Strut Channel Roll Forming Machines

Strut channel roll forming machines are used to form metal coil into C-shaped strut channels, which have a wide variety of structural applications. This comprehensive guide provides an overview of strut channel roll former equipment, including types, components, specifications, and suppliers. It also covers key considerations for application, installation, operation and maintenance.

Overview of Strut Channel Roll Forming Equipment

Strut channel roll forming machines take flat metal coil stock and form it into U-shaped or C-shaped channels through a series of bending and forming rollers. The continuous channels produced are used for structural framing, supports, braces and studs in construction, racks, scaffolding, trailers, greenhouses, solar panel mounting and more.

Key benefits of using a strut channel roll former include:

  • Highly customizable and adjustable channel dimensions
  • Efficient, automated production of continuous channel lengths
  • Consistent quality and structural strength of formed channels
  • Versatile for small, medium or large production requirements
  • Cost-effective compared to other forming methods

Strut channel profiles are available in various sizes like 1-5/8”, 2”, 2-1/2″, 3″, 4″, 6″ as per application needs. Common materials used are low carbon steel, galvanized steel and stainless steel in gauges from 16 gauge to 11 gauge.

Types of Strut Channel Roll Forming Machines

Roll Former TypeDescription
ManualBasic machines for small scale production. Require manual feeding and cutting of channels
Semi-automaticHave powered forming rollers but require manual feeding of coil
Fully AutomaticHave powered decoilers, feed tables, forming sections and cut-offs for automated production in a line
CNC Roll FormerFeature computer numerical control for precision forming and quick changeovers between sizes
Custom Roll FormerTailor made to specifications with special forming rollers, controls, speeds etc.

Main Components of a Strut Channel Roll Former

ComponentFunction
DecoilerHolds and uncoils the flat sheet metal coil stock
Feed TableFeeds coil into forming section at set speed
Forming RollersProgressively bend and form the coil into channel shape
Punching UnitsOptional for creating holes as per profile design
Cutoff KnifeCuts formed channels to length as per product dimensions
Support Roll StandsProvide structural support for forming rollers
ControlsSet and monitor forming parameters like speed, feed, length etc.
ConveyorCatches and transports finished channels for storage or packing
strut channel roll forming machine
Strut Channel Roll Forming Machines 4

Strut Channel Roll Former Specifications

The key specifications to consider for strut channel roll forming machines include:

Production Speed and Efficiency

Speed RangeUp to 16 feet/min for manual and 100 feet/min for fully automatic roll formers
Coil Width CapacityUp to 72 inches
Coil Weight CapacityUp to 6000 lbs on decoiler
Formed Channel Length6 ft to 24 ft as per cutoff settings
Roller PowerUp to 20 HP

Forming Adjustability and Precision

Forming Stations10 to 16 progressive bending and forming stations
Roller Diameter3 to 5 inches based on channel size
Roller Adjustability+/- 0.5 mm for precision channel dimensions
Roller HardnessD65 hardened steel rollers
Forming AccuracyWithin +/- 1 mm of designed profile

Construction and Durability

FrameworkHeavy duty welded steel frames
Sheet Thickness CapacityUp to 3.2 mm (11 ga) steel sheets
Machine Weight9000 to 25000 lbs depending on model
Paint CoatingPrimer + powder coated paint
Safety FeaturesEmergency stops, guarding

Applications and Uses of Strut Channels

Strut channel profiles produced by roll forming have extensive structural uses across industries:

Construction and Infrastructure

  • Building and roof framing
  • Scaffolding, shoring systems
  • Tower and pole support structures
  • Conveyor support systems
  • Mezzanine flooring, platforms

Material Handling

  • Racking, shelving
  • Conveyor framing
  • Crane beams
  • Warehouse partition framing

Transport

  • Truck, trailer framing
  • Container frames
  • Railway freight structures

Energy

  • Solar panel mounting structures
  • Pipe support frames
  • Wind turbine interior frames

Other Applications

  • Greenhouses, polyhouses
  • Machinery frames, guarding
  • Stage, event structures
  • Signage and billboard frames
  • Gym, storage shelving

With customized hole punching and bracket insertion, the possible uses of roll formed strut channels are endless!

Choosing Strut Channel Roll Forming Equipment

Selecting the right strut channel roll former involves balancing production needs, part specifications, sizes, budgets and other factors.

Key Considerations for Equipment Selection

FactorDetails
Production VolumeMatch speed, automation level and output to hourly/daily needs
Channel SizesConfirm machine can produce required widths and depths
Material ThicknessCheck capacity for forming sheet gauge needed
AdjustabilityPrecision rollers for quick size changeovers preferred
Custom OptionsHole punching, notching, embossing needs
BudgetCompare initial cost vs production efficiency benefits
Lead TimeProduction urgent or can wait for delivery?
Space AvailableDimension constraints for new equipment
Power SupplySufficient electrical load capacity?

In summary, analyze current and future production needs, type of parts needed, available budget and factory constraints before investing in a strut channel roll former. Getting the key parameters right ensures the machine matches requirements and provides maximum ROI.

strut channel roll forming machine
Strut Channel Roll Forming Machines 5

Top Strut Channel Roll Forming Machine Manufacturers

There are many established global suppliers producing quality strut channel roll forming equipment. Some top manufacturers to consider include:

Top Strut Channel Roll Former Brands

BrandLocations Served
DimecoNorth America
PeddinghausUSA
FormtekUSA
Shanghai EtcoChina
Shandong U-NovaChina
Jouanel IndustrieFrance
GaspariniItaly
FACCINBrazil

These industry leaders supply machines worldwide and can provide guidance on selecting the right strut channel roll former based on part parameters and production needs. Most offer customization options as well. Reputed manufacturers also provide superior after-sales service support.

Strut Channel Roll Former Price Ranges

Strut channel roll forming machine prices depend on many specifications and can range widely:

Strut Channel Roll Former Cost Considerations

Machine TypeTypical Price Range
Manual Roll Former$8,000 to $15,000
Semi-Automatic Machine$15,000 to $35,000
Fully Automatic Roll Former$50,000 to $120,000
CNC Roll Former$80,000 to $250,000
Custom Roll Former$100,000+ (application specific)

The major factors affecting strut channel roll forming equipment cost are:

  • Automation level and speed
  • Production output rate
  • Overall size and roller capacity
  • Precision and adjustability features
  • Optional customizations like hole punching
  • Reputation and quality of manufacturer

Requesting quotes from shortlisted suppliers based on your production requirements is the best way to estimate actual machine costs.

How to Install a Strut Channel Roll Former

Proper installation is key to maximizing the performance of a strut channel roll forming system. Here are some best practices:

  • Prepare suitable foundation – level concrete or bolted structural base
  • Position machine with enough space around for safe operation
  • Lifting equipment may be needed for larger roll former placement
  • Align and bolt down machine securely on foundation
  • Connect electric power supply and confirm voltages
  • Install decoiler, feed table, other unattached components
  • Check and set machine parameters – speed, roller gaps etc.
  • Test run the roll former and make any adjustments
  • Organize the coil loading and finished product offloading flow

Taking the time to correctly install the strut channel roll forming line saves time and prevents issues in the long run. Always follow the manufacturer’s specific guidelines as well.

How to Operate a Strut Channel Roll Former

Learning to properly operate a strut channel roll forming machine maximizes output while minimizing errors and safety risks. Key operation tips:

  • Understand the entire forming process flow from decoiler to finished cut channels
  • Load coils of the correct width onto the decoiler using overhead crane
  • Set forming speed, feed rate and cut length as per product dimensions
  • Adjust roller gaps and alignment for precise channel forming
  • Monitor strip feed, folding and cutoff operation as it runs
  • Inspect quality of initial formed channels and adjust as needed
  • Organize efficient offloading of finished product from the line
  • Maintain cleanliness around equipment during operation
  • Follow all safe working practices provided by manufacturer

With experience, operators learn how to fine-tune an strut channel roll former to produce perfect quality profiles every time.

Strut Channel Roll Former Maintenance

Regular preventative maintenance ensures continuous smooth functioning of strut channel roll forming equipment. Key maintenance tasks:

  • Clean machine daily, clear dirt and metal debris
  • Lubricate bearings, gears, chains according to schedule
  • Check bolts, guards, connections are tight
  • Monitor rollers and other wear parts, replace as needed
  • Change hydraulic oils and filters periodically
  • Inspect electrical wiring for damage
  • Confirm emergency stop buttons functional
  • Test and calibrate sensors, controls
  • Check decoiler arm, brake and strip alignment
  • Repair or replace any damaged or worn parts

Plan maintenance shut downs during production breaks. Keep spare parts inventory. Record all maintenance for tracking.

Properly maintained strut channel roll formers operate reliably for decades.

How to Select a Strut Channel Roll Former Manufacturer

Picking the right supplier is crucial when investing in a strut channel roll forming machine. Key selection criteria:

Factors to Consider in a Roll Former Manufacturer

CriteriaWhat to Look For
Product QualityProven reputation, customer reviews, quality certifications
ReliabilityYears in business, strong client base
CustomizationFlexibility to build as per your specifications
Design ExpertiseSolutions to fit production requirements
Manufacturing CapabilityModern plant, machining and fabrication capacity
Service RecordResponsiveness to issues, professional support
PricingCompetitive pricing for features and production capacity

Take the time to thoroughly evaluate multiple manufacturers before deciding on the best roll former supplier for your production needs and budget.

Advantages and Limitations of Strut Channel Roll Formers

Key Benefits of Strut Channel Roll Forming Lines

  • Highly customizable and adjustable channel profiles
  • Automated operation for speed and efficiency
  • Consistent quality and structural integrity
  • Lower cost than alternate forming methods
  • Minimal material waste from coiled raw material
  • Flexible production volumes from low to high
  • Long lifespan exceeding 20 years

Potential Limitations to Consider

  • High initial machine purchase cost
  • Regular maintenance required
  • Skill needed to set up and operate
  • Size limits based on model specifications
  • Not ideal for low volume or prototype parts
  • Can require plant space and infrastructure

When utilized for suitable applications and production scale, strut channel roll formers provide excellent ROI through continuous, efficient forming of top-quality metal channels.

strut channel roll forming machine
Strut Channel Roll Forming Machines 6

FAQ

Strut Channel Roll Former FAQs

Q: What sizes of strut channel can be formed on these machines?

A: Common strut channel sizes from 1-5/8″ up to 8″ width can be produced, depending on machine capacity. Channel depth is adjustable as well.

Q: How long does it take to changeover to run a different size channel?

A: On automated CNC machines with precision rollers, size changeover takes 15-30 minutes. For manual machines, it may take 1-2 hours.

Q: What power supply do strut channel roll formers require?

A: Most industrial roll formers require a 380V to 480V, 3 phase power supply. Exact voltage and amps depend on the machine motor size.

Q: What is the typical production rate of strut channel roll formers?

A: Production rates range from 10 ft/min on manual machines to 100 ft/min on high speed automated lines, depending on model.

Q: How should finished strut channels be handled and stored?

A: Use non-marring slings and avoid dropping. Store on racks in clean, dry area to prevent damage.

Q: What safety measures are recommended for strut channel roll former operation?

A: Install machine guards, employee PPE, safety mats, and follow lockout/tagout procedures. Only trained personnel should operate.

Q: Should strut channels be painted or coated after roll forming?

A: Yes, applying paint or zinc galvanization is recommended to protect from corrosion over time.

Conclusion

Strut channel roll forming provides an ideal processing method to efficiently mass produce cold formed metal channels with high dimensional accuracy, finish quality and structural strength.

This detailed guide summarizes all the vital information needed – from types of machines and technical specifications to practical benefits, applications, operation, maintenance and selection criteria.

Whether you are looking to purchase your first strut channel roll former or add capacity to existing lines, this overview helps identify the optimum equipment configuration and manufacturer for your production scale, part parameters and business needs.

With these insights, manufacturers can utilize strut channel roll forming technology to gain significant competitive advantages in construction, infrastructure, material handling, transportation and diverse industrial markets.

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