treated to ensure longevity and precision.
2. Frame Size: Heavy-duty steel frame construction designed to withstand high operational demands and ensure stability during high-speed production.
3. Motors and Power:
   • Main Motor: 7.5 kW to 15 kW depending on production capacity.
   • Hydraulic Motor: 4 kW for hydraulic systems used in cutting and punching processes.
4. PLC Control System: A programmable logic controller (PLC) system with a touchscreen interface for easy and precise control over production parameters. Compatible with remote PLC systems for enhanced flexibility.
5. Production Speed: Typically ranges from 15-30 meters per minute, depending on the profile complexity and machine configuration.
6. Profile Widths and Heights: Customizable to produce various floor deck panel widths (600-1000 mm) and heights (50-75 mm), depending on client requirements and building standards.
7. Material Gauge: Handles a variety of material gauges, typically from 0.8 mm to 1.5 mm, suitable for different load-bearing requirements.
8. Cutting System: Hydraulic cutting system with high precision. The cutting is synchronized with the roll forming speed to ensure clean and accurate cuts.
9. Safety Features: Includes safety guards, emergency stop functions, and enclosures to ensure operator safety during high-speed operations.
10. Optional Extras:
    • Uncoilers and Recoilers: For automated coil handling.
    • Automatic Stacker: For efficient stacking of finished panels.
    • Leveling System: To ensure evenness and flatness in the final product.
    • Punching Unit: Optional unit for adding embossments to improve bonding with concrete.

Profile Description

The floor deck panels created by these machines are made from galvanized steel or other durable metals suitable for structural applications. Profiles include embossments and grooves that improve bonding between the concrete and the decking panel. Common profiles vary by regional standards but typically include ribbed or corrugated designs, ideal for composite flooring systems.

Industries and Applications

• Building and Construction: Used in commercial buildings, industrial facilities, and residential buildings for composite flooring systems.
• Infrastructure Projects: Ideal for bridges, tunnels, and elevated platforms.
• High-Rise Buildings: Widely used in multi-story construction for enhanced load distribution and structural integrity.

Floor Deck Roll Forming Machine Pricing

Prices for floor deck roll forming machines can range widely based on customization, speed, and included features:

• Low-Range Machines: Simple models with basic features, typically costing between $30,000 and $50,000.
• Mid-Range Machines: Machines with additional features like punching and automated stacking, priced around $50,000 to $80,000.
• High-End Machines: Advanced models with high-speed production, complete automation, and optional extras. These can cost between $80,000 and $120,000.

Setup and Installation

Installation involves positioning the machine, aligning the rollers, setting up the PLC system, and testing production output. Professional installation services are often recommended to ensure optimal performance. After installation, the machine should undergo regular calibration and maintenance checks to maintain output quality.

Maintenance Requirements

Regular maintenance includes:

• Lubricating moving parts and cleaning rollers.
• Inspecting hydraulic and electrical systems for optimal functioning.
• Regular checks on the PLC system and software updates.
• Ensuring safety features and guards are operational.

Question and Answer Section

Q1: What materials are compatible with a floor deck roll forming machine?
A1: Floor deck roll forming machines are compatible with galvanized steel, aluminum, and other high-strength metals with gauges between 0.8 mm and 1.5 mm, suitable for heavy-duty structural applications.

Q2: How does a floor deck panel improve structural strength in construction?
A2: The floor deck panels are designed with grooves and embossments to improve bonding with concrete, distributing loads evenly and enhancing the structural integrity of floors, roofs, and slabs, especially in multi-story and high-rise buildings.

Q3: Can the machine be customized to produce different profiles?
A3: Yes, most floor deck roll forming machines can be customized to produce various profile widths, heights, and embossment patterns. The PLC system allows for adjustments in profile dimensions based on specific project requirements.

Q4: What safety features are included in a floor deck roll forming machine?
A4: Safety features include protective guards, emergency stop buttons, and safety enclosures to protect operators from moving parts and high-speed production operations.

Q5: How often should maintenance be performed on the machine?
A5: Regular maintenance should be performed monthly, focusing on lubrication, part inspection, and system checks to prevent wear and ensure consistent production quality.

Q6: How long does it take to set up a floor deck roll forming machine?
A6: Setup times vary based on machine complexity and facility layout. It generally takes one to three days to install and calibrate the machine for full production, especially if performed by professional technicians.

Q7: Is training required to operate the machine?
A7: Yes, training is recommended for operators to understand the machine’s PLC control system, maintenance routines, and safety procedures. Many manufacturers provide training as part of the installation package.

This guide offers a comprehensive view of floor deck roll forming machines, helping users understand their specifications, applications, and maintenance requirements. If you're considering investing in a floor deck roll forming machine, be sure to consult with the manufacturer for specific details and customization options to best meet your project needs.