Composite floor deck roll forming machines are specialized lines designed to cold-form metal coils into profiled steel floor decks for concrete slabs in buildings. This automated process efficiently produces finished floor decks.
This comprehensive guide provides everything you need to know about composite floor deck roll forming equipment, including:
Introduction to Composite Floor Deck Roll Forming
Roll forming shapes flat strip steel through a series of progressive dies into trapezoidal, re-entrant or other profiles for composite floor decks.
Benefits:
- Highly efficient continuous forming
- Quality and uniformity of decks
- Minimal material waste
- Automated mass production
- Flexibility to change profiles
Main Components:
- Coil payoff reel
- Feed rollers
- Forming stations
- Punching unit
- Shearing cutoff
- Control system
Latest composite floor deck roll formers deliver robust performance, precision and reliability ideal for deck production.
Types of Composite Floor Deck Roll Forming Machine
Composite floor deck roll forming machines come in several configurations:
| Types | Descriptions |
|---|---|
| Mechanical | Basic machines with mechanical drives |
| Servo-motor | Advanced programmable servo motor drives |
| All-electric | Energy efficient AC motors |
| Hydraulic | Powered by hydraulic power packs |
| Automatic | Fully automated infeed and cutoff |
| Portable | Compact mobile roll formers |
Modern servo-controlled roll formers with automated features provide the best accuracy and productivity.
Floor Deck Profiles Produced
Common profiles that can be roll formed include:
- Formlok – Re-entrant wide ribbed deck
- Multideck – Trapezoidal profile with intermediate ribs
- Regallok – Wider trapezoidal deck with re-entrant bottom
- Insulated Comdek – Foam-filled deck
- Curved decks – For special architectural designs
- Embossing – Aesthetic patterns
With quick die changeover, lines can be rapidly switched between different deck profiles.
Floor Deck Materials Used
Common materials roll formed into composite floor decks:
- Galvanized steel
- Zinc-coated steel
- Pre-painted steel
- Stainless steel
- Fibergrate – FRP deck
- Aluminum
Steel offers the optimal combination of strength, weight, span capability and cost.
Composite Floor Deck Roll Forming Process
The production sequence involves:
- Loading a steel coil into the feed system
- Feeding the strip through progressive roll forming stations
- Gradually cold-forming the target deck profile
- Punching any required holes for utilities or installation
- Shearing the deck sheets to specified length
- Conveying finished deck sections for stacking
Automated servo-motor controls precisely coordinate material movement through the in-feed, forming, punching, shearing and exit conveyor for rapid production.
Composite Floor Deck Roll Former Specifications
Typical specifications can be customized:
| Parameters | Range |
|---|---|
| Forming Speed | 10 – 30 m/min |
| Strip Width | 600 – 1200 mm |
| Thickness | 0.7 – 2 mm |
| Deck Height | 30 – 200 mm |
| Rib Spacing | 50 – 250 mm |
| Sheet Length | 2 – 15 m |
| Power | 15 – 50 kW |
| Automation | Manual to Fully Automatic |
Choosing appropriate strip parameters, deck dimensions and speed capacity is vital.
Standards for Composite Floor Decks
Major standards include:
- ASCE 3-91 – Cold formed steel design standard
- ASTM A653 – Steel sheet Zinc-coated by hot dip process
- CAN S16 – Strength design / limit states design of steel structures
- ASCE 7 – Minimum design loads for buildings and structures
- SFA 9500 – Roll formed steel floor deck design manual
- FM Global – Factory Mutual – fire safety standards
Compliance is critical for performance, quality and fire safety.
Composite Floor Deck Roll Forming Machine Manufacturers
Leading global manufacturers of floor deck roll forming lines include:
| Company | Location | Description | Pricing |
|---|---|---|---|
| Metform | USA | Custom high capacity lines | $$ to $$$ |
| Behemoth | Canada | Robust heavy duty lines | $$ to $$$ |
| Zhongrui | China | Affordable standard lines | $ to $$ |
| Zeman | Czech | Advanced European lines | $$$ |
| Its | Korea | Value engineered lines | $ to $$ |
Pricing Considerations:
- Production speed and automation
- Line width capacity
- Quick changeover features
- Brand, quality and support services
- Customization of specifications
Partner with qualified manufacturers providing properly engineered equipment matched to your production needs.
Buying Considerations for Floor Deck Lines
Important factors when investing in composite floor deck roll forming equipment:
- Required deck specifications and profiles
- Production volume and speed goals
- Width capacity for coil stock
- Automation capabilities preferred
- Quick changeover functionality between profiles
- Precision, accuracy and reliability needs
- Available production space and layout
- Power supply requirements
- Operator skill level
- Ongoing service and support
Clarifying key requirements will help identify appropriate roll former specifications and capabilities.
Installing and Operating Floor Deck Roll Forming Machines
Proper installation and operation procedures include:
- Stable, level and smooth foundation
- Adequate space around the equipment
- Securing stations and verifying alignments
- Electrical, pneumatic and hydraulic connections
- Integrating safety features and protocols
- Programmed setup and trials for each profile
- Preventive maintenance and lubrication
- Adhering to all safety procedures
Thorough installation, commissioning and maintenance is key for maximizing production uptime and achieving a long service lifetime.
Benefits of Composite Floor Deck Roll Forming Machine
Key advantages over other forming methods:
- Continuous high speed production from coil
- Consistent and precision deck dimensions
- Minimal material waste
- Lower operational costs
- Flexible, quick changeovers between profiles
- Safer enclosed process than open sheet fabrication
- Automated process ideal for large volume production
- Deck integration possible with other prefab techniques
Roll forming provides an efficient and economical deck manufacturing method.
Limitations of Composite Floor Deck Roll Forming
Some limitations include:
- High initial capital expenditure
- Substantial production volumes required for ROI
- Dedicated tooling for each profile
- Size constraints – width, bend radii etc.
- Material thickness and strength capabilities
- Secondary operations like punching may be needed
Other processes like press braking or stamping may suit lower volume production.
Cost Analysis for Roll Formed Floor Decks
- Equipment – $100,000 to $750,000
- Tooling per profile – $5,000 to $15,000
- Material coil – Varies based on steel specs
- Operating costs – Labor, maintenance, utilities
- Amortized equipment cost – Based on yearly production rate
- Secondary processing – Punching, stiffening etc.
- Logistics – Inbound coils, outbound deck delivery
High production levels provide lowest cost per square foot and rapid payback on equipment.
Future Outlook for Composite Floor Deck Roll Forming
The future outlook for composite floor deck roll forming is positive:
- Ongoing construction industry growth worldwide
- Transition from manual fabrication to automated lines
- Declining equipment costs over time
- Increasing line speed, precision, efficiency and flexibility
- Quick-change tooling enabling faster changeovers
- Tighter integration with upstream coil processing and downstream fabrication
- Overall market maturation and consolidation among manufacturers
With technology improvements, roll formed composite floor decks will continue gaining market share.
FAQ
Q: What materials can be roll formed into floor decks?
A: Most commonly galvanized steel and zinc-coated steel coils. Other options include stainless steel, painted steel and aluminum.
Q: What thickness coils are typically formed into decks?
A: Standard thicknesses range from 0.7mm to 2mm. Maximum depends on equipment capacity.
Q: How long does it take to form each deck sheet?
A: On high speed lines producing 6m+ lengths, decks can be formed in under 1 minute.
Q: How are roll formed floor decks cut to length?
A: A shearing press built into the line cuts decks at the production speed.
Q: What expertise is required to operate a deck roll former?
A: Machine operators require training. Skilled technicians needed for programming, maintenance and troubleshooting.
Q: What safety equipment is mandatory?
A: Guards, e-stops, interlocks, automatic shutdowns, and strict operating procedures.
Q: How much does a composite floor deck roll forming line cost?
A: Equipment costs range from $100k to $750k+, depending on the production speed, width, automation level, and features.
Q: How much does tooling cost for each deck profile?
A: Roll forming tooling typically costs $5k to $15k per profile set, based on size and complexity.
Q: How long does it take to changeover between profiles?
A: With quick change tooling, profile changeover takes 15-45 minutes typically.
Q: Can custom deck profiles be produced?
A: Yes, custom tooling allows production of specialized proprietary deck designs.
