Have you ever wondered how sturdy industrial warehouses, aesthetically pleasing roofing systems, or intricate cable tray networks are produced with remarkable speed and precision? The answer lies in roll forming machines—pioneering technology that is revolutionizing the construction and industrial sectors. From C/Z/U purlins, corrugated roofing, decking floors, to cable trays, machines like the Purlin Machine, Kliplock Roll Forming Machine, and Cable Tray Roll Forming Machine not only enable high-volume production but also deliver exceptional durability, aesthetics, and cost-efficiency. Join us as we explore how these remarkable machines are shaping the future of modern construction in this comprehensive guide! How Roll Forming Machines Meet the Demands of Construction and Industry?
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1. What Are Roll Forming Machines?
Basic Concept
Roll forming machines are industrial equipment designed to shape metal sheets or coils into specific profiles through a series of rollers. This process, known as roll forming, operates continuously, allowing metal to be gradually bent into complex shapes such as C/Z/U purlins, smartframe construction systems, corrugated roofing, cable trays, decking floors, kliplock, or seamlock panels without compromising the material’s structural integrity.
Operating Principle
Key Components
Roll forming machines consist of several critical components:
- Decoiler: Unwinds metal coils to feed the forming process.
- Guide System: Aligns the metal sheet for accurate entry into the rollers.
- Roll Forming Stations: A series of rollers that shape the metal.
- Cutting System: Trims the formed metal to the desired length.
- Drive System: Powers the rollers with motors and gearboxes.
- Control System: Uses PLC and HMI for precise operation.
- Stacking System: Collects finished products for packaging.
The process is controlled by a PLC system, ensuring automation, high precision, and efficient mass production.
Types of Roll Forming Machines
Common roll forming machines include:
- Purlin Machine: Produces C, Z, U purlins.
- Roofing Machine: Manufactures round-wave roofing sheets.
- Corrugated Machine: Creates square-wave corrugated sheets.
- Steptile Roll Forming Machine: Produces tile-patterned roofing.
- Decking Roll Forming Machine: Makes steel decking floors.
- Standing Seam Roll Forming Machine: Produces standing seam roofing panels.
- Cable Tray Roll Forming Machine: Manufactures cable trays.
- Kliplock Roll Forming Machine: Produces kliplock roofing panels.
- Seamlock Roll Forming Machine: Produces seamlock roofing panels.
- Batten Roll Forming Machine / Top Hat: Produces roof battens or lightweight steel frames.
- Smartframe Machine: Manufactures lightweight steel frames for modular buildings.
2. Key Features of Roll Forming Machines
2.1. High Automation
Modern roll forming machines are equipped with programmable logic controllers (PLC) and human-machine interfaces (HMI). Brands like Siemens, Delta, or Mitsubishi ensure precise monitoring and control. Key automation features include:
Automatic Profile Adjustment: For instance, Purlin Machines can switch between C, Z, U profiles without changing rollers.
Precise Cutting: Hydraulic or servo-driven cutting systems ensure accurate dimensions with tolerances below 0.5 mm.
High Speed: Average forming speeds of 7-13 m/min, ideal for large-scale production.
2.2. Durability and High Quality
Rollers: Made from high-grade alloy steel (e.g., C45, SKD11), CNC-machined, and chrome-plated for durability and smooth operation.
Machine Frame: Heavy-duty (12-18 tons) and robustly designed for stable operation during continuous 20-22 hour/day runs.
Quality Components: Featuring motors from Toshiba or ABB, Yuken hydraulic systems, or Siemens servos, ensuring 10-15 years of reliable performance.
2.3. Production Flexibility
Roll forming machines can be customized to produce various profiles. For example:
Purlin Machine: Produces purlins with adjustable widths and thicknesses (1.5-3.2 mm), with automatic size changes.
Kliplock/Seamlock Machine: Creates roofing panels with customizable lengths for diverse roof designs.
Cable Tray Machine: Manufactures cable trays with tailored sizes and punch patterns.
2.4. Cost Efficiency
Material Optimization: Roll forming generates minimal waste, maximizing coil usage.
Reduced Labor Costs: Automation minimizes the need for manual labor.
Low Maintenance: Simple designs reduce downtime and maintenance costs.
3. Applications of Roll Forming Machines in Construction and Industry
3.1. Construction Industry
Products from roll forming machines are integral to modern construction, from residential homes and industrial warehouses to commercial and infrastructure projects.
a. Steel Frameworks (Purlin Machine, Smartframe Machine)
C, Z, U Purlins: Produced by Purlin Machines, these are key components in steel frameworks, offering high strength and load-bearing capacity. They are used in warehouses, factories, and modular buildings.
a.1. Purlin Machine
The fully automatic CZ purlin roll forming machine from VIETSTEEL is specially designed to produce C and Z purlins with various flexible sizes. This product is also known as the Quick Change C/Z Purlin Roll Forming Machine or the C & Z Slotted Channel Roll Forming Machine. With advanced technology, the machine offers high automation capabilities, enhancing production efficiency and ensuring absolute precision.
The quality of the machine is ensured by importing components from high-quality manufacturers, and the machine has a long service life, making it a cost-effective investment for businesses. The machine can also handle a variety of materials, including thick and hard materials like stainless steel blanks. Overall, the purlin roll forming machine is a valuable investment for businesses in the steel manufacturing industry.
| Model | CZ-EA Model |
| Power | Transmission: 2x15kw – 1/30 1×7.5kw – 1/30 Motor – pump: 11kw – 45cc Size changed: 3×1.5kw – 1/25 Punch table: 2×1.5kw |
| Weight of machine | 28 tons |
| Dimension | L=16m; W=2.5m, H=2.0m |
| Forming speed | 16 – 20 meters/minute (w/o punching) Lower with punching |
| Roller stations | – Lip forming: 06 – Side forming: 11 – Pulling stations: 05 – Anti-flare adjustment: 01 |
| Transmission system | Electric motor and Gear box |
| Cutting system | Hydraulic cylinder |
| Cutting technology | Part-cutting and scrap cutting |
| Punching system | Hydraulic cylinder |
| Punching technology | 03 separate punching stations. Position reached by servo |
| Control system | PLC, HMI automatic programmable |
| Size range | C100–C350 and Z100–Z350 |
| Size changed | Automatic by servo motor |
| Material thickness | 1.2 – 3.2 mm |
| Material width | For C: 200-563mm For Z: 206-569m |
| Material Yield Strength | G300 – G550 Mpa |
Lightweight Steel Frames: Smartframe Machines produce frames for residential or prefabricated villas, reducing construction time and costs.
a.2. Smartframe Machine
SmartFrame solution is a solution that was created using the designs, manufacturing and construction of light steel buildings to replace tradition construction methods and was made possible by Smartframe machines and a specialized design software
Smartframe machines are a type of machine that rolls steel products into the correct shape and size according to the designs and drawings made. This is an advanced technology that has been applied to countries such as New Zealand, Australia, Canada, etc.
| PARAMETER | TS-SA MODEL |
| Wattage | Servo Motor 11kW Hydraulic Motor 7.5kW |
| Weight | 5 tons |
| Dimensions (LxWxH) | 5m x 1.0m x 1.5m |
| Speed | 28 mpm (without punching) 5-8 mpm (not including punching) |
| Number of shaft pairs | 07 |
| Drive system | Servo motor and gearbox |
| Cutting system | Hydraulic cylinder |
| Punching system | Hydraulic cylinder |
| Control system | Programmed and monitored by dedicated software |
| Workpiece Thickness | 0.6-1.2mm |
| Workpiece hardness | 345-550Mpa AS1365 & AS 1397 |
| Type of workpiece | Galvanized sheet & zinc aluminum alloy plated |
b. Roofing and Cladding (Roofing, Corrugated, Steptile, Kliplock, Seamlock, Standing Seam)
Roofing Sheets: Machines like Roofing, Corrugated, and Steptile Roll Forming Machines produce square-wave, tile-patterned, or standing seam roofing panels for homes, factories, and commercial centers. These sheets meet demands for durability, waterproofing, and aesthetics.
b.1. Roofing Roll Forming Machine
Roofing Panel Roll Forming Machine – A standard roofing roll forming machine, also known as a trapezoidal, rib-type, spandek, trimdek, 4-angle roofing, or wave roofing machine. Depending on the country, there are various rib-type profiles, including 5, 6, 7, 8, 9, 10, 11, 12, 13, and 14 ribs, with the 5-rib type profile being the most common
| Items | RF-HD Model |
|---|---|
| Power | Motor-Pump: 7.5-15kw |
| Weight of machine | 9 -15 tons |
| Dimension | L=9-13m; W=1.5-2.0m; H=1.6m |
| Roller stations | 20 – 32 |
| Transmission system | Hydraulic Motor |
| Pre – Cutting | Hydraulic cylinder |
| Profile – Cutting | Hydraulic cylinder |
| Control system | PLC, HMI automaticprogrammable |
| Material thickness | 0.2 – 0.6mm |
| Material with | 914/ 940/ 1200/ 1220/ 1250/ 1450 mm |
| Material Yield Strength | G300 – G550 Mpa (GI/PPGI, GL/PPGL) |
b.2. Corrugated Roll Forming Machine
Material Compatibility: It processes galvanized steel, stainless steel, aluminum, or even copper, with thicknesses ranging from 0.2 mm to 1.2 mm (sometimes up to 2 mm for specific applications). This versatility allows manufacturers to cater to diverse project requirements, from lightweight roofing to heavy-duty cladding. Customizable Profiles: While the classic sinusoidal (round-wave) corrugated profile is most common, the machine can be configured to produce trapezoidal or square-wave profiles by adjusting or replacing rollers. This flexibility makes it suitable for both traditional and modern architectural designs.
Link product: Corrugated Roll Forming Machine
| Items | RC-EH Model |
|---|---|
| Power | Transmission: 7.5 – 22 kwMotor-Pump: 7.5-15kw |
| Weight of machine | 14 -18 tons |
| Dimension | L=12-14m; W=1.6-2.0m; H=1.6m |
| Roller stations | 26 – 32 |
| Transmission system | Electric motor and Gear box |
| Pre – Cutting | Hydraulic cylinder |
| Profile – Cutting | Hydraulic cylinder |
| Control system | PLC, HMI automaticprogrammable |
| Material thickness | 0.17 – 0.35mm0.25 – 0.6mm |
| Material with | 914/ 940/ 1200/ 1220/ 1250/ 1450 mm |
| Material Yield Strength | G300 – G550 Mpa (GI/PPGI, GL/PPGL) |
b.3. Steptile Roll Forming Machine
Step tile roll forming machine is a type of equipment used in the manufacturing process of roofing sheets. It is a roll forming machine that produces roofing sheets with a stepped profile. This type of machine can produce roofing sheets with different steps or waves, depending on the customer’s requirements.
The machine works by feeding a flat metal coil through a series of rollers that gradually shape the metal into the desired stepped profile. The metal is then cut to the required length and stacked for packaging. Step tile roll forming machines are often automated, making them more efficient and reducing labor costs.
| Items | ST-SH Model | ST-EH Model |
| Power | – Transmission: 11 – 15 kW – Motor-Pump: 15kw | – Transmission: 7.5 – 15kw – Motor-Pump: 11 kW |
| Weight of machine | 12 – 18 tons | 12 – 18 tons |
| Dimension | L= 6 – 12 m; W= 2.3-2.6m; H=1.6 m | L= 6 – 12 m; W= 2.3-2.6m; H=1.6 m |
| Forming Speed | 8 meters/minute | 4 – 6mpm |
| Roller stations | 12 – 26 | 12 – 26 |
| Transmission system | Servo motor and Gear-box | Electric motor and Gear box |
| Cutting and Pressing system | Hydraulic cylinder | Hydraulic cylinder |
| Control system | PLC, HMI automatic programmable | PLC, HMI automatic programmable |
| Material thickness | 0.18 – 0.5mm | 0.18 – 0.5mm |
| Material width | 914/ 940/ 1200/ 1220/ 1250 mm | 914/ 940/ 1200/ 1220/ 1250 mm |
| Material Yield Strength | G300 – G450 Mpa (GI/PPGI, GL/PPGL) | G300 – G450 Mpa |
b.4 Kliplock Roll Forming Machine
The Kliplock Roll Forming Machine is a highly specialized and intriguing piece of industrial equipment designed to produce Kliplock roofing panels, a popular choice in modern construction due to their unique clip-lock mechanism, strength, and aesthetic appeal. This machine stands out among other roll forming machines (like the Corrugated Roll Forming Machine or Purlin Machine) for its ability to create seamless, leak-proof roofing systems that are both functional and visually striking.
| Items | KL-EH Model |
| Power | Transmission: 15 – 22 kw Motor – Pump: 7.5 kw |
| Weight of machine | 14 – 16 tons |
| Dimension | L=12-14m; W=1.9m; H=1.7m |
| Forming speed | 22 – 25 meters/ minute |
| Roller stations | 28 – 40 |
| Transmission system | Electric motor and gear box |
| Profile Cutting | Hydraulic cylinder |
| Pre-Cutting | Hydraulic cylinder |
| Control system | PLC, HMI automatic programmable |
| Material thickness | 0.4 – 0.6 mm |
| Material width | 598/ 914/ 1200/ 1220 mm |
| Material Yield Strength | G400 – G550 Mpa (GI/PPGI, PPGL) |
Kliplock and Seamlock Panels: Manufactured by Kliplock and Seamlock Roll Forming Machines, these panels feature locking edges for leak-proof, easy-to-install roofing. They are ideal for large-scale roofs in factories, airports, or warehouses.
b.5. Seamlock Roll Forming Machine
Seamlock Roll Forming machine (SL-HD Model) is considered to be a high precision sheet rolling machine with high durability and stability, easy operation, and a reasonable price.
Seamlock Roll Forming machine (SL-HD Model) is designed to create finished products that are screwless roofing sheets, linked by double locking joints to ensure absolute tightness and increase the lifetime of roofing sheets and buildings. The hydraulic motor drive system helps the SL-HD model to operate quietly and achieve high productivity.
| Items | SL-HD Model |
| Power | Motor-Pump:7.5kw |
| Weight of machine | 6 – 7tons |
| Dimension | L= 6-7.5m; W= 1m; H=1.6m |
| Forming Speed | 18-22mpm |
| Roller stations | 14 – 18 |
| Transmission system | Hydraulic motor |
| Cutting system | Hydraulic cylinder |
| Control system | PLC, HMI automatic programmable |
| Material thickness | 0.35– 0.6mm |
| Material width | 400/457/500/600 mm |
| Material Yield Strength | G400 – G550 Mpa |
b.6. Standing Seam Roll Forming Machine
Standing Seam Roll Forming Machine – Standing seam metal roofing panels are known for their durability and sleek appearance, utilizing concealed fasteners for attachment. Originally, clips were used to engage with the vertical legs of the panels, securing them to the roofing substructure. With the evolution of panel options, clipless panels have also become a common feature in this product family.
Standing Seam Machine is a specialized roll forming machine used to produce standing seam metal roofing panels. These panels are known for their durability, weather resistance, and clean, modern appearance. The Standing Seam Machine shapes metal sheets into panels with raised seams that are then interlocked and fastened with concealed clips or fasteners, providing a sleek and secure roofing system.
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Cladding: Some roll-formed products serve as insulated or soundproof cladding for offices or industrial facilities.
c. Steel Decking (Decking Roll Forming Machine)
Decking Floors: Decking Roll Forming Machines produce profiled steel panels used as load-bearing floors in high-rise buildings, bridges, or factories. Decking reduces structural weight, speeds up construction, and saves concrete costs.
Also known as a deck forming machine, this machine produces steel decking used in composite concrete floors in high-rise buildings.
Vietsteel’s metal sheet forming machine for decking includes automated decoiling and precise hydraulic cutting for high-end production.
| Items | FD-EH Model |
| Power | – Transmission: 22 – 30kw – Motor-Pump: 11 – 15kw |
| Weight of machine | 20 – 25 tons |
| Dimension | L = 12-22m ; W = 2.1m ; H = 1.9m |
| Forming Speed | 16 – 20mpm |
| Roller stations | 32 – 42 |
| Transmission system | Electric motor andGear box |
| Cutting system | Hydraulic cylinder |
| Control system | PLC, HMI automatic programmable |
| Material thickness | 0.7 –1.6 mm |
| Material width | 1200– 1250mm |
| Material Yield Strength | G350 – G550 Mpa |
d. Roof Battens (Batten Roll Forming Machine / Top Hat)
- Top Hat Battens: Produced by Batten Roll Forming Machines, these are used as roof supports or secondary components in roofing systems, ensuring durability and stability.
- A batten is popular used in sheet metal, construction, manufacturing industries. A batten roll forming machine is a specialized machine used in the manufacturing process of roof battens. This machine is designed to efficiently and accurately produce roof battens of various profiles and dimensions.
| Items | BT-HD Model |
| Power | Motor-Pump: 7.5kw |
| Weight of machine | 4 tons |
| Dimension | 4m x 0.6m x 1.4m |
| Forming Speed | 20mpm |
| Roller stations | 12-14 |
| Transmission system | Hydraulic motor |
| Cutting system | Hydraulic cylinder |
| Control system | PLC, HMI automatic programmable |
| Material thickness | 0.35 – 0.6mm |
| Material width | 100-185 mm |
| Material Yield Strength | G450 – G550 Mpa |
3.2. Industrial Applications
Beyond construction, roll forming machines serve various industrial needs.
a. Cable Trays (Cable Tray Roll Forming Machine)
- Metal Cable Trays: Used to manage and protect electrical cabling in factories, data centers, or commercial buildings. These trays are durable, corrosion-resistant, and easy to install.
The flexibility of your system, referred to as baskets, trunking, or cable ladders, makes it suitable for various applications, especially for running large quantities of data cables overhead or under the floor.
Cable trays are components of support systems for power, transmission system by gear motor, Punching system is Hydraulic cylinder. A cable tray system supports and protects both power and signal cables and facilitates upgrading, expanding, reconfiguring, or relocating networks. Tray systems are alternatives to wireways and electrical conduit, which completely enclose cables.
| Items | CB-EM Model |
| Power | – Transmission: 22kw – Motor – Pump: 22kw |
| Weight of machine | 14 – 26 tons |
| Dimension | L=14m;W=2.2m; H=1.8m |
| Forming Speed | 1-5mpm |
| Roller stations | 22 – 26 |
| Transmission system | Electricmotor andGearbox |
| Cutting and Punching system | Hydraulic cylinder |
| Control system | PLC, HMI automatic programmable |
| Changing size | By screw |
| Material thickness | 1 – 2 mm |
| Material width max | 830mm |
| Material Yield Strength | G450 – G550 Mpa |
| Name | CB-EM Model |
| PLC | SIEMENS – Germany |
| Touch panel | SIEMENS – Germany |
| Encoders | KUBLER – Germany |
| Inverter | YASKAWA – Japan |
| Electric motor | TOSHIBA – Japan |
| Servo motor | |
| Hydraulic components | YUKEN – Japan |
| Cutting dies SKD11 | Japan |
| Rollers | Alloy steel |
| Gear box | Taiwan |
b. Metal Accessories
Roll forming machines produce accessories like rails, brackets, or profiled components for mechanical engineering, shipbuilding, and automotive industries.
3.3. Benefits in Modern Projects
Durability: Roll-formed products, made from galvanized steel, stainless steel, or aluminum, offer excellent corrosion resistance and strength.
Aesthetics: Tile-patterned, kliplock, or seamlock panels provide a modern look, aligning with contemporary architectural trends.
Cost Savings: Fast production, minimal waste, and easy installation reduce overall project costs.
4. Advantages and Disadvantages of Roll Forming Machines
4.1. Advantages
High Efficiency: Rapid production suited for large-scale operations.
Precision: Products meet tight tolerances and international standards.
Cost-Effective: Minimizes waste, labor, and construction time.
Durability: Machines operate reliably for years with minimal maintenance.
4.2. Disadvantages
High Initial Cost: Machines and custom rollers are expensive.
Technical Expertise: Requires skilled engineers for operation and maintenance.
Elastic Deformation: Some products may experience minor springback after forming.
5. Why Roll Forming Machines Are the Optimal Choice
Roll forming machines meet construction and industrial demands with their ability to produce high-quality products quickly and cost-effectively. They create a wide range of profiles, from purlins and roofing to decking and cable trays, suitable for diverse projects. With advanced automation and premium components, these machines enhance productivity while ensuring durability and aesthetics.
A leading expert in Vietnam designing, manufacturing and installing all kind of Roll forming machines, such as: Roofing machines, purlin machines, Ctruss machines, Cut to length and slitting machines, Roofing RollForming Machine, Corrugated Roll Forming Machine, Steptile rollForming Machine, Decking Roll Forming Machine, Purlin Machine, System Construction System, Kliplock, Seamlock, Cable Tray Machine, Standing Seam Machine … VIETSTEEL offers somes types of big product roll forming machines with extremely reasonable prices.
The reason why you should choose to buy the machine at VIETSTEEL:
Pioneered in roll forming machine with over 25 years of experience
Delivered +5000 machines to +500 customers in +50 countries over the world
Vietsteel machines produce products with almost absolute precision.
Our machine runs stably for 15 years with 1-year warranty
24/7 professional and fast customer support
The strong financial capacity guarantees on-time delivery on each contract
For the best quotation, please contact Vietsteel now +84 906 898 860
Email: vietsteel@vietsteel.com
Website: www.vietsteel.com
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