Guardrail roll forming machine

Guardrail Roll Forming Machine 

 

As a professional manufacturer of cold roll forming machinery, we proudly present our advanced Guardrail Roll Forming Machine** — a fully integrated, high-precision production line engineered specifically for the volume fabrication of highway safety barriers, including W-beam (two-wave) and thrie-beam (three-wave) guardrail profiles . This robust system is meticulously designed to transform raw steel coil into standardized, high-strength crash barrier components with exceptional efficiency, dimensional accuracy, and structural integrity, meeting the rigorous demands of global infrastructure and transportation projects .

 

Rack upright roll forming machine working flow 

Steel Coil → Decoiler → Leveling → Punching → Roll Forming → Cutting → Output Table

 

Guardrail roll forming machine manufacturers parameters
1	Decoiler	8 Ton single-arm decoiler
2	Machine body frame	500H Beams welding
3	Forming guide feed frame	Side arch type
4	Forming Machine Type	55 portal frame with chain drive
5	Diameter of shaft	Ø120 mm
6	Transmission System	TX230 distribution gearbox + 180 cross shaft universal coupling
7	Main Motor Power	Dual 22 kW motors with K107 reducer
8	Forming Speed	5-15 m/min
9	Roller station	15-18 rows
10	Material of rollers	High-quality CR12, quenched and precision machined
11	Hydraulic system power	22 KW with four-valve plunger pump
12	Cutting Method	Hydraulic triple-blade shearing
13	Punching Units	Three sets (one for center hole, two for side holes)
14	Cutting blade	Cr12, Quenched treatment 58℃-62℃
15	Forming Thickness	2.0-4.0 mm ( Length Tolerance: ±2 mm)
16	Control System	Delta PLC, Doble 22 kW Delta inverters, Delta touch screen
17	Machine Dimensions	1400mm*2400mm(L*W)

Our **Guardrail Roll Forming Machine** represents the convergence of heavy-duty engineering and intelligent automation. It is purpose-built to produce the critical safety barriers that protect motorists on expressways, freeways, bridges, and high-speed roadways worldwide . These guardrail profiles are specifically engineered to absorb and redirect the impact energy of vehicles, significantly enhancing road safety and reducing the severity of accidents .

 

 Complete and Automated Production Workflow

 

Our **Guardrail Roll Forming Machine** orchestrates a seamless, continuous manufacturing sequence from coil to finished, stacked product:

 

1. Precision Decoiling & Coil Loading:** The process begins with a heavy-duty hydraulic decoiler, optionally equipped with a coil car for large-quantity production without downtime during coil changeover . Coil weight capacity typically ranges from 5 to 10 tons, with inner diameters of 470-520mm and maximum outer diameters up to 1800mm .

 

2. Advanced Leveling System:** The steel strip passes through a precision leveler with 7-9 leveling rollers . The leveling rollers are manufactured from 40Cr steel, quenched to HRC48-52°, ensuring exceptional flatness and elimination of internal coil stresses . This critical stage prepares the material for subsequent high-precision punching and forming operations.

 

3. Integrated Hydraulic Punching:** A high-capacity hydraulic punching system (typically 63-315 tons) performs all necessary hole punching and notching operations . Our **Guardrail Roll Forming Machine** utilizes premium mold materials such as Cr12 or Cr12MoV alloy steel, quenched to HRC58-62°, ensuring extended tool life and consistent hole accuracy over millions of cycles . The punching unit is fully programmable via PLC, accommodating various hole patterns including 9-hole and 10-hole configurations with middle reinforcement hole punching mechanisms .

 

4. Servo-Controlled Feeding:** A servo-feeding mechanism ensures precise material advancement into the roll forming mill, with length accuracy typically maintained within ±3.0mm . The touch-screen interface allows operators to input multiple production batches and easily modify technical parameters .

 

5. Progressive Roll Forming Stations:** The core of the system features 16-25 stations of precision roll forming dies, depending on profile complexity . Rollers are crafted from high-grade GCr15 bearing steel, quenched to HRC58-62°, and hard-chrome plated for exceptional wear resistance . The main shaft (typically Φ65-110mm, 45# forged steel) is driven by a gearbox transmission system with universal shafts, delivering robust torque for forming guardrail steel up to 4.0-4.5mm thickness .

 

6. 2-in-1 Interchangeable Capability:** A distinctive advantage of our **Guardrail Roll Forming Machine** is the interchangeable cassette system, enabling one production line to seamlessly switch between two-wave and three-wave profiles by exchanging only the final forming stations and cutting tooling . This(interlocking) of modular tooling design significantly enhances production flexibility and reduces capital expenditure for manufacturers serving diverse project specifications .

 

7. Hydraulic Cutting System:** A high-pressure hydraulic cutting station (operating up to 60MPa) provides clean, square, burr-free cuts to exact programmed lengths (standard 4320mm, 6000mm, or custom specifications) . Blade material is Cr12 or equivalent, quenched to HRC58-62° for exceptional longevity .

 

8. Automatic Stacking System:** Finished guardrail beams are automatically conveyed to a heavy-duty stacking system, capable of organizing 20+ pieces per bundle for safe transport and storage . The PLC-controlled stacker dramatically reduces manual labor and increases overall production efficiency .

 Intelligent Control & Industry 4.0 Integration

 

Every **Guardrail Roll Forming Machine** is governed by an advanced PLC control system (Panasonic, Omron, Siemens, or Mitsubishi) with HMI touchscreen interface . Operators can monitor real-time production status, modify parameters, access diagnostic error reporting, and utilize failure detection functions that automatically halt operations upon discovering irregularities . The system supports manual/auto operation modes and includes comprehensive emergency stop safety features .

Engineering for Extreme Duty Cycles

 

Understanding that highway infrastructure projects demand uncompromised durability, our **Guardrail Roll Forming Machine** features:

- Heavy-duty cast iron HT200 or welded steel plate frames 

- Precision-ground main shafts and high-capacity bearings (7216, 32216) 

- Robust gearbox transmission systems with hardened gears 

- Forming speed of 8-20 meters per minute, with output capacity reaching 500-1,500 tons per month 

 

 Comprehensive Customization & Global Support

 

We recognize that highway safety standards vary worldwide. Therefore, our **Guardrail Roll Forming Machine** offers extensive customization of:

- **Material thickness**: Customizable from 2.0mm to 4.5mm, with heavy-duty versions available up to 6.0mm 

- **Forming speed**: Adjustable 8-20 m/min depending on profile and thickness 

- **Punching patterns**: Fully programmable for national standard requirements worldwide 

- **Electrical voltage and control system language**: English, Spanish, Chinese, and other options available 

 

Our commitment extends beyond machinery delivery. We provide comprehensive after-sales support, including **real-time video online guidance** from our senior engineers for immediate troubleshooting, operator training, and process optimization . On-site installation and commissioning services are also available upon request .

 

Investing in our **Guardrail Roll Forming Machine** production line equips your manufacturing operation with the capacity to produce certified, high-integrity highway safety barriers that meet CE, EAC, TUV, and ISO 9001 international standards . It is a strategic investment in quality, capacity, and access to the growing global infrastructure market.

            

 

   

 

Contat us to learn more

Whatsapp:0086 18526079110 

E-mail:Kevin@hx-machinery.com

 

Our photos with our customers

About us

 

HOPEX (Wuxi) Intelligent Technology Co., Ltd.: Pioneering Roll Forming Innovation Since 1996
Founded in 1996 with a dedicated R&D team for roll forming technology, HOPEX has evolved into a global force in intelligent manufacturing. Established in Wuxi in 2003, we launched our core product lines—semi-automatic purlin machines, cable tray machines, and guardrail machines—laying the foundation for our commitment to 100% customized solutions.In 2016, we doubled our team and expanded our offerings to include solar strut machines and heavy-duty leveling/slitting lines, while strengthening R&D for our flagship products. By 2022, HOPEX achieved 100% sales growth and revolutionized production through full automation, upgrading all equipment to smart manufacturing standards and growing our R&D team to 10+ experts.Today, we export cutting-edge machinery worldwide—serving Russia, Australia, India, the Middle East, Southeast Asia, and beyond—as we fully enter the global market in 2025. Our vision is clear: to be the global leader in roll forming technology, making precision engineering easier and hassle-free for industries everywhere.

FAQ

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Q: Are you a trading company or a factory?
A: We are a factory with a professional production team and service consciousness, just for exporting various types of cold roll forming machines.

Q: Can a machine produce only one style of panel profile?
A: Not complete. Suitable for a highway guardrail forming machine. It can produce more than 3 panels.

Q: How long does it take to manufacture the machine?
A: In general, the highway guardrail forming machine be completed in 20 to 45 business days. But if you need machines urgently, we can save you time.

Q: Is there quality control when producing the production line?
A: Yes, we have a team that is responsible for quality control, including the laying of raw materials, processing rolls and other parts, processing, assembly, testing, and packaging on the roll surface and shaft.

Q: What can you do if the machine breaks?
A: Our machine is warranted for 24 months. If the damaged part cannot be repaired, we can send a new part to replace the damaged part, but you will need to pay the courier fee yourself. If the warranty period is exceeded, we can resolve the issue through negotiation, and we provide technical support for the entire life cycle of the device.