OEM Floor Deck Roll Forming Machine

 

Floor deck roll forming machines are used to produce corrugated floor decks from metal coils. OEM (Original Equipment Manufacturer) floor deck roll formers are built to order for the customer’s requirements. This guide provides a detailed overview of OEM floor deck roll forming machine capabilities, working principles, suppliers, costs, installation, operation and maintenance.

 

Oem Floor Deck Roll Forming Machine Overview

 

Floor decking sheets are an important structural component in concrete floor slab construction. Corrugated profiles provide strength and act as permanent concrete formwork. Roll formed metal floor decks are lightweight and fast to install compared to wood or other alternatives.

 

OEM roll forming lines are custom built to specification so buyers can get capabilities matching their exact floor deck product requirements. Key parameters that can be customized include:

 

• Table: OEM Floor Deck Roll Former Customization Options

 

Parameter	Customization Options
Material	Steel coils, stainless steel, aluminum
Thickness	0.7mm to 3mm
Width	Up to 1500mm
Profile	Trapezoidal, reentrant, dovetail, custom shapes
Features	Embossing, holes, drainage channels
Coating	Pre-painted, galvanized
Speed	Up to 35 m/min
Automation	Coil loading/unloading, stackers

 

 

Main Components Of Oem Floor Deck Roll Forming Machine

 

An OEM floor deck roll forming system contains the major components below:

 

• Uncoiler: Feeds metal coil stock into the roll former
• Feeding tables: Support and guides the strip
• Roll forming stations: Progressively bend metal strip into designed profile
• Hydraulic system: Provides power for bending and calibration
• Cut-off press: Cuts profiled sheet to length
• Stacker: Stacks finished floor deck sheets

 

Table: Main Components of Floor Deck Roll Forming Line

 

Component	Role
Uncoiler	Feeds metal coil into system
Feeding tables	Guide strip through machine
Roll forming stations	Bend strip into floor deck profile
Hydraulic system	Power for forming process
Cutting system	Trims sheets to length
Stacker	Stacks produced floor decks

 

Oem Floor Deck Roll Forming Machine Working Principle

 

Floor deck sheet production utilizes continuous cold roll forming technology. Metal coil stock is unrolled and passed through a series of roller stations. The rollers have machined contours that progressively bend the strip into the desired corrugated shape.

 

Step-By-Step Process

 

The oem floor deck roll forming machine functions via the steps below:

 

1. Uncoiling – Coil mounted on a powered unwind mandrel. Strip feeds into machine.
2. Feeding – Guide tables support and align the strip through the roll former
3. Forming – Roller stations bend the strip in stages into floor deck profile
4. Critical forming – Last stations finalize shape accuracy
5. Calibration – Hydraulic cylinders apply pressure to calibrate
6. Cutting – Shearing blade trims sheet to length
7. Stacking – Conveyors move done sheets for counting and stacking

 

Correct forming requires precision machined rollers, precise gap settings between stations, proper strip feed and tensioning pressure. The last stations provide critical calibration to achieve dimensional and shape accuracy per specifications.

 

OEM Floor Deck Profile Design Capabilities

 

OEM roll former lines offer extensive profile design flexibility for floor decking production. Common profiles include:

 

• Trapezoidal: Most popular shape with inclined flanges
• Re-entrant: Flanges bend inwards for composite concrete interaction
• Dovetail: Improves concrete bonding for higher performance

 

In addition, custom shapes can be produced for specialized applications:

 

• Embossing: For improved concrete grip
• Perforations: Allow conduits and services to pass through
• Stiffening folds/lips: Enhance strength
• Drainage channels: Prevent water pooling on roof decks

 

Experienced OEMs have extensive roll forming knowledge to produce proven profiles or develop new custom shapes matching project requirements.

 

Oem Floor Deck Materials, Sizes And Finishes

 

OEM equipment allows configuring floor deck parameters like:

 

• Materials: Steel, stainless steel, aluminum coils
• Thickness: 0.7mm to 3mm
• Width: Up to 1500mm
• Coatings: Pre-painted, hot dip galvanizing, organic coatings

 

Certain specialized materials like weathering steel or corrosion resistant alloys can also be formed.

 

 

OEM Floor Deck Roll Former Automation Features

 

Standard OEM floor deck roll forming lines have basic automated functions:

 

• Powered uncoiler: Reduces labor for coil loading
• Servo feed system: Ensures smooth strip feed
• Flying cut-off: Cuts sheets without stopping production
• Exit tables/conveyors: Transfer done sheets

 

Optional enhancements for higher automation include:

 

• Fully automated coil loading and unloading
• In-feed guides/straighteners for coil strips
• Automatic stackers to neatly pile finished sheets
• Length cutoff systems with counting functionality
• Programmable PLC controls for parameter adjustment
• Production data monitoring systems

 

Determining correct automation level depends on production volumes, labor costs and budgets. OEMs can provide guidance on ideal setup.

 

OEM Floor Deck Roll Former Suppliers

 

Many custom metal processing equipment manufacturers offer floor deck roll forming machines. When selecting an OEM supplier, key aspects to evaluate include:

 

• Table: OEM Floor Deck Roll Former Selection Criteria

 

Parameter	Importance
Profile precision	High – Ensures floor deck accuracy
Roller machining	High – Complex profiles need high precision
Line speed	Depends on output targets
Quick tooling change	Medium – For future profile adjustments
Automation features	Depends on labor costs
International certifications	Medium – Sign of quality management
Experience record	High – Proven ability to execute projects
Customization flexibility	High – For special requirements
Budgetary quote	High – Important to compare affordability

Reputable OEMs provide a design phase with engineering drawings, FEM analysis and iterations before manufacturing. They also offer complete floor deck production solutions including auxiliary equipment like slitters, stackers, benders and software.

 

Installing OEM Floor Deck Roll Forming Machines

 

Proper installation is key for operational efficiency and safety. OEMs provide complete guidance, but major aspects involve:

 

• Civil structure: Level concrete foundations to mount the equipment
• Assembly: Bearings, stations and subsystems assembled as per drawings
• Power: Connect electrical supply lines and hydraulics
• Trial runs: Check functioning of all working parts
• Safety: Install guarding, emergency stops and interlocks

 

Most modern machines have quick install designs. Precision roller stations and tooling utilize quick change systems or easy dismantling for maintenance. Allen bolts allow straightforward assembly and alignment.

 

Some best practices during installation:

 

• Have technicians from the OEM supervise for best results
• Keep assembly area clean to avoid dust ingress
• Follow torque specs for bearings and hydraulic fixtures
• Adjust alignment precisely using laser systems
• Apply lubrication during assembly to critical moving joints

 

Operating OEM Floor Deck Roll Forming Machines

 

After installation, equipment is optimized for best performance. Steps include:

 

• Feed material coil matching design specs
• Set parameters like sheet length, line speed
• Initialize strip through the stations slowly
• Test roll former producing a few sheets
• Check formed profile accuracy dimensions
• Adjust roller gaps, pressure as needed
• Run machine to rated speed and test full capability
• Inspect sample sheets dims, finish quality

 

For peak efficiency, comprehensive operator training from OEM technicians is highly recommended during commissioning. Proper machine operation principles linked to the custom equipment capabilities optimizes production.

 

Maintenance Of OEM Floor Deck Roll Forming Equipment

 

Preventative maintenance is vital for maximum roll former uptime. General upkeep tasks include:

 

Component	Maintenance Frequency	Tasks Performed
Rollers	Monthly	Inspect surface wear; Replace if needed
Bearings	3 months	Lubricate; check set screws; replace if worn
Hydraulics	6 months	Inspect lines, cylinders & pumps; replace seals if leaking
Drive systems	Yearly	Check motors, gearboxes, clutches & chains; Lubricate chains
Structural	Yearly	Re-torque loosened station bolts; Weld cracks; touch up paint
Controls	As needed	Calibrate sensors; Check wiring; replace fuses & relays

Table: Recommended Maintenance Schedule

 

Unexpected downtime is hugely expensive – lost production + repair costs. That is why scheduled maintenance budgets save money long term.

 

Modern flexible designs allow replacing only damaged components. Most stations have replaceable wear items. Qualified technicians can respond promptly for breakdown repairs or preventative work.

 

Choosing The Right OEM Floor Deck Roll Former

 

Evaluating options to pick the ideal OEM floor deck roll forming system involves:

 

Application Requirements

• Floor deck sizes, materials, annual output targets
• Site conditions – available space, power, labor
• Budget constraints

 

Equipment Capabilities

 

• Profile accuracy standards guaranteed
• Speed versus needed volumes
• Automation features to match labor availability
• Overall quality and OEM reliability

 

Ancillary Equipment

 

• Options like sheet stackers, sheet splitters, sheet straighteners
• Software for production monitoring

 

Cost Considerations

 

• Per metric ton equipment cost
• Operating costs – labor, maintenance, consumables
• Freight and taxes to import equipment
• Payment terms – upfront or installment options

 

Carefully balancing these aspects ensures procurement of the ideal OEM roll former matching floor deck requirements now and in the future.

 

Pros And Cons Of OEM Floor Deck Roll Forming Technology

 

Advantages

 

• High production volumes possible
• Lightweight finished sheets for construction
• Smooth surfaced uniform profiles
• Consistent quality monitored via custom software
• Flexibility – can adjust parameters easily
• Low maintenance and operation cost

 

Limitations

 

• High initial equipment purchase cost
• Complex customization needs experienced OEM
• Installation space required
• Auxiliary material handling equipment needed

 

Applications Of Roll Formed Metal Floor Decks

 

OEM roll formed floor decks serve varied applications:

 

• Concrete floor slab reinforcing layers in buildings
• Metal decking with concrete topping in offices
• Stair or balcony platforms in high rise projects
• False ceiling roofing support for lights, ducting
• Floor and roof drainage channels
• Mezzanine flooring structures in warehouses
• Container and trailer bed platforms

 

Floor deck sheets provide strength performing as structural formwork while being lightweight and faster to install than alternatives.

 

Most Effective Application Areas

 

Roll formed floor decks are extremely effective for:

 

• Commercial buildings needing flat soffits
• Industrial spaces with long clear spans sought
• High rise projects where weight reduction needed
• Metal composite concrete flooring systems

 

 

Total Cost Analysis For 500,000m2 Floor Deck Project

 

Roll formed floor decking is usually compared to traditional material alternatives. Let’s analyze sample total cost metrics for 500,000 m2 of 0.9mm thick galvanized steel floor decking:

 

Cost Component	Wood Formwork	Other Permanent Systems	Roll Formed Steel Deck
Material cost	High	High	$750,000
Construction labor	High labor intensity	Medium	Low – easy fixing
Formwork handling cost	High	Medium	None
Concrete usage saving	None	None	10% less concrete needed
Construction time saving	None	Minimal	40% faster completion
Environmental impact	High	Medium	Low
Recycling value	Low	Low	High scrap value for steel

Table: Sample Total Cost Comparison on Major Metrics

 

The above metrics make a strong case for choosing roll formed floor decks for large area projects due to substantial savings in time, cost and environmental impact.

 

FAQ

 

Q: What materials can use roll formed into floor decking?

 

A: Most common is galvanized steel coil feeds, but stainless steel, aluminum and other metal coils are also formed into corrugated decking sheets .

 

Q: Can floor deck roll forming lines make different profiles?

 

A: Modern OEM equipment allows tooling setups for different shapes like dovetail, trapezoidal and reentrant profiles within an hour using quick change roller stations.

 

Q: What thickness range is possible for floor decks?

 

A: Normal thickness range is 0.7mm to 2mm though some producers offer lighter or heavier gauges on request based on application structural needs.

 

Q: What parameters are monitored on a PLC control system?

 

A: PLC allows controlling and monitoring key parameters like line speed, sheet length counter, strip tension values, hydraulic pressure and allows troubleshooting faults.

 

Q: Does the machine require foundation or civil work?

 

A: A level concrete foundation as per OEM drawings is ideal. Otherwise floor needs to withstand machine loads and vibrations which affects accuracy.

 

Q: How much operator training is needed to run the machine?

 

A: A week of supervised hands-on operation by technicians during commissioning ensures operators understand the working principle and key aspects like strip feed, maintenance steps etc.

 

Q: What auxiliary equipment would be needed with the roll former?

 

A: Common additions like sheet stackers at the exit, sheet straighteners at entry, slitting machines to trim coil width are integrated for total floor deck production.

 

Q: What is the production capacity range possible?

 

A: Output depends on machine width, speed and operation duration. Typically 25,000 sqm to 100,000 sqm per month range is offered. Yearly capacity upto 500,000 sqm is possible.

 

Q: What is the warranty period provided?

 

A: OEM warranty normally covers one year. Extended warranty, AMC contracts after commissioning are advisable for continued support.

 

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