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Corrugated sheeting is the most versatile and modern coating. Today you can easily make corrugated sheeting for a facade or roof. Our article will tell you about the installation of profiled sheets and the technologies for producing the material.
Corrugated sheets can be used as:
Production stages profile sheets:
Metallic profile for roofing is made from steel using the cold method. Corrugated sheets come in both protective coating(polymer, enamel), and without it.
Each type of corrugated sheet has its own thickness. When using high-quality raw materials (for example, steel), the material is produced with a zinc coating of 26 microns.
If the thickness of the coating is reduced by half, then wear of the material increases. Therefore, it is very important to use both first-class raw materials and high quality equipment.
Requirements for designing the production of corrugated sheets:
Requirements for equipment placement:
The first step is to draw up a design sketch and make mathematical calculations. After this, the color and thickness of the future material are selected.
Stages of corrugated sheet production:
The production equipment includes in its structure the cold rolling method and the hot method of processing metal sheets. The most common method is cold processing. It does not require complete heating of the raw material at the beginning of work.
Thanks to special lines, the material is rolled and cut. perhaps in the form of profiling, that is, the material takes on a profile shape.
Profiled sheets come in various modifications. The machine equipment is responsible for this. After the production of corrugated sheets, the type is determined.
In accordance with the stages of mechanization, the machine for metal profiles varies:
Mobile equipment is used for the production of arched corrugated sheets. It is advisable to produce such sheets directly on construction site. Arched corrugated sheets are used in the construction of hangars, grain storage rooms or airfields.
Composition of the profile production line:
Equipment workflow stages:
It is worth noting that today the demand for corrugated sheets is growing every year. Therefore, many experts believe that investments in the production of rolled steel quickly pay off. Big choice construction companies provides wide range similar services.
Profiled metal sheets, without exaggeration, can be called the most versatile building material. Due to high demand, its production, and, as a consequence, the manufacture and sale of machines for the production of corrugated sheets, is a very profitable business.
Example of a machine made from corrugated sheets with partial automation
There are two main types of equipment for the production of corrugated sheets - these are manual machines used for the production of small volumes of corrugated sheets, and automatic and semi-automatic rolling mills that produce metal profiled sheets on an industrial scale.
A manual machine for the production of corrugated sheets can perform profiling of metal sheets up to 2.5 m long and is an alternative to powerful industrial rolling mills in cases where it is necessary to produce small batches of corrugated sheets.
For example, such a machine is practically indispensable in cases where it is necessary to mount roof covering at remote sites. In these cases, delivery of a metal profiled sheet to the site can often cost much more than the cost of its manufacture.
The manual machine for profiled sheets is easy to maintain and is driven by human muscle power. Moreover, due to the lever system, much effort is not required.
A manual machine for making corrugated sheets, the price of which is about $2,000, will pay for itself within two to three weeks, even if you use it to produce only 50-100 sheets of corrugated sheets per day. Provided that the productivity of such machines can reach 300 m² of profiled sheets per day, and even more. As example of payback For such a solution, we will provide a calculation of the cost of profiled sheets produced on such a machine.
average price rolled thin-sheet galvanized steel is about 1300-1500 US dollars per ton. From this amount of metal, using a manual profile sheet machine, it is possible to produce approximately 250 m² of profiled sheet in just one day. Knowing that the price of galvanized steel corrugated sheet is about 8 US dollars per square meter, you can calculate that the cost of 250 m² will be 2000 US dollars. Thus, in addition to the cost of the metal, if you buy this amount of finished corrugated sheeting, you will pay approximately $600 for its production.
Based on the data provided and taking into account how much a machine for corrugated sheeting costs, it is easy to calculate the payback period of this investment. As a rule, it is only a few weeks.
The advantages and benefits of manual machines for corrugated sheets include the following:
Many modifications of such equipment, such as, for example, the machine for making profiled sheets SPR-2.1, produced in Ukraine, can produce products not only from galvanized metal, but also from thin sheet steel with a polymer protective and decorative coating.
Many machine-building enterprises in Europe and the CIS countries make machines for the production of corrugated sheets, so buying a machine for corrugated sheets will not be difficult.
The machine for producing corrugated sheets works as follows:
You can buy a machine for making corrugated sheets in a variety of modifications. They differ in the volume of equipment. For example, some types of machines are equipped with replaceable dies for the production of various grades of corrugated sheets. The manual machine kit may also include a special roller knife for cutting metal sheets. Depending on the configuration and manufacturer, the price of a machine for profiled sheets may differ several times, so be careful and choose only those options that you really need.
It is often said that in factory conditions, profiled sheets are produced on rolling mills. But it is more correct to call them corrugated sheet production lines, since the rolling mill or machine for the production of profiled sheets is only part of them.
Such a line usually includes the following equipment:
You can buy a machine for making profiled sheets in a different configuration. Many manufacturers offer as additional options replacement modules of rolling mills. Replaceable modules allow you to quickly switch from producing one grade of profiled sheet to another, without wasting time on replacing rolling mill rollers.
Rolling mill - key element lines for the production of corrugated sheets
You may also be offered a forklift to install the sheet steel coils on the decoiler and transport the profiled sheet from the receiving device to the packaging area or warehouse finished products.
Installing an automation system on a production line allows you to create a high-performance machine for the production of corrugated sheets, the price of which will be slightly higher than semi-automatic options, but the productivity will increase significantly. Namely, the payback period and profitability of investments depend on productivity.
The productivity of the line for the production of corrugated sheets is determined by the rolling speed. Modern automated lines this characteristic can reach 40m/min. In fact, the line performance is somewhat less speed rolling. This is due to the fact that it takes some time to cut each sheet of finished product. Therefore, at a rolling speed of 40 m/min, the line productivity will be 32-34 m/min.
Automation panel on a machine for the production of profiled sheets
The table below shows the cost of production lines for the production of certain types of profiles.
| Name equipment |
Machine for production corrugated sheets, price in rub. VAT included |
| Automated complex for the production of corrugated sheets S25-1050 |
2 137 500 |
| Automated complex for the production of corrugated sheets S18-1100 |
1 710 000 |
| Automated complex for the production of corrugated sheets S10-1100 |
1 898 820 |
| Automated complex for the production of corrugated sheets S21-1000 |
2 057 220 |
| Automated complex for the production of corrugated sheets H114 |
3 727 500 |
| Automated complex for the production of corrugated sheets H75-750 |
3 135 000 |
| Automated complex for the production of corrugated sheets S44-950 |
3 195 800 |
| Automated complex for the production of corrugated sheets C7 |
1 463 000 |
| Automated complex for the production of corrugated sheets NS35-1000 |
2 350 300 |
| Automated complex for the production of corrugated sheets H60-845 |
2 369 300 |
Today, corrugated sheets are increasingly becoming popular among those who build modern buildings, erects fences, reliably strengthens partitions, and renews the appearance of old buildings. Also, with profiled steel, wide possibilities for construction become available. original roof residential building or office building. Due to the high quality of rolled steel, corrugated sheets can be used during the construction of structures such as warehouses and hangars.
Sheets of corrugated sheets can be used as a material for the following purposes:
walling different types structures;
roofing for buildings for various purposes;
production of formwork;
installation of partitions and fences.
Next you need to start assembling the table, along the surface of which the workpiece will be fed into the machine. The table should have a length that is several times the length of the finished product. There must be enough free space on the surface to accept ready product. The optimal table surface material is aluminum sheet.
We do not tighten all the bolts to full strength - now our homemade manual machine for making corrugated sheets can be used for the first running-in of the material. If the corrugated sheet produced by the machine has the required shape, we fix the parts in place and tighten all the bolts firmly. If the shape of the corrugated sheet does not meet our requirements, we adjust certain details and repeat the procedure.
It must be remembered that a machine for producing corrugated sheets is equipment that is dangerous to operate. This machine is equipped big amount cutting and piercing elements, which, if safety precautions are not followed, can cause injury to the operator. Therefore, it is allowed to work on the machine only in protective clothing and safety glasses.
From sheet metal they make a lot of products - drainage systems, shaped parts for sheathing or metal tiles, flashings for the base, corners for structures made of corrugated sheets, etc. All this can be done by a special bending machine- for sheet metal. We’ll talk about how to make a sheet bending machine with your own hands in this article.
All these devices are classified as sheet bending machines. The easiest way to make one with your own hands is the unit of the first group, a little more difficult - the third (rollers for sheet metal). So we’ll talk about them - from how to make a sheet bending machine with your own hands.
Shaped metal parts cost a lot of money. Even more than corrugated sheeting or metal tiles, so it makes sense to do the simplest machine for bending sheet metal, and with its help, make as many corners, ebbs and other similar parts as you need, and exclusively to your dimensions.
Bending machine - side view 
If you're worried about appearance, then in vain. On sale today there is sheet metal not only galvanized, but also painted. In all designs, the sheet is fixed tightly, so that when working it does not slide on the table, which means that the paint does not rub off or get scratched. It is also not damaged in places of bending. So the products will look quite decent. If you try, they will look even better than what they sell on the market.
For this sheet metal bending machine you will need Smooth surface(table), preferably metal, three corners with a shelf width of at least 45 mm, metal thickness of at least 3 mm. If you plan to bend long workpieces (more than a meter), it is advisable to take wider shelves and thicker metal. You can use brands, but this is for bending sheets of metal of great thickness and length.
You will also need metal ones door hinges(two pieces), two screws large diameter(10-20 mm), “lambs” on them, spring. Will still be needed welding machine- weld the hinges and make holes (or a drill with a metal drill).
For a homemade sheet bender, a 70 mm brand was used - three pieces of 2.5 m each, two bolts of 20 mm in diameter, a small piece of metal 5 mm thick (for cutting jibs), a spring. Here's the procedure:
This option is very powerful - you can bend long workpieces and sheets of considerable thickness. Such scales are not always in demand, but they can always be reduced. The video suggests a similar design of a smaller size, but with a different fastening of the clamping bar. By the way, no one bothers you to also install a spring on the screw - it will be easier to raise the bar. What’s interesting about this design is that you can make beading on it, something that such devices usually cannot do.
This model is welded from a thick-walled angle, the frame is made like an ordinary construction sawhorse, which is welded from the same angle. The handle is from a luggage trolley. The design of the screws is interesting - they are long, the handle is curved in the shape of the letter “L”. Convenient to unscrew/screw.
This homemade sheet metal bending machine has many features:
Now let's move on to the design of the clamping bar (pictured above). It is also made from a corner, but is laid on the machine with an upward bend. To ensure that the bar does not bend during operation, reinforcement is welded on - metal jumpers. Small metal platforms are welded at both ends of the strip, in which holes are drilled for bolts.
Another important point- the edge that faces the fold is cut off - to obtain more acute angle bending
The clamping bar is placed on the machine, and a spring is placed in the place where the nut is installed. The handle is installed in place. If it does not press the bar, it is raised above the surface due to the elastic force of the spring. In this position, the workpiece is tucked under it, positioned, and pressed.
Place a spring under the hole, then a bolt
Not a bad option for home use. It will not be possible to bend thick metal, but tin and galvanized steel can be bent without difficulty.
This type of sheet bending machine can have three types of drive:
Do-it-yourself rollers for sheet metal with manual or electric drive. Manual ones have 3 shafts, electric ones can have 3-4, but usually there are also three.
This machine needs a good solid foundation. This could be a separate bed or some kind of workbench or table. The basis of the structure is rolls. They are made the same size. The two lower ones are installed permanently, the upper one is movable, so that in the lower position it is located between the rollers. By changing the distance between the lower rollers and the upper one, the radius of curvature changes.
The machine is set in motion using a handle attached to one of the shafts. Then the torque is transmitted to other rollers through sprockets. They are selected so that the rotation speed is the same.
If the equipment is intended to produce pipes, the upper roller on one side is made removable, with a quick fixation system. Once the sheet is rolled into a pipe, there is no other way to pull it out.
Nowadays, everyone without exception Construction Materials They are constantly becoming more expensive, and corrugated sheeting, which is very widely used in construction, is no exception. The material is made from a sheet of metal, which is given a certain shape.
The main function of such a machine is cutting and rolling the workpiece, as a result of which it takes the form of a finished profiled sheet. Nowadays, you can even make a similar manual machine for making corrugated sheets with your own hands, knowing how to work with metal blanks and, preferably, having engineering skills.
The main difference between corrugated sheets and other similar metal sheets is that the corrugation has a trapezoidal shape. At first glance, it may seem that it is impossible to make a machine for the production of such material yourself, but this is not so.
Production lines of such material represent a whole complex of mechanisms, each of which performs its own functions.
Thus, even the simplest automatic line for the production of profiled sheets consists of:
It’s clear that you can do this yourself automatic line unreal. But it’s quite possible to make a manual machine that can bend workpieces at the required angle so that you get a sheet of corrugated sheets.
It should be borne in mind that a home manual machine will not be able to produce profiled sheets that are too thick - maximum thickness workpieces - about 5 mm.
Self-production rolling machine begins with assembling a frame to accommodate all equipment components. In this case, it is enough to install reliable supports, securing them to the base: preferably a concrete floor.
Next, a table is assembled, along the surface of which the workpiece will be fed into the machine. Its length should be several times greater than the length of the finished product, since the surface will require free space so that the finished product can be accepted. Optimal material The table surface is aluminum sheet.
There should be a special bar on the table that can secure the workpiece to the table using bolts. In the same way, a manual lever is secured, which feeds sheets of material along the table into the machine for corrugated sheets, setting the required feed angle.
The next component - rolling shafts - is very difficult to assemble with your own hands, so it is best to purchase them ready-made. Finding such devices on the market these days is not difficult.
Using brackets made from metal angles, the shafts are secured to the machine frame near the hand lever.
Having tightened all the bolts not to full strength, the almost completely hand-made machine for the production of corrugated sheets is ready for the first running-in of the material. If the manufactured corrugated sheet has the desired shape, the parts can be secured in place by firmly tightening all the bolts. Otherwise, adjustments are made to certain parts, and the procedure is repeated.
Even if you experienced master, you should work very carefully on a machine made by yourself, since any malfunction in any component of the mechanism can lead to injury during its use.
At the same time, we must not forget about safety precautions, working with extreme caution, especially if.
Thus, the self-assembled machine for corrugated sheeting is ready. The principle of its operation is very simple:
In order to avoid any work-related injuries, when working with such a machine, you must always adhere to safety regulations.
The machine on which corrugated sheeting is produced is a very dangerous piece of equipment, since it has many cutting and piercing components that can pose a danger to the operator. Therefore, working on the machine is only allowed in protective clothing and goggles.
Before each work with such a manual device, you should carefully check the functionality of all its components. On manual machines It is highly not recommended to bend very thick metal sheets.
Thus, having the skills to work with metal materials, even with your own hands you can make a mechanism for rolling corrugated sheets, which will provide enough high quality the resulting products. The main thing is not to make any mistakes when assembling it, and also remember the rules safe use.
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