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Steel Floor Decking Roll Forming Machines

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Steel Floor Decking Roll Forming Machines

Feb 01, 2024

Floor decks are corrugated structural sheets providing the base for concrete slabs in buildings. Roll forming offers a continuous, efficient process to mass produce steel floor decking. This guide covers the end-to-end system for setting up steel deck production lines.

Overview Of Steel Floor Decking Roll Forming Machine

Roll forming shapes steel coils into various floor decking profiles using consecutive roller dies. Key benefits include:
High throughput for cost efficiency
Flexible output with quick die changeovers
Consistent quality with precision tolerances
Small equipment footprint for space savings
On-demand just-in-time supply avoiding inventories
Fully automatic for reduced direct labor

Steel Floor Decking Roll Forming Machines 12

Main Components Of Steel Floor Decking Roll Forming Machine

Table 1: Key Components of a Steel Floor Deck Roll Line

Component	Description	Purpose
Decoiler	Unwinds raw steel coils	Feeds strip stock into system
Feed table	Supports strip before forming	Provides stability
Forming stations	House profile shaping rolls	Incremental bending
Flying shear	Cuts sheets off main strip	Chops sheets to length
Delivery table	Catches cut sheets	Collects production

Decoiler: Pays off coil stock into the roll former
Feed table: Pre-forming material guidance
Forming stations: Progressively bend strip
Flying shear: Cuts finished profiles from strip
Delivery table: Gathers formed sheets

Profile Options For Steel Floor Decks

Typical decking profiles made by steel roll forming include:

Table 2: Common Steel Floor Deck Profiles

Profile shape	Description	Characteristics
Trapezoidal	Angled fluted cross-section	Good concrete bond
Re-entrant	Inverted bottom ribs	Low structural depth
Cellular	Fully enclosed bottom face	Increased load capacity
Dovetail	Interlocking side hooks	Alignment of adjacent sheets
Sinusoidal	Wavy profile	Composite interaction with concrete

Trapezoidal: Angled flutes provide mechanical keying
Re-entrant: Bottom ribs enhance strength
Cellular: Closed structure for robustness
Dovetail: Edge geometry aligns overlapping sheets
Sinusoidal: Curvature aids concrete bonding

Choosing suitable shapes boosts structural performance.

Technical Specifications

Key parameters for customizing steel floor deck roll lines are:

Table 3: Typical Specifications of Roll Formed Steel Floor Decks

Parameter	Range	Unit
Line speed	10 – 35	m/min
Forming stations	12 – 24	Nos.
Material thickness	0.7 – 2	mm
Sheet width	750 – 1500	mm
Sheet length	500 – 8000	mm
Installed load	15 – 60	kW

Speed: Production rate capability
Stations: Number of profile shaping stands
Thickness: Raw material coil gauge
Sheet size: Formed part dimensions
Power needs: Electricity supply

The optimum specification combination depends on performance targets, space availability, and budget.

Strip Stock Feed Options

The common material inputs for steel floor decking are:

Table 4: Strip Stock Feeding Methods into Roll Lines

Method	Description	Suitability
Automatic coil carousel	Rotates multiple coils sequentially	Unmanned high-volume production
Coil joining	Butt-welds tail of exhausted coil to new head	Mid-volume, non-stop input
Manual loading	Operator replaces depleted coils	Low-volume batches, prototyping

Carousel: Allows automatic sequential coil changeovers
Joining: Provides continuous welding of coil ends
Manual: Operator replaces empty coils

Higher automation levels minimize downtimes needed for coil replenishment.

Post-Forming Secondary Operations

Typical post-roll forming processes are:

Table 5: Common Post-Forming Operations for Steel Floor Decks

Process	Method	Purpose
Cutting	Flying shear on exit end	Chops sheets from continuous strip
Hole punching	Pneumatic hole punch station	Service holes or alignment gaps
Embossing	Inkjet or laser marking	Sheet numbering, logos
Stack handling	Mechanical arms, bins	Organize sheets before transport

Cutting: Separates sheets from continuous strip
Punching: Punctures sheet for ducting access
Embossing: Identification and traceability
Stack handling: Systematic palletizing

Efficient post-processing avoids output bottlenecks after forming.

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Solar mounting strut channel roll forming machine
Strut Channel Roll Forming Machine

Global Manufacturers

Table 6: Leading International Steel Floor Deck Roll Former Manufacturers

Company	Headquarters	Contact
Gasparini	Italy	info@gasparini.it
Epic	USA	sales@epicrollforming.com
Sigma	Turkey	sales@sigmaref.com.tr
FZTechnik	Germany	info@fz-technik.de
Joung Jin	South Korea	sales@joungjin.kr

Gasparini: Robust European-built production lines
Epic: Custom USA-made roll forming equipment
Sigma: Reliable Turkish roll former OEMs
FZTechnik: High-precision German engineering
Joung Jin: Cost-effective Korean manufacturer

These companies offer turnkey deck roll forming equipment solutions.

Indicative Pricing

Table 7: Typical Price Ranges for Steel Deck Roll Lines

Production speed	Price range
10 – 20 m/min	$40,000 – $85,000
20 – 30 m/min	$85,000 – $170,000
30 – 40 m/min	$170,000 – $260,000

Influencing cost factors:
Desired output rate and automation level
Overall line length based on part sizes
Type and number of ancillary modules
Customization needs for profile and accessories
Brand value of equipment OEM
Taxes and shipment costs

Higher flexible lines enable rapid product changes but cost more upfront. Starting smaller and incrementally expanding production capacity keeps initial spends lower.

Installation And Commissioning

Key tasks in installing steel floor decking roll lines:

Table 8: Roll Line Installation Activities

Task	Description	Purpose
Site preparation	Floor flatness/leveling, access routes	Stable foundation
Positioning	Set proper machine clearances	Smooth material flow
Anchoring	Anchor to ground using bolts	Prevent vibrational drifts
Alignment	Orient and level forming sections	Decentered rolls distort material flow
Connection	Electrical, hydraulic, pneumatic systems	Actuate motors and actuators
Safety	Guarding, emergency switches	Protect operators
Trial runs	Validate performance before production	Reduce debug time losses

Careful installation enhances equipment lifetime and avoids defects from component misalignment. Thorough testing during commissioning decreases faults occurring mid-production.

Maintenance Activities

Proactive servicing of steel floor deck roll lines involves:

Table 9: Recommended Maintenance Schedule

Frequency	Task	Purpose
Daily	Fluid level checks, leak fixes	Prevent unplanned stoppages
Weekly	Sensor recalibration	Ensure correct strip tracking
Monthly	Lubricate moving sub-assemblies	Reduce friction and wear
Quarterly	Re-alignment if needed	Re-orient forming sections
Annually	Oil changes for gearboxes	Extend mechanical lifetime
As-needed	Worn component replacement	Restore normal function

Inspections: Early detection of issues
Recalibration: Maintain output accuracy
Lubrication: Smooth low-friction operation
Re-alignments: Restore directionality
Fluid changes: Keep oil contaminant-free
Part replacement: Fix faulty components

Scheduled preventive servicing minimizes unplanned line stoppages and quality defects.

Supplier Selection Guidelines

The key parameters for evaluating steel deck roll former manufacturers are:

Table 10: Comparison Criteria for Steel Deck Line OEMs

Factor	Description
Experience	Successfully built reference plants
Quality	Use branded components and robust fabrication
Customization	Offer needed specification range
Design support	Help optimize forming process
Responsiveness	Quick issue resolution
Delivery	On-time equipment availability
Cost	Competitive pricing agreeing to budget

Experience: Domain expertise benefits product design
Quality: Reliable equipment with longevity
Customization: Meet production targets
Design support: Ensure process optimization
Responsiveness: Support post-order and during production
Delivery: Prevent project delays
Cost: Reasonable pricing and payment terms

Evaluating OEMs on these aspects minimizes project execution risks.

Benefits Of Steel Floor Decking Roll Forming Machine

Table 11: Advantages and Limitations of Roll Forming Decks

Pros	Cons
High production speeds	Significant initial capital cost
Continuous processing method	Complex programming for new profiles
Consistent quality and precision	Limited raw material coil width constrains part sizes
Lower operating costs through automation	Downtime for die changeovers during profile switches
On-demand just-in-time supply	Require auxiliary equipment like decoilers, straighteners etc
Compact equipment footprint	Skilled workforce needed for operation and maintenance

Key Advantages:

Fast forming rates reduce manufacturing costs
Parameter controlled process ensures repeatable quality
Lower long term overheads through automation
Buffer inventory minimization with just-in-time production
Scalable capacity upgrading through modular extensions

Major Limitations:

Substantial initial investment requirement
Multiple debugging iterations needed for new profiles
Maximum sheet widths restricted by coil stock dimensions
Production halts for die changeover during profile type switches
Dependence on additional supporting equipment like decoilers, stackers etc.
Specialized skill requirement for programming and maintenance

Understanding pros and cons allows suitable application of steel floor deck roll forming.

End Use Sectors

Typical buildings using steel floor decks:

Table 12: Major Building Types Using Roll Formed Steel Floor Decks

Sector	Application	Deck function
Warehouses	Distribution hubs	Platforms for storage racks
High-rise	Office towers	Concrete floor slabs
Bridges	Flyovers	Structural base
Stadiums	Arenas	Multi-level stands
Transport	Airport, metro stations	Terminals, elevated corridors

Warehouses: Structurally sound racking platforms
High-rises: Reinforced heavy concrete floors
Bridges: Load bearing structures
Stadiums: Sloped spectator gallery slabs
Transport hubs: Vast floor plates

Roll formed steel decks expedite construction across infrastructure sectors.

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Frequently Asked Questions

Q: What type of steel is generally used for floor decks?

A: Hot-dip galvanized steel coils prevent deck corrosion and are commonly roll formed into floor decks.

Q: What thickness provides optimal strength?

A: Deck thicknesses between 0.9 – 1.2 mm offer adequate load capacity while avoiding excessive steel usage.

Q: How are deck sheets fixed to supporting structures?

A: Self-tapping concrete screws anchor overlapping deck sheets along the crest to purlins or beams before concrete topping.

Q: What special safety measures are needed when installing decks?

A: Permanent perimeter safety railing and temporary fall protection barriers safeguard workers placing decking sheets on elevated floors.

Q: Can custom patterns be incorporated on floor decks?

A: Yes, customized male-female roller dies can imprint specialized surface patterns inline during roll forming based on application needs.

Conclusion

Roll forming enables high volume manufacturing of various structural steel floor decking profiles. With comprehensive planning guided by this reference covering relevant equipment procurement aspects, manufacturers can gain strategic and economic benefits by adopting in-house deck production. The combination of efficiency, versatility and customizability makes roll forming ideal for developers needing large decking quantities.

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