Light Steel Keel Roll Forming Machines

Light steel keel roll forming machines are an essential equipment used for manufacturing light steel keels and frames for the construction industry. This guide provides a comprehensive overview of light steel keel roll forming machines covering their working, types, main components, specifications, applications, advantages, limitations and more.

Overview of Light Steel Keel Roll Forming Machines

Light steel keel roll forming machines are designed to cold-form different light steel sections and profiles used as load bearing members in light steel framed buildings and structures. They continuously form structural C,U,Z,Sigma and other shaped profiles from steel coil of thickness 0.7-2.0mm into required cross-sections by gradually bending the strip through a series of roller dies.

Compared to other steel structural members, light steel keels and studs formed by these machines offer advantages like light weight, high strength, easy and fast installation, design flexibility, environment friendly construction and more. They find wide applications in walls, floors, roofs and frameworks for residential, commercial and industrial buildings.

The most important components of a light steel roll forming machine include the decoiler unit, feeder, pre-cutter, roll forming stations, post-cutter and other auxiliary devices. Based on number of profiles produced, they are available in single and multi-profile designs from various manufacturers around the world.

Main Features of Light Steel Keel Roll Formers:

  • Cold roll high strength light steel coils into C,U,Z,Sigma and custom profiles
  • Form keels up to 2mm thickness and 200mm height
  • Output up to 120m/min with tolerance +/-0.5mm
  • PLC controller for automatic production
  • Roller dies made of wear-resistant materials like GCr15 steel
  • Computerized hydraulic decoiler for feeding coil strips
  • Servo motors for precision feeding and cutting
  • Easy size changeovers with quick change forming rollers
  • Safety devices like strip breakage detection sensors
  • Optional inline punching units and stackers

Working Principle of Light Steel Keel Rolling Machines

The working principle involves continuously forming structural light steel sections from steel coil by passing it through a series of roller dies that gradually bend the strip into the required profile shape.

Steps in Light Steel Profile Roll Forming Process:

  1. Decoiling – The decoiler feeds the light gauge steel coil strip into the roll former
  2. Feeding – Feed rollers grip the strip and pull it through the forming stations
  3. Pre-cutting – Cuts the strip to preset lengths for forming keel frames
  4. Roll forming – Strip passes through series of stands with roller dies to bend it
  5. Post-cutting – Cuts formed profiles to required lengths
  6. Counting and stacking – Formed keels are counted and stacked automatically

The roller dies are the key forming parts arranged in stands along the machine line. As the strip passes through each stand, the rollers make gradual bends until the final profile shape is achieved. The number of stands required depends on the complexity of the section.

Precise feed control, well aligned roller dies and optimal pass schedules are critical to achieve the tight tolerances and high quality demanded for structural light steel profiles.

Advanced machines also integrate inline processes like punching holes, embossing logos and automated stacking for complete production in a single line.

light steel keel roll forming machine
Light Steel Keel Roll Forming Machines 4

Types of Light Steel Keel Roll Forming Machines

Light steel keel roll forming machines are available in different configurations designed to produce various types and sizes of profiles as per application requirements:

Types of Light Steel Roll Forming Machines

Machine TypeDescription
Single ProfileFor rolling one profile shape like C, U or Sigma continuously
Double ProfileProduces two profiles simultaneously like C + U
Multi Profile3 or more profiles like C, U, Z, Sigma together
Fixed SizeLimited to rolling profiles of fixed heights and thicknesses
AdjustableForms adjustable range of profile sizes
ManualBasic models with manual size changing
AutomaticMotorized roll and screw adjustments for size changes
StandardFor regular light steel structures
Heavy DutyFor special large or thick profiles

Factors for Selecting Type of Roll Former:

  • Number and types of profiles required
  • Range of sizes and thicknesses
  • Production speed and output
  • Frequency of size changeovers
  • Level of automation needed
  • Available space and budget

Getting the right type of roll forming machine is important to match the production demands and get optimum efficiency.

Main Components of Light Steel Keel Roll Machines

Light steel keel roll forming machines consist of several important components and auxiliary devices for smooth and efficient operation:

Core Components of a Roll Forming Line:

  • Decoiler: Feeder unit that holds the steel coil and uncoils the strip
  • Feeding System: Rollers that grip and feed the strip through the stations
  • Pre-Cutting Unit: Shears the strip to pre-cut lengths before forming
  • Forming Stations: Roller dies mounted in stands to bend the strip
  • Post-Cutting Unit: Cuts profiles to final required lengths
  • Stacking System: Counts, collects and stacks the formed sections

Other Auxiliary Parts:

  • Strip Accumulator: Holds excess strips to avoid stoppages
  • Punching Unit: To punch web holes in the profiles
  • Control Panel: Housing the PLC controller and operation switches
  • Safety Devices: Limit switches, breakage sensors, safety guards etc.

Key Aspects:

  • The decoiler, feeding system and cutters ensure continuous smooth material flow
  • The profiler sections with roller dies are the heart to form the shapes
  • Automated stacking improves efficiency and minimizes effort
  • Advanced computerized controls make the processes automatic
  • Safety devices are critical for safe working during high speed production

Proper selection, setup and maintenance of each component is vital for optimal performance of the roll forming system.

Specifications of Light Steel Keel Roll Forming Machines

Light steel keel roll forming machines are available in a range of sizes and capacities to produce profiles for different applications. Below are the key technical specifications considered while selecting a roll former:

Typical Specifications of Light Steel Roll Forming Machines

ParameterTypical Range
Roller Diameter100-150 mm
Max Coil ID1000-1500 mm
Max Coil OD1500-2500 mm
Max Strip Width1200-1500 mm
Min Strip Thickness0.3-0.7 mm
Max Strip Thickness1.5-2.5 mm
Forming Speed10-120 m/min
Tolerance+/- 0.5 mm
Max Profile Height150-250 mm
Power Consumption15-50 kW
Voltage380-415V, 50Hz
  • Size and speed determine production capacity
  • Coil and strip sizes affect model selection
  • Power rating depends on tonnage and automation
  • Voltage, frequency should match power supply

Consult manufacturers to get machines matching the required production specifications. Custom built models are also available.

Applications and Uses of Light Steel Keel Roll Forming

The light steel profiles produced by keel roll forming find wide applications in residential and commercial building construction:

Typical Applications of Roll Formed Light Steel Keels/Studs

Wall FramesLoad bearing studs in walls for houses, offices etc
Floor JoistsC or U studs supporting floor slabs
Roof TrussesFor rafters, purlins in industrial roofs
Structural FramingColumns, beams framework in buildings
Prefab HousesWhole structural frames for fast construction
FurnitureProfiles for racks, storage, furniture etc
InfrastructureHighway signs, solar mounts, poles etc
  • Provide strength while being lightweight
  • Easy to handle and fast to install on site
  • Design flexibility for custom profiles
  • Consistent quality with close tolerances
  • Cost effective material utilization
  • Eco-friendly green construction

Light steel profiles enhance strength, speed up construction and offer sustainability.

How to Choose a Light Steel Roll Forming Machine Supplier

Choosing the right light steel roll forming machine manufacturer is key to get equipment that meets the production needs efficiently. Below are important factors for selecting a good supplier:

Key Considerations for Choosing a Roll Forming Machine Supplier

ExperienceMany years of experience in roll forming
Production CapabilitiesType and size of machines they offer
CustomizationAbility to customize profiles if needed
QualityGood tolerances, reliability and durability
CertificationsISO and other standards compliance
AutomationLevel of automation possible
ServicesInstallation, commissioning, support etc
ReputationReliable after-sales service record
PricingCompetitive pricing for value offered
Lead TimeOn time delivery as per schedule
  • Interview multiple manufacturers before deciding
  • Visit facilities to inspect first-hand if possible
  • Ask for client references to check quality satisfaction
  • Ensure supplier understands requirements clearly
  • Optimize automation features suiting budget

Choosing the right partner ensures long lasting efficient roll forming production.

light steel keel roll forming machine
Light Steel Keel Roll Forming Machines 5

Pros and Cons of Light Steel Keel Roll Forming

Advantages of Light Steel Roll Forming Machines:

  • High production speed and output
  • Consistent quality with close tolerances
  • Flexibility to produce different profiles
  • Lower fabrication costs compared to other methods
  • Minimal material wastage
  • Lower energy consumption than hot forming
  • Safer with reduced risks than hot processes
  • Automated production improves efficiency
  • Allows innovative steel building designs
  • Overall economical construction solution

Limitations of Light Steel Roll Forming:

  • Higher initial machine investment cost
  • Regular maintenance required for quality
  • Size changeovers can affect productivity
  • Limited to certain mild steel grades and thicknesses
  • Design complexity affects production rate
  • Risk of deformities if parameters not set correctly
  • Noise generation requiring safety precautions
  • Skilled technicians needed for operation

Proper machine selection and process control minimizes the limitations for cost effective production.

Installation and Operation of Light Steel Keel Roll Machines

Correct installation and operation procedures are vital for smooth functioning and optimum performance of light steel roll forming machines.

Installation Guidelines

  • Select flat, level concrete foundation with sufficient strength
  • Ensure adequate space around for material movement
  • Lifting tools required for unloading heavy components
  • Prepare grouted foundation bolts as per layout drawings
  • Assemble machine frame, stands, and roll forming sections
  • Install hydraulic power packs and electrical connections
  • Align roller dies and devices as per specification

Operation Guidelines

  • Strictly follow manufacturer’s operational instructions
  • Ensure all safety devices and guards are intact
  • Select correct roller dies for profile shape required
  • Set strip feeding, pre-cut and post-cut lengths
  • Adjust decoiler, rollers for smooth material flow
  • Gradually increase speed during test runs, verify formations
  • Ensure formed profiles adhere to tolerances
  • Conduct trial production runs before actual use
  • Perform regular maintenance for continuous production

Proper installation and operation training by the supplier is highly recommended for optimal performance.

Maintenance of Light Steel Keel Roll Forming Machines

Regular maintenance is crucial for trouble-free operation and maximum production uptime of the roll forming lines.

Recommended Maintenance Activities and Frequency

Bolt tighteningWeekly
Alignment checksMonthly
Hydraulic oil replacement6 Months
Wear checks on rollers, bearings, guides6 Months
Replacement of damaged/worn partsAs needed

Key Maintenance Tips:

  • Keep machines clean, inspect wear, damage daily
  • Lubricate bearings, sliding parts regularly
  • Perform periodic alignment, adjustments
  • Use genuine spare parts for replacements
  • Keep hydraulic systems clean, change oil periodically
  • Schedule annual overhaul after production season
  • Maintain maintenance logs for records
  • Train technicians on proper methods

Proper maintenance improves production, reduces breakdowns and extends machine service life.

How to Select Right Light Steel Roll Forming Machine

Choosing the optimal light steel roll forming machine is important for efficient profile production. Below are tips for selecting the right roll former:

  • Analyze part profiles, sizes, production volume required
  • Determine suitable machine type – single, multi, heavy-duty etc.
  • Consider automation features like auto size changeovers
  • Ensure machine capacity matches desired output levels
  • Check reliability and durability of components
  • Select reputable manufacturer with quality certifications
  • Compare suppliers on pricing, services, delivery terms
  • Evaluate after-sales support for periodic maintenance
  • Consider possibilities for future upgrades, expansions
  • Review safety aspects, ease of operation
  • Physical trial of machine operation is recommended

The correct forming machine ensures fast payback on investment via years of trouble-free production. Discuss specific needs with expert suppliers to choose the optimal roll former.

Costs Related to Light Steel Keel Roll Forming

The costs associated with procuring and operating light steel roll forming machines include:

Roll Forming Equipment Cost Components

Cost FactorDetails
Machine costCapital cost depending on type, size, features
Auxiliary equipmentDecoilers, stackers, conveyors etc
Design and toolingFor custom profile tooling if needed
Handling and installationUnloading, positioning, utilities connections
Site preparationLeveling, foundation, space provisions
Spare partsInitial essential spare parts kit
TrainingOperator training for production
Freight and taxesAdded costs based on location

Operational Costs

  • Raw material coils
  • Utility bills for electricity and oil
  • Consumables like lubricants
  • Salaries for operators
  • Maintenance and repairs
  • Tooling changeovers, reworks if any
  • Safety gear, accessories

Cost Optimization:

  • Choose machine size suiting production needs
  • Standard models are economical for regular profiles
  • Automation improves productivity and ROI
  • Schedule reasonable production cycles
  • Train personnel for efficient working
  • Maintain machines well to minimize breakdowns
  • Utilize production capacity optimally

Selecting the right forming machine and using it efficiently is key to derive maximum return on investment.

Light Steel Roll Forming Machine Manufacturers

Some leading manufacturers of light steel keel roll forming machines include:

Key Light Steel Roll Forming Machine Brands

Botou XianfaChina
Gasparini S.p.A.Italy
Bradbury GroupUK
Samco MachineryChina
An Sheng MachineryChina
Zeman BauelementeAustria
  • Established manufacturers with decades of experience
  • Offer standard and customized roll forming solutions
  • Advanced technology for high production efficiency
  • Key presence in Asia, Europe, North America markets
  • Compliant with CE, ISO, and other global standards
  • Provide installation support, operator training
  • Have extensive service networks

Review multiple suppliers before selecting light steel roll forming equipment for specific production needs and budget.

Light Steel Roll Forming Machine Pricing

The price range for light steel keel roll forming machines depends on:

Cost Influencing Factors

  • Type of machine – single profile, multi profile, heavy duty etc
  • Production speed and output capacity
  • Level of automation – manual, semi, fully automatic
  • Additional accessories like punching, stacking units
  • Roller size, tooling, and raw material requirements
  • Brand, manufacturing country, quality standards

Approximate Price Range

CapacityPrice Range
Up to 30 m/min$8,000 – $15,000
31-60 m/min$16,000 – $50,000
61-100 m/min$51,000 – $150,000
Above 100 m/min$150,000+
  • Entry level basic machines are economical
  • Medium capacity automated lines offer good value
  • Heavy duty high speed models are premium priced
  • Custom built roll formers are costlier
  • Consider long term production needs for ideal investment

Discuss specific profile requirements with vendors to get accurate price quotations for optimal equipment selection.

light steel keel roll forming machine
Light Steel Keel Roll Forming Machines 6


Q: What materials can be roll formed into light steel keels?

A: Low carbon steels like SS400, SAE1010, Q235 with thickness 0.5-2mm having good cold formability are commonly used.

Q: What profiles can be produced on light steel roll machines?

A: C, U, Z, Sigma, L shaped profiles are commonly rolled. Custom shapes are also possible.

Q: How to calculate production rate for a roll forming line?

A: Production rate = Forming speed x Number of profiles x 60. For example 40 m/min x 2 profiles x 60 = 4800 keels per hour.

Q: What maintenance is required for light steel roll forming machines?

A: Regular maintenance like cleaning, lubrication, inspection of components, alignment checks, spare parts replacement and annual overhauls are recommended. Proper maintenance minimizes breakdowns.

Q: How to change profile sizes on adjustable roll forming machines?

A: Adjustable machines have powered roll and screw settings to alter roller positions. Operators select required profile on the control panel for automated size changeover.

Q: What safety precautions are important for roll forming operation?

A: Safety guards, light curtains, emergency stops, strip detection sensors should be functional. Workers should wear protective gear and be trained on safe working procedures.

Q: How much area is needed to install a light steel roll forming machine?

A: Approximately 30-50 sq.ft area is needed for a standard roll former. More space is required for material movement for larger machines. Proper layout by the manufacturer is important.

Q: What factors determine if a profile can be roll formed?

A: Key factors are type of steel grade, thickness, width, total bend angle, bend radii, direction changes. Feasibility studies are done to design suitable roll tooling.

Q: What is the typical tolerance that can be achieved in roll forming?

A: Light steel profiles are normally formed within +/- 0.5mm tolerance. Precision roller dies, good alignment and feed control help achieve tight tolerances.

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