Palisade Roll Forming Machines

November 16, 2023

Palisade roll forming is an efficient process for producing long lengths of metal palisade fencing profiles. This guide provides a comprehensive overview of palisade roll forming machine types, capabilities, working principles, suppliers, costs and other key details.

Overview of Palisade Roll Forming Machines

Palisade roll forming machines continuously form metal coil strip into various palisade fence post and pale profiles. The process involves sequentially bending and shaping the strip through a series of precision roll stations.

Benefits of palisade fencing produced by roll forming include:

High production speeds and output
Consistent quality along entire profile lengths
Tight tolerances compared to other processes
Excellent surface finishes free of defects
Cost-effective for long production runs
Minimal scrap and material waste

This guide covers the major types of palisade roll formers, configurations, features, working principles, and considerations for selecting equipment.

Types of Palisade Roll Forming Machines

There are two primary machine configurations used:

Horizontal Roll Forming Lines

Material fed from a coil straightening machine
Series of horizontal forming stands shape the strip
Typical 10-16 stations depending on profile
Produces long, straight fence lengths
High production capacity for long runs

Vertical Roll Forming Lines

Compact arrangement of 8-12 vertical forming heads
Coil fed directly from an integrated de-coiler
Mandrel holds coil for continuous production
Shorter profile lengths produced
Frequent profile changeovers
Smaller batches and lower volume production

Additional Options

Cut-off saws for cutting to length
Hole punching units to add slots or holes
Counting and bundling of finished posts
Powder coating equipment for coating lines

Working Principle of Palisade Roll Forming

Palisade fence production involves progressively bending and shaping coil strip stock as it flows through multiple stands to form the final profile:

Process Steps

Material feeding
Accumulator controls strip tension
Entry guides align strip
Sequential bending and shaping through stands
Calibration and sizing
Cutting posts to length
Output stacking

The number of stands, roller design, and temperature controls are tailored to the specific profile shape and material grade. Advanced 3D software simulates the bending sequence for optimal design.

Features and Capabilities of Roll Formed Palisade Fencing

Key benefits of palisade fencing produced via roll forming include:

High speeds – Up to 100 ft/min production rate
Superior consistency – Eliminates defects from manual processes
Accuracy – Roll formed posts hold 1 mm dimensional tolerance
Surface quality – Smoother surface than other processes
Finishes – Can apply liquid or powder coatings
Strength – Up to 20% stronger than simple bent posts
Lower costs – Reduced labor and material savings
Flexibility – Faster changeovers for alternate profiles
Durability – Consistent quality improves product life

These advantages make roll forming ideal for palisade fencing production.

Materials Used for Roll Formed Palisade Fencing

Common materials include:

Mild steel – Most widely used material grade
Galvanized steel – Added corrosion resistance
Stainless steel – Superior corrosion resistance
Aluminum – Lightweight, good corrosion resistance

Steel thickness generally ranges from 16 gauge to 13 gauge (1.5mm to 2.5mm). Tooling enables forming thinner or thicker materials if needed.

Standard vs. Custom Palisade Profiles

Roll formers produce both standard and custom palisade profiles:

Standard Profiles

Common post and pale sizes
Pre-engineered tooling
Lower cost
High volume production

Custom Profiles

Unique or specialized shapes
Engineered tooling
Higher initial tooling cost
Lower order quantities
Match custom fencing designs

Quick change tooling allows easy switching between standard and custom parts.

Design Considerations for Roll Formed Palisade Fencing

Roll forming places some design limitations:

Constant cross-section – Profile must maintain uniform shape
Bend orientation – Only transverse bends relative to material flow
Bend radii – Limitations on achievable inside radii
Wall thinning – Thickness reduction at tight radiuses
Features – Limits on small details and geometry

Consulting early in the design process ensures manufacturability.

Suppliers of Palisade Roll Forming Equipment

There are many palisade roll former manufacturers worldwide. Some major suppliers include:

Company	Location	Machine Types
Samco Machinery	Canada	Combined straighteners and roll lines
Shanghai Metal Corporation	China	High speed vertical roll forming
T&H Lemont	USA	Customized roll forming lines
Metform International	Turkey	Cut-to-length lines
Zani Roll Forming	Italy	Powder coating integrated lines
Bradbury Group	USA	Standard and custom palisade lines

Both standardized and custom engineered machines are available to meet production needs.

Palisade Roll Forming Equipment Costs

Main roll forming line cost components include:

Equipment – $50,000 to $500,000
Tooling per profile – $5,000 to $15,000 for common shapes
Installation – Approximately 15-25% of machine cost
Training – 2-3 weeks recommended
Maintenance – Around 5% of machine cost annually

Automated lines with higher throughputs provide faster payback on investment from labor and material savings.

Pros and Cons of Roll Formed Palisade Fencing

Advantages	Disadvantages
High production speeds	High initial capital investment
Superior consistency and quality	Fixed tooling costs per custom profile
Low scrap and material waste	Limitations on profile geometries
Minimized labor requirements	Regular maintenance needed
Adaptable automation features	Space required for equipment
Ability to integrate steps like coating	Skilled operators required

Palisade Roll Forming Applications

Main application areas include:

Perimeter fencing at commercial properties
Privacy fencing around residential yards
Security fencing at utilities and infrastructure
Architectural fencing for buildings
Temporary fencing for construction sites
Crowd control barriers and enclosures

Any application requiring linear feet of palisade fencing benefits from the consistency and efficiencies of roll formed production.

FAQ

Q: What thickness of metal is typically used?

A: For palisade fencing, thicknesses between 16 gauge (1.5mm) to 13 gauge (2.5mm) are typical. Custom tooling enables thinner or thicker material forming.

Q: What safety precautions are required?

A: Roll forming equipment contains hazards requiring proper safeguards, interlocks, grounding, and personal protective equipment.

Q: How long does it take to changeover between profiles?

A: With quick change tooling, skilled operators can change over profiles in 30-60 minutes. Without quick change features, several hours are typically needed.

Q: Can a powder coated finish be applied after roll forming?

A: Yes, powder coating after roll forming is commonly done and provides increased coating adhesion compared to coating a coil directly.

Q: Are roll formed palisade fences higher quality than other processes?

A: Roll forming eliminates defects resulting in superior consistency and quality along the entire profile length. Strength can be 10-20% higher than simpler bending methods.

Conclusion

Palisade roll forming provides an efficient automated process for producing fencing profiles with accuracy and repeatability. When properly engineered, roll formed palisade offers durability, material savings, and quality advantages over manual production methods.

With flexible changeover capabilities, palisade roll formers enable producers to meet varying project demands cost-effectively. Integrated finishing like powder coating further expands process benefits.

know more Roll forming