A device for making corrugated sheets with your own hands. Inexpensive and high-quality machines for corrugated sheeting. Production of corrugated sheets using manual equipment

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.

Manual machine for the production of corrugated sheets

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 an example of the payback of such a solution, we will give a calculation of the cost of profiled sheets produced on such a machine.

Example

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 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:

• small production area required to accommodate such equipment;
• easy reconfiguration of the number of waves or trapezoids of the profile;
• high productivity (two workers in one shift can produce up to 300 m² of corrugated sheets);
• does not require electricity consumption;
• reliability and ease of maintenance and operation;

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 manufacture machines for the production of profiled sheets. machine-building enterprises Europe and the CIS countries, so buying a machine for corrugated sheeting will not be difficult.

The machine for producing corrugated sheets works as follows:

• using manual or stationary electromechanical scissors, a workpiece of the required size is cut from sheet steel;
• the prepared workpiece is inserted into the machine sideways;
• using a special handle, guides are activated, bending the entire length of the sheet of metal to the required angle;
• Having thus formed one side of the profile trapezoid, the workpiece moves on the work table to form the next trapezoid and so on;
• after this, the sheet of metal is unfolded and the other side of all trapezoids of corrugated sheeting is formed in the same sequence;

You can buy a machine for making corrugated sheeting in a variety of modifications. They differ in the volume of equipment. For example, some types of machines are equipped with replaceable dies for manufacturing various brands corrugated sheets Included manual machine 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.

Industrial machines for the production of corrugated sheets

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:

• cantilever or two-support unwinder;
• circular knife for cutting a steel billet from a roll;
• multi-stand rolling mill;
• guillotine shears for cutting profiled sheets;
• receiving device with a retractable trolley;
• automated system line control.

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. In modern automated lines, this characteristic can reach 40 m/min. In fact, the line productivity is slightly less than the rolling speed. 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 production lines for the release of certain types of profiles.

Cost of various machines for the production of corrugated sheets

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

Nowadays, all building materials without exception 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, a similar manual machine for making corrugated sheets can be made even with your own hands, knowing how to work with metal blanks and, preferably, having engineering skills.

Automatic and manual machines for the production of profiled sheets

The main difference between profiled sheets and other similar ones metal sheets– 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:

• unwinder of rolls of metal sheets;
• rolling mill, where the material is actually formed;
• scissors that look like a guillotine;
• receiving device.

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.

Preparing supports and table for feeding workpieces

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 you can accept ready product. 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 sheeting, setting the required feed angle.

Installation of rolling shafts and first start-up

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 required form, the parts can be secured in place by tightening all the bolts firmly. Otherwise, adjustments are made to certain parts, and the procedure is repeated.

Features of working with a homemade manual machine

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, with my own hands assembled machine ready for corrugated sheeting. The principle of its operation is very simple:

• the workpiece sheet is placed on the table;
• using a special bar, the workpiece is fixed on the table;
• using a hand lever to install optimal angle feeding material into rolling shafts;
• At the exit, the finished sheet should move freely on the table.

To not get any industrial 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 this manual device you should carefully check the functionality of all its components. It is highly not recommended to bend very thick metal sheets on manual machines.

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.

Drawings for making a machine yourself

The equipment necessary for the production of corrugated sheets is divided into three main groups:

• Manual machine for the production of corrugated sheets;
• Automated and semi-automatic production lines;
• Mobile equipment.

In the second case, everything technological operations are performed with minimal participation of technological personnel or completely do not require human participation.

Automatic and semi-automatic lines are also available in mobile versions. Such machines are convenient to use in the construction of modular buildings or arched structures at remote construction sites, when the cost of delivering finished profiled sheets is very high.

Example of a manual machine for corrugated sheeting

Finally, a manual machine for the production of corrugated sheets is driven by human muscle power. Typically, such machines are used for the manufacture of small products or various additional elements. This machine is extremely easy to use and it is on this that we will discuss in detail further.

Manual machine for corrugated sheeting - what are the advantages of such a solution?

Currently, many machine-building enterprises produce such equipment, and anyone can buy a manual machine for corrugated sheeting. Its main advantage is that such a machine does not require external energy sources to operate, since human physical strength is sufficient to operate it.

In order to set up the production of profiled sheets on a manual machine in a matter of hours, you only need small room(although even this is not necessary, just a regular canopy is enough) and two workers familiar with the structure of the machine.

A manual machine for making corrugated sheets is indispensable for small construction company, which is often faced with the need to use a small number of products from profiled sheets. It is simply not practical to order them because the cost of delivery to the site is too high.

With the help of such a machine, it is possible to produce directly on the construction site various additional elements necessary, for example, when installing a roof. A manual machine for the production of corrugated sheets is so simple that it requires virtually no maintenance other than periodic lubrication.

The advantages of such a machine include its relatively low cost. A manual machine for corrugated sheets, the price of which is about 2000 US dollars, will pay for itself after producing 750-800 m² of profiled sheets, which is approximately its daily productivity. And this does not take into account the cost of delivery of this corrugated sheet to construction site in case of purchase. But you can also buy a machine that has already been used. It will cost several times less, and will last for many more years, since the forces acting on its main components are negligible and their wear is minimal.

Disadvantages of a manual machine for corrugated sheets

A manual machine for the production of corrugated sheets also has some disadvantages. First of all, this is the short length of the resulting corrugated sheet. It is usually 2.0-2.5 m. When large sizes working plate, uneven bending of the profile in the form of an arc is possible, arising due to different compression forces on different areas pressed lips.

In addition, it is worth noting that on a manual machine for corrugated sheets it is possible to produce only one brand of corrugated sheet. However, machines with a replaceable matrix are now being produced, which makes it possible to produce corrugated sheets with various shapes and the height of the trapezoid. In this case, the bending dies must be replaced manually.

And the most main drawback is that using a manual machine it is possible to produce profiled sheets only from galvanized steel. When deformed, the polymer coating of the metal may become covered with small cracks, which will subsequently lead to premature corrosion of the corrugated sheet.

This problem is solved using special modern manual machines for processing thin sheet steel with polymer coating. However, they are significantly more expensive standard options. In addition, galvanized profiled sheets can be painted. Wherein modern technologies application paint coatings, such as, for example, powder painting, create a decorative and protective layer that is in no way inferior, and maybe even superior in quality, to a polymer protective and decorative coating.

Design and principle of operation of a manual machine for making corrugated sheets

The manual machine for profiled sheets consists of three main units.

The main working body is a bending mechanism installed on a special frame. The bending mechanism itself, in turn, consists of hinges and gears that can be rotated using manual levers, as well as a replaceable bending matrix and a pressure beam.

In addition, each manual loom has a feed (back) table. A sheet steel blank is placed on it, which is moved to the necessary direction and “tucked” into the bending mechanism. A special roller knife is also installed here, usually included with the machine. It is made from high-strength steel, the quality of which allows cutting 25 km of steel with a thickness of 0.5 mm. If necessary, the knife can be sharpened or replaced.

Finally, one more element is absolutely necessary - a receiving table with special stops. They can be customized depending on the specified dimensions of the profiled sheet that needs to be produced. A plate is also installed here, with the help of which the required bending angle is set and the steel sheet is fixed.

The entire process of manufacturing profiled sheets on such a machine consists of the following steps:

Steel sheet placed on the table and fixed with a special clamp.

Using a matrix, a steel beam forms a trapezoid or wave profile (the bending force is adjusted depending on the thickness of the metal of the workpiece).

Mechanical control sensors in right moment stop metal bending.

The travel of the traverse and the bending angle of the metal are controlled using a special scale.

After bending, the steel roll is unwinded and the process is repeated again from steps 1 to 5.

Once the required length is reached, the steel is cut with a special guillotine knife.

The design of the cam mechanism of the manual drive makes it possible to operate with one hand. The presence of a roller knife and the installation of an unwinder make it possible to use rolled thin-sheet steel without preliminary cutting.

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.

Types of sheet benders

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.

Simple manual

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.

Powerful sheet bending machine from brands

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:

Two brands are folded, and grooves are cut into them at both ends for hinges. The edges of the recesses are beveled at 45°. The third tee is cut in the same way, only the depth of the recess is made a little larger - this will be the clamping bar, so it should move freely.

Weld the loops on both sides (weld on the front and back).

Two jibs on each side are welded to one of the brands (the one farthest from you, if you “open” them). They are needed so that you can install the clamping bar clamp bolt on them.

Weld the bolt nut to the jibs.

Install the clamping bar (third cut tee), weld in the upper part metal plates with a hole in the middle. The diameter of the hole is slightly larger than the diameter of the bolt. Center the holes so that they are on the same vertical line with the welded nut. Weld.

Cut the spring so that it raises the pressure bar by 5-7 mm. Pass the bolt into the “ear” of the clamping bar, put on the spring, tighten the nut. After installing the same spring on the other side, the clamping bar rises on its own when unscrewed.

Weld two pieces of reinforcement to the screw head to serve as handles for tightening.

Weld a handle to the movable (closest to you) brand. That's it, you can work.

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.

From a corner with a different type of clamping bar

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. Interesting design screws - they are long, the handle is curved in the shape of the letter “L”. Convenient to unscrew/screw.

In this homemade machine There are many features for sheet metal bending:

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 strips are welded at both ends metal platforms, 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 sheets can be easily bent.

Sheet metal rollers or roller bender

This type of sheet bending machine can have three types of drive:

• manual;
• hydraulic;
• electric.

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.

However, it is worth noting that when starting to work in this area of ​​business, you need to take into account the level of competition in each specific region. This is due to the fact that the production of corrugated sheets is available not only to large factories, if any, but also small companies those with the necessary funds, and even individual entrepreneurs.

As for the material itself, corrugated sheeting is actively used in construction or repair work, be it building a roof or cladding the walls of garages, utility rooms, warehouses, most often non-residential premises. The material is well suited for the rapid construction of fences and all kinds of fencing, canopies and other structures.

This line consists of three main components and includes:

• Unwinding center
• Table including roller blade
• Rolling mill

Organization of mini production of corrugated sheets.

Corrugated sheeting, depending on the purpose of its use, comes in different types.
The main ones are: roofing and wall, load-bearing corrugated sheeting or in the form of a sandwich panel. The average width of corrugated sheet rolls varies between 980-1850 mm, the length may vary depending on the purpose of use.

If there are large factories in your area producing this building material, be prepared to spend a certain and often considerable amount of money to attract your own customers in a highly competitive environment.

In addition, in the presence of serious competition, at first you should not hope for a full profit, since often beginning entrepreneurs have to lower the price of their own products in order to conquer a certain niche in the building materials market.

Things will be much easier if long distance There will not be a single plant producing corrugated sheets from your production.
Another positive point- developed metallurgical production, which will allow purchasing necessary materials By affordable price, which does not include a surcharge for long-distance transportation.

When drawing up a business plan, also take into account the quality and types of products produced by competing companies, promotions and special offers they organize.

In addition, it is worth paying attention to the characteristics of the region in which you are going to sell corrugated sheets. How much demand it will have can be predicted by taking into account, for example, the number of private houses in cities and beyond, buildings under construction, etc.

Business practice.

Statistics show that one of the most popular sizes of corrugated sheets are 1.5 m, 1.8 or 2 meters. Popular colors remain galvanized, wine red, chocolate, and moss green. As for thickness, most often it is about 0.5 mm.

As some private entrepreneurs note, in order for the business of manufacturing and selling corrugated sheets to generate significant income, it is necessary to sell at least 100 per day square meters, that if available regular customers not so much.

It should be taken into account that the sale of building materials is largely a seasonal activity. Most often, orders for the purchase of corrugated sheets are received from April to November, since in cold times construction and renovation work are suspended.

Will good help, if you can find a corrugated sheet production line at an affordable price and fairly cheap materials. This will allow you to save money and spend it, for example, on wages workers or electricity payments.

Experience in marketing corrugated sheet products.

A few more tips. IN winter time, as already said, construction material for sale, to put it mildly, it doesn’t matter. To improve this matter a little, you can offer customers more favorable conditions. For example, good discounts on goods and various promotions and offers to purchase corrugated sheets in installments or, for example, take out on credit.

At the same time, it is advisable to limit the validity of discounts to a time frame, in particular, before the arrival of warming and the beginning of the main sales season. As some entrepreneurs note, the method is quite effective, and you can get a good profit even during a period of reduced product sales.

Also, regardless of the time of year, do not forget about advertising your products. High-quality and well-constructed advertising will allow you to significantly increase the number of your regular customers.

After the business begins to generate good profits, you can think about investing money in optional equipment, which, in turn, will help to establish production and increase the number of products produced.
Business development prospects.

A promising direction for the development of the corrugated sheet production business will be the production garages pencil cases, warehouses and of course fences. Additionally, for this area you will have to purchase welding equipment and hire installers.

Production of corrugated sheets manual equipment.

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