Full Automatic Highway Guardrail Roll Forming Machine

For Two-Wave and Three-Wave Profiles

Integrated Coil Feeding, Leveling, Servo Feeding, Roll Forming, Punching, Cutting and Finished Product Handling

Product Overview

The ZTRFM Full Automatic Highway Guardrail Roll Forming Machine is designed for the production of metal highway guardrail panels used in road infrastructure and traffic safety barrier systems.

The production line integrates coil decoiling, material leveling, servo feeding, roll forming and finished product handling. Punching and cutting units can be configured according to the required guardrail profile and production process.

With a heavy-duty forming structure, gearbox transmission and industrial electrical control system, the machine is designed for continuous manufacturing of guardrail profiles to approved drawings and technical specifications.

Depending on the selected tooling and machine configuration, the production line can be designed for two-wave W-beam and three-wave Thrie-beam guardrail profiles. Profile changes, tooling compatibility and production parameters should be confirmed before ordering.

Zhongtuo offers customized equipment solutions based on customer drawings, material specifications, required output and factory electrical conditions.

Key Features & Advantages

Technical Specifications

The following values are based on the supplied equipment information. Specifications not provided in the source description should be confirmed with the manufacturer before placing an order.

10-Ton Hydraulic Decoiler

The hydraulic decoiler supports coil loading and controlled material unwinding for heavy-duty guardrail production.

• Maximum rated coil capacity: 10 tons
• Hydraulic expansion mechanism
• Reference coil inner diameter: 508 / 610 mm
• Maximum coil outer diameter: 1500 mm
• Hydraulic power: 3 kW
• Decoiler motor power: 7.5 kW
• Variable-frequency speed regulation
• Pressure arm configuration to be confirmed

Leveling Device & Servo Feeding System

The leveling and feeding section prepares the metal strip for subsequent forming operations. Guide rollers and leveling rollers help control strip alignment and reduce unevenness before the material enters the forming machine.

• Front and rear guide roller arrangements
• Four-roller leveling groups as described
• Controlled material alignment and feeding
• Leveling motor power: 11 kW
• ZQ350 reducer with reference ratio
• Reference leveling speed: 10–25 m/min
• Variable-frequency speed control

Heavy-Duty Main Forming Machine

The main forming machine progressively shapes the prepared metal strip into the specified guardrail cross-section. Its heavy-duty frame and gearbox-driven transmission are designed for stable industrial production.

• Cast-iron archway forming structure
• Gearbox transmission system
• 18 sets of GY230 gearboxes, according to the supplied specification
• 2 × 22 kW main motors
• Universal joint coupling between drive and roller shafts
• Variable-frequency drive speed control
• Profile tooling customized to the approved drawings

6-Meter Production Receiving & Stacking Table

The receiving table collects and transfers finished guardrail panels after forming and cutting. The lifting and lateral movement functions help arrange finished products for subsequent handling.

• Welded square-tube frame
• Roller-based sliding arrangement
• 4-meter lifting and stacking arrangement, as specified
• Lifting motor power: 3 kW
• Lateral movement motor power: 1.5 kW
• Cylinder-operated swinging discharge mechanism
• Receiving table length: 6 meters

The receiving, lifting and stacking configuration should be confirmed against the final machine layout and finished panel dimensions.

Highway Guardrail Applications

Finished guardrail profiles are used in road safety barrier systems and other approved vehicle restraint applications.

Note: The machine manufactures profiles. Guardrail safety performance depends on the complete barrier system, engineering design, materials, installation and applicable certification or crash-test requirements.

Customized Highway Guardrail Production Solutions

Different markets and infrastructure projects may require different guardrail dimensions, material grades, punching arrangements and electrical configurations. Zhongtuo can evaluate the production requirements and propose a suitable machine configuration.

• Two-wave or three-wave profile tooling options
• Customized profile dimensions and panel lengths
• Coil width, thickness and material requirements
• Automatic decoiler and material handling options
• PLC and electrical component brand options
• Customized factory voltage and frequency
• Receiving, lifting and stacking arrangements
• Installation guidance and commissioning support as agreed

Frequently Asked Questions

Q1: Can one machine produce both two-wave and three-wave guardrails?

This depends on the tooling and machine configuration. Please provide both profile drawings so the manufacturer can confirm whether one line can accommodate both profiles and what changeover arrangements are required.

Q2: What is the maximum decoiler capacity?

The supplied specification lists a 10-ton hydraulic decoiler. Coil width, inner diameter, outer diameter and expansion range must be checked against the actual coil specification.

Q3: What is the production output?

The supplied reference is approximately 2–3 panels per minute for a finished length of 4320 mm. Actual output depends on the profile, material thickness, punching and cutting cycle, and production setup.

Q4: Can the electrical components be customized?

Delta and Siemens control component options are listed in the supplied information. The final PLC, electrical components, power supply and operating language should be confirmed in the quotation.

Q5: What information is needed for a quotation?

Please provide profile drawings, material grade and thickness, coil dimensions, finished panel length, required production output and factory power supply.