Guardrail roll forming machines are specialized equipment designed to produce highway guardrails and crash barriers, commonly used for road safety and infrastructure projects. These machines ensure the precise and efficient manufacturing of guardrails with consistent quality and durability. Guardrails are essential for vehicle and pedestrian safety, making the reliability of the manufacturing process critical.

This roll forming equipment uses a series of rollers to shape flat metal sheets into W-beam, Thrie-beam, or other guardrail profiles. It accommodates a variety of materials such as galvanized steel, stainless steel, and aluminum, offering versatility in production to meet global safety standards.

Specifications of Guardrail Roll Forming Machines

1. General Machine Specifications

• Material Thickness: 2.0 mm to 4.0 mm
• Material Width: 300 mm to 600 mm (adjustable based on profile)
• Material Type: Galvanized steel, stainless steel, aluminum, or pre-coated steel
• Machine Speed: 10–15 m/min (standard) or up to 30 m/min (high-speed options)
• Profile Types: W-beam, Thrie-beam, custom guardrail profiles
• Roller Stations: 14–20 stations depending on profile complexity
• Roller Material: High-grade GCr15 or Cr12 steel, heat-treated for durability
• Cutting System: Hydraulic cutting with a mold system or flying cut-off saw
• Punching System: Hydraulic punching with pre-designed dies for holes and slots
• Control System: PLC-based system with HMI for user-friendly operation

2. Frame and Structural Specifications

• Main Frame: Heavy-duty steel for stability
• Shaft Material: 45# steel with hard chrome plating
• Machine Dimensions: Approximately 10–15 meters in length, 1.5–2 meters in width
• Weight: 15–20 tons (depending on configuration)

3. Power Requirements

• Main Motor Power: 22–45 kW (varies by production capacity)
• Hydraulic Station Power: 7.5–15 kW
• Voltage: Customizable (380V, 50Hz or as per client specifications)

4. Additional Features

• Safety Guards: Enclosures around rollers for operator safety
• Coil Handling System: Automatic decoiler with a capacity of up to 10 tons
• Stacking System: Fully automated stacker for finished guardrails
• Customization: Adjustable rollers for different profile widths and depths

Machine Description

A guardrail roll forming machine operates in a sequential process:

1. Decoiling: The raw material coil is fed into the machine through an automatic decoiler.
2. Leveling: The material is leveled to ensure flatness before entering the rollers.
3. Punching: Pre-designed dies punch holes or slots for guardrail installation.
4. Roll Forming: The material passes through a series of rollers that shape it into the desired guardrail profile.
5. Cutting: A hydraulic cutting system cuts the profile to the required length.
6. Stacking: The finished guardrails are automatically stacked for collection.

The process is fully automated, reducing labor costs and ensuring high precision, making it suitable for mass production.

Frequently Asked Questions (FAQs)

1. What is the production capacity of a guardrail roll forming machine?

The production capacity varies depending on the machine speed. Standard machines operate at 10–15 m/min, while high-speed machines can reach up to 30 m/min.

2. Can the machine produce multiple types of guardrails?

Yes, the machine can be configured to produce W-beam, Thrie-beam, and other custom profiles with interchangeable rollers and dies.

3. What materials are compatible with this machine?

Guardrail roll forming machines can process galvanized steel, stainless steel, aluminum, and pre-coated steel within the specified thickness range of 2.0–4.0 mm.

4. Is the machine customizable for different power supplies?

Yes, the machine can be customized to match your region's power supply requirements, such as 380V, 50Hz, or 220V, 60Hz.

5. What maintenance does the machine require?

Routine maintenance includes lubrication of moving parts, inspection of rollers for wear and tear, regular cleaning, and ensuring proper alignment of components.

6. How is the punching system configured?

The hydraulic punching system is equipped with pre-designed dies that can be customized for different hole sizes and positions as required by guardrail installation standards.

7. What optional features are available?

Optional extras include an automatic stacker, remote PLC control systems, advanced coil handling systems, and additional safety enclosures.

8. What is the delivery time for the machine?

Delivery time typically ranges from 60 to 90 days, depending on customization requirements and order volume.

9. Can the machine be integrated into an existing production line?

Yes, it can be integrated seamlessly into an existing production line with minimal adjustments.

10. What is the warranty period?

Most manufacturers offer a 12–24 month warranty, covering parts and labor for manufacturing defects.