Metal deck roll forming machine in Japan

Metal deck roll forming machines are specifically designed to manufacture metal decking profiles used in construction, especially for roofing and flooring systems. Metal decks produced by these machines are widely used in commercial and industrial buildings due to their strength, durability, and cost-effectiveness. These profiles enhance structural integrity, provide insulation, and reduce the overall weight of the construction.

Machine Description

A metal deck roll forming machine automates the production of metal decking sheets by transforming coiled steel into finished deck profiles through a series of precisely designed rollers. The machine is controlled by a Programmable Logic Controller (PLC), allowing operators to achieve high accuracy in production with minimal supervision. Metal deck roll forming machines are suitable for high-volume production and are capable of producing decks in various thicknesses, lengths, and patterns, depending on the project requirements.

The typical components of a metal deck roll forming machine include:

• Decoiler: Holds the steel coil and feeds it into the machine.
• Rollers: Shapes the sheet metal into the deck profile.
• Punching System: Creates necessary holes for screws and fasteners.
• Cutting System: Cuts the deck profiles to specified lengths.
• Control Panel: Allows operators to set parameters and monitor the machine's performance.
• Stacker (optional): Collects and stacks finished profiles for easy packaging and transportation.

Key Specifications

• Roller Materials: High-strength steel, often with a chrome coating for durability.
• Frame Size: Heavy-duty frame for stability during high-speed operation.
• Motor Power: Typically between 15 kW and 30 kW, depending on the production speed and deck thickness.
• Machine Speed: Around 10–30 meters per minute, though some models can reach higher speeds.
• Punching System: Hydraulic or mechanical punching, capable of precise, customizable hole placement.
• Cutting System: Hydraulic cutting for high precision and smooth edges.
• Profile Sizes: Vary depending on the machine model but commonly range from 0.8 mm to 1.5 mm in thickness and widths from 600 mm to 1200 mm.
• PLC Control System: Ensures accurate length cutting, minimal waste, and efficient operation.
• Safety Features: Safety guards and emergency stop functions to protect operators.

Profile Description

• Materials: Galvanized steel, aluminum, or stainless steel, depending on application and corrosion resistance requirements.
• Profile Sizes: Customizable to fit project needs, with standard profiles often including 50 mm to 150 mm deep corrugations.
• Material Gauge: Commonly ranges from 0.8 mm to 1.5 mm.
• Market Size: Widely used in industrial and commercial construction sectors.
• Industries: Construction, roofing, flooring, and structural applications in high-rise buildings, bridges, and warehouses.
• Popular Countries: Metal decking is especially popular in the U.S., China, India, and the Middle East due to the demand for durable and efficient construction materials.

Optional Extras

• Remote PLC Control System: Enables remote operation and monitoring of the machine.
• Automatic Stacker: Assists in collecting and stacking profiles, reducing labor costs.
• Leveling System: Ensures precise leveling of the material before it goes through the rollers.
• Coil Car Tippers and Uncoilers: Simplify coil handling and loading, ensuring a smoother feeding process.

Setup and Installation Process

1. Location Preparation: The machine requires a large, stable area with suitable power supply and access to raw materials.
2. Machine Assembly: Components like decoiler, rollers, and cutting systems are assembled and aligned according to specifications.
3. Calibration and Testing: The machine undergoes calibration to ensure precise punching, cutting, and profiling.
4. Training for Operators: Operators are trained on using the PLC control, setting parameters, and safety measures.
5. Trial Production: Test runs are conducted to ensure the machine operates smoothly and produces accurate profiles.
6. Ongoing Maintenance: Regular maintenance is essential, including lubrication of moving parts, checking roller alignment, and inspecting the cutting system for wear.

Maintenance Requirements

• Routine Inspection: Check rollers, bearings, and motors for wear and tear.
• Lubrication: Regularly lubricate moving parts to prevent friction and ensure smooth operation.
• Alignment Check: Ensure rollers and cutting tools are correctly aligned to avoid profile distortions.
• Electrical Maintenance: Inspect wiring and control systems to prevent electrical faults.
• Cleaning: Keep the machine clean, especially around moving parts, to avoid debris buildup.

Question and Answer Section

Q1: What materials can be used with a metal deck roll forming machine?

A: Metal deck roll forming machines typically work with galvanized steel, aluminum, and stainless steel. The choice of material depends on the specific requirements, such as corrosion resistance, strength, and application type.

Q2: How fast can a metal deck roll forming machine operate?

A: The speed of these machines ranges from 10 to 30 meters per minute, with some advanced models achieving even higher speeds. Speed often depends on the deck thickness and profile complexity.

Q3: What are the common applications for metal deck profiles produced by this machine?

A: Metal deck profiles are commonly used in roofing and flooring applications in industrial and commercial buildings, such as warehouses, factories, high-rise buildings, and even bridges.

Q4: Can I adjust the deck profile thickness on this machine?

A: Yes, most metal deck roll forming machines allow adjustments for different profile thicknesses, typically ranging from 0.8 mm to 1.5 mm.

Q5: What are the safety features on a metal deck roll forming machine?

A: Safety features include emergency stop buttons, safety guards around rollers and cutting areas, and sometimes automated shutdown systems in case of malfunction.

Q6: How do I ensure precise hole placement in the deck profiles?

A: The machine uses a hydraulic or mechanical punching system that is controlled via the PLC. Operators can set precise parameters for hole placement and sizes according to project requirements.

Q7: How often should I maintain my metal deck roll forming machine?

A: Routine maintenance is recommended every 1–2 months, depending on the machine’s usage frequency. Major components like rollers, cutting blades, and the PLC system should be inspected regularly to ensure optimal performance.