High Productivity Professional Manufacture Metal Floor Deck Roll Forming Machine

 Work Flow of Metal Floor Deck Roll Forming Machine

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Introduction of floor decking machine

As a key piece of equipment in modern industrialized construction, floor deck roll forming machines are specialized production tools designed for efficient prefabrication and installation of floor slabs. They serve as important technical carriers for promoting the intensification and automation of construction processes.

Their core advantage lies in integrating high-strength alloy steel as the base material with precision machining and automated control technologies to achieve integrated production of floor decks from raw material processing to forming, significantly improving the efficiency and quality stability of floor slab construction.

I. Equipment Overview

Floor deck roll forming machines are specialized production equipment developed for construction floor slab scenarios, integrating multiple technologies such as material forming, automated control, and continuous production. Their core function is to process high-strength steel (typically Q355 and above grade low-alloy high-strength steel) into floor decks with specific cross-sectional shapes through continuous processing techniques.

These floor decks, serving as the load-bearing framework of floor slabs, can directly combine with concrete to form composite floor structures.
The overall design of the equipment centers on “efficient production”.

Through modular structural layout and intelligent control systems, it realizes full-process automation from steel loading, forming processing to finished product output.

A single production line can meet the daily output demand of thousands of square meters of floor decks, greatly shortening the construction period of traditional floor slab construction and reducing labor costs and material waste.

II. Core Features of the Equipment

1. Efficient continuous production capacity
The equipment adopts a multi-station continuous forming process, combined with a servo drive system, enabling uninterrupted processing of steel.

The forming speed can reach 10-15 meters per minute, which is 3-5 times higher than traditional prefabrication methods. It is particularly suitable for mass production needs of large-scale construction projects.
2. High-precision automated control
Equipped with a PLC programmable control system and a touch-screen operation interface, it can real-time adjust parameters such as forming pressure, speed, and temperature (for special models requiring thermal processing).

This ensures that the cross-sectional dimension error of each floor deck is controlled within ±0.5mm, meeting the precise docking requirements of building structures.

Meanwhile, the equipment is equipped with automatic detection devices that can real-time monitor steel thickness and forming quality, automatically stopping and alarming in case of abnormalities to reduce the rejection rate.
3. Strong adaptability to structures and materials
The mold system of the equipment adopts a modular design.

By replacing molds of different specifications (such as closed, open, and reduced-opening types), it can produce floor decks with various cross-sectional shapes. It is suitable for floor designs with different spans (e.g., 1.5-6 meters) and different load requirements (e.g., live loads of 5-20kN/m²), covering various construction types such as residential buildings, shopping malls, factories, and warehouses.
4. Reliable performance of finished products
Due to the adoption of cold-formed forming (some models combined with thermal processing) technology, the steel structure of the floor deck remains undamaged, retaining the high-strength characteristics of the raw material (yield strength ≥355MPa).

At the same time, through optimized cross-sectional design (such as a wave height of 100-200mm and a rib spacing of 150-300mm), the bending and shear resistance of the floor deck are enhanced. When combined with concrete, it can significantly improve the overall bearing capacity of the floor slab.
5. Low maintenance and high durability
Key components of the equipment (such as forming rollers, bearings, and drive motors) are made of high-strength alloy materials with a sealed design, enabling them to adapt to dusty and high-humidity environments at construction sites.

The mean time between failures (MTBF) exceeds 1000 hours. Daily maintenance only requires regular lubrication and mold cleaning, with maintenance costs 30% lower than traditional processing equipment.

III. Working Principle

The core principle of floor deck roll forming machines is “continuous cold roll forming” (the mainstream process), with some special models supplemented by local thermal processing:

1. Raw material pretreatment: After uncoiling, high-strength steel coils are leveled by a flattening device to remove material stress, ensuring the steel surface is flat and preventing warping after forming.
2. Continuous forming: The steel enters multiple sets of forming roller molds (each set corresponding to a cross-sectional deformation step). Through the extrusion and bending action of the rollers, the flat steel is gradually processed into the designed cross-sectional shape (such as U-shaped, V-shaped, closed-type, etc.). The entire process is precisely controlled by servo motors for roller speed and pressure to ensure forming consistency.
3. Fixed-length cutting: The formed continuous floor deck is automatically cut to a preset length (such as 6 meters, 9 meters) by a flying saw device, with cutting accuracy up to ±1mm.
4. Finished product output: The cut floor decks are conveyed to the stacking area via roller conveyors, completing the entire production process.

For thick plates (≥3mm) or high-strength steel, some equipment will add local heating devices (with temperature controlled at 200-300℃) before forming to reduce material deformation resistance and avoid cracks during forming.

The main parameters of the machine

IV. Operation and Application Specifications

1. Equipment commissioning: During installation, the equipment frame must be calibrated with a level to ensure the axis of the forming rollers is parallel to the ground, with an error ≤0.1mm/m. After replacing molds of corresponding specifications according to the floor deck model, trial production is required.

The cross-sectional dimensions and straightness of the first product are measured to fine-tune mold clearance and pressure until they meet the drawing requirements.
2. Production monitoring: During operation, it is necessary to observe in real-time whether there are scratches on the steel surface or wrinkles/distortions after forming. If abnormalities occur, the machine must be stopped to check for mold wear or uneven material tension.

Meanwhile, regularly clean oxide scales and oil stains on the mold surface to avoid affecting the surface quality of finished products.
3. Safety regulations: When the equipment is running, operators must stay away from the forming area and transmission parts, and it is strictly prohibited to touch the material by hand during steel conveying. The main power supply must be cut off during shutdown maintenance to prevent accidental startup.

With the above features and specifications, floor deck roll forming machines can stably produce high-quality floor deck products, providing reliable guarantees for the rapid construction and structural safety of modern buildings.

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