Double Layer Corrugated Trapezoidal Roof Sheet Machine 2-in-1 Corrugated & Trapezoidal Double Layer Machine

Overview

2-in-1 Corrugated and Trapezoidal Double Layer Roof Sheet Roll Forming Machine with dual finished panel samples and touchscreen PLC console

The Zhongtuo 2-in-1 Double Layer Roof Sheet Roll Forming Machine is an integrated, space-saving manufacturing solution designed to produce two distinct roofing profiles on a single machine frame: classic sinusoidal corrugated sheets on the upper deck and heavy-duty trapezoidal (IBR / box rib) cladding sheets on the lower deck. By consolidating two full production lines onto one shared 350H structural steel bed, plant operators eliminate the capital expenditure, facility footprint, and labor overhead of running two separate machines.

Driven by a 7.5 kW main motor with an integrated chain transmission clutch, operators can switch production between layers in under 5 minutes without rethreading or disassembling tooling. With 18 forming stations for the upper corrugated profile and 20 stations for the lower trapezoidal profile, precision D2 die steel rollers, and heavy 70 mm solid forged steel shafts, the line runs 0.4–0.8 mm prepainted galvanized steel (PPGI) coil at a nominal speed of 20 m/min. The entire line is governed by an automated Delta PLC touchscreen system paired with an independent dual-blade hydraulic cutting station.

• 2-in-1 dual deck configuration: upper layer corrugated (WF-12-36) & lower layer trapezoidal (WF-636)
• Total 38 forming roller stations (18 upper / 20 lower) on heavy 350H welded steel base frame
• Precision D2 tool steel rollers and quenched 45# solid shafts (70 mm outer diameter)
• Nominal production speed 20 m/min; 1,200 mm feed width; 0.4–0.8 mm rolling thickness
• Quick 5-minute layer changeover via chain brake clutch; dual profile-matching hydraulic shear
• Certified to CE, BV, STV and ISO standards; backed by comprehensive lifetime technical support

Key Features

• Two Profiles, One Footprint. Compact vertical double-tier layout saves up to 50% factory floor area compared to two standalone machines, making it the most cost-efficient choice for commercial roll formers.
• Rapid 5-Minute Layer Switchover. A built-in mechanical chain clutch isolates the unneeded deck while engaging the active level, allowing swift order changeover without electrical or mechanical reconfiguration.
• D2 Mould Steel Rollers. Premium D2 die steel rollers undergo CNC precision turning and vacuum quenching, offering exceptional wear resistance and zero paint scratching on color-coated coils.
• 70 mm Heavy Forged Solid Shafts. High-grade No.45 forged steel shafts are tempered and fine-ground, ensuring minimal torsional deflection even when rolling full 0.8 mm high-tensile steel.
• Integrated Dual-Die Hydraulic Cut-Off. The heavy post-cut shear features dual upper/lower Cr12 cutting dies matching each panel contour, ensuring burr-free cuts without panel deformation.
• Touchscreen Delta PLC Automation. Full digital synchronization across feeding, rolling, counting, and shearing. Operators simply enter order length and batch quantity on the console.
• Rigid 350H Steel Base. The entire forming bed is constructed from 350H welded section steel to maintain absolute alignment across all 38 forming stands over years of heavy use.

Technical Specifications

Machine Structure

The double-deck layout integrates two independent rolling pathways onto a single heavy welded structural spine. Steel strip feeds from the uncoiler through precision dual-tier entry guide tables with rubberized calibration rolls. The upper tier directs material through 18 corrugated forming passes, while the lower tier guides strip through 20 trapezoidal rib passes. At the exit, an integrated dual-deck hydraulic shearing press cuts either profile cleanly to length with dedicated contour dies, eliminating post-cut burrs or crown distortion.

Dual hydraulic shear station with upper wave and lower trapezoidal cutting dies, positioned behind the ergonomic Delta PLC control console

Full plant perspective showing dual-tier entry guide table, 350H welded base, solid 70 mm shafts, and decoiler infeed station

Dual Profiles & Applications

This 2-in-1 manufacturing line delivers two of the most popular and commercially profitable building cladding panels on the global market:

• Sinusoidal Corrugated Sheets (Upper Deck). The classic smooth wave profile offers excellent rainwater runoff, lightweight structural efficiency, and high flexibility for curved roofs, agricultural sheds, and wall cladding.
• Trapezoidal Rib / IBR Sheets (Lower Deck). High-tensile box-rib profile with integrated stiffening ribs, engineered for wide-span commercial warehouses, industrial portal frames, and architectural roofing.

Real factory-formed blue color-coated roof panels: upper 5-rib trapezoidal sheet and lower classic sinusoidal corrugated sheet

Quality, Certifications & Factory Strength

Zhongtuo Roll Forming Machinery operates a modern, certified manufacturing facility with joint venture engineering standards. All double layer lines undergo rigorous static load testing, roll-gap calibration, and full-speed test rolling before packaging. Every shipment includes certified inspection reports and official documentation.

International certification credentials: CE Machinery Directive compliance certificates (UDEM, COTECNA) and ISO9001 quality system documentation

Zhongtuo manufacturing strength: international joint venture facility facade, modern showroom and honors gallery, and crane-equipped heavy assembly bay

Customization Options

Packaging & Delivery

FAQ

What are the principal advantages of a double layer roll forming machine?

A double layer machine manufactures two distinct roofing sheet profiles on a single machine body. It halves required workshop floor space, eliminates the purchase cost of a second standalone line, and enables rapid product switching with minimal labor.

Can both layers produce roofing sheets simultaneously?

No. To guarantee operator safety and maintain exact forming tolerances, one layer runs at a time. The transmission is equipped with a quick clutch mechanism, allowing an operator to switch drive power between decks in less than 5 minutes.

What coil widths and raw materials can be processed?

The machine standardly handles 1,200 mm coil feed widths across prepainted galvanized steel (PPGI), aluzinc/galvalume (PPGL), hot-dip galvanized (GI), and colored glaze steel within a 0.4–0.8 mm thickness range.

How is cutting handled for two different profiles?

The line incorporates a multi-tier hydraulic shear station fitted with two distinct contour cutting dies made of heat-treated Cr12 mould steel. The PLC automatically actuates the corresponding cutting blade according to the currently active production tier.

What warranty and technical assistance are provided?

The machine includes more than 5 years of structural warranty backed by lifelong technical support. Full machinery test certificates, video outgoing inspection records, and on-site overseas installation services are provided.

Can the profile drawings and forming speed be customized?

Yes. Both the upper and lower deck tooling can be tailored to any customer profile drawing, including IBR, corrugated, glazed tile, or step-tile profiles, with custom production speeds up to 30 or 60 m/min available on request.