Technology for manufacturing corrugated sheets. Production of corrugated sheets: serious equipment and manual machines Suppliers of raw materials for corrugated sheets

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The constant increase in demand for corrugated sheets is the root cause of the increase in its production. Using this material, you can not only cover and repair the roof, but also use it as an element of wall structures. In addition, it can be quickly erected industrial building, hangars, shopping pavilions, as well as temporary or permanent fencing, which requires corrugated sheeting to meet quality standards.

How is corrugated sheeting made?

For getting quality material appropriate equipment for corrugated sheeting is required, so organizing the production of this roofing covering requires a large initial investment, but its payback time is minimal.

A production line is only possible if the workshops:

• There is gantry crane, or any similar equipment;
• complied with temperature regime(not lower than +4 degrees);
• for storing steel coils and others finished products spacious warehouses are equipped.

Depending on the purpose of use, corrugated sheeting may have a special coating, or it may be produced without it. The starting material can be metal for the manufacture of corrugated sheets, which is coated with polymers for external work, and without coating is successfully used in the construction of concrete formwork.

The use of first-grade steel is common - in this case, a zinc coating of 20-26 microns is applied over the profile. If the coating thickness is noticeably reduced, the service life of the material is reduced several times.

Based on this, the production of corrugated sheets requires the use of high-quality raw materials with additional spraying and production equipment from a large company reputable in the mechanical engineering industry.

Technology for self-production of corrugated sheets (mechanical sheet bending machine)

The profiled sheet is presented in the form of a bent sheet profile with trapezoidal corrugation. To produce such a metal profile, it is rolled using a manual machine called a sheet bender (read: ""). The thickness of the galvanized sheet in this case can be no more than 0.5 mm.

Currently, manual production of corrugated equipment is used in piece production or for the production of components - these can be valleys, ridges, cornice strips.

Description of the technical data of the sheet bending machine:

• sheets no more than 2 m long;
• thickness up to 0.5 mm;
• bend no more than 150 degrees.

The work is performed as follows: the sheet is placed on the frame, and a pressure bar is installed on top of it. The lever, when activated, bends the sheet at a certain angle - you can verify the correct execution by comparing the result with what is shown in the photo.

The machine is offered on the market at a relatively low price, but it is not suitable for working with polymer-coated material, as it can quickly fail.

Characteristics of the industrial line for the production of corrugated sheets

Thanks to the use of cold rolling, the production of corrugated sheets in large volumes with a variety of profile geometries is ensured.

Large manufacturers of profiled sheets use special devices to create a standard production line, each of which performs a specific function:

An integral stage of the production technology is cutting the material with guillotine shears. The shears operate on a hydraulic, electromechanical or pneumatic drive ( last option used in rare cases), their shape must match the geometry of the sheet profile. Using scissors with a clear design, you can be sure of producing the highest quality profiled sheets.

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Industrial method, which is used by all corrugated sheeting manufacturers in Russia, differs significantly from the manual method:

• ideal profile geometry;
• compliance with uniform tension throughout the entire surface of the sheet, so during operation it will not appear on the folds;
• absence of rolls, which often happens during re-molding due to inaccurate profile geometry.

Corrugated sheeting is cost-effective, easy to use and reliable material, in demand in many construction fields. It is used for external and interior decoration, arrangement of barriers, hangars, workshops, internal roofing. Light weight, good rigidity indicators, long service life, low installation and maintenance costs have determined the popularity of this roofing material in mass and private construction.

Below is information about the production of corrugated sheets, equipment for production with a video of how they are made, as well as additional helpful information to organize your business.

The situation on the domestic corrugated sheet market

Given the large volumes of consumption, the production of corrugated sheets is a promising and highly profitable activity. However, a newcomer to the market will have to face serious competition.

This material produces a whole series of large factories specializing in rolled metal, as well as a large number of individual entrepreneurs. Accordingly, before making a decision to open production, it is necessary to carefully analyze the prospects for work in a particular region. The following parameters will help you decide:

• Presence in the immediate vicinity of another large plant for the production of corrugated sheets. Without a significant amount of funds to start, it is quite difficult to compete with such a competitor. On the contrary, if there are no similar enterprises within a radius of 200 km, and the consumer is forced to purchase corrugated sheets in remote regions, it becomes possible to attract the client by reducing the price, primarily due to minimal transport costs.
• Presence of rolled metal manufacturers in the region. Obviously, purchasing raw materials directly from a manufacturer whose facilities are located nearby is more cost-effective than executing a supply agreement through an intermediary.
• Cost, list of items, sales volume, competitive advantages"neighboring" manufacturers of corrugated sheets.
• Features specific to a particular region. Here we're talking about about construction volumes, seasonal fluctuations in demand, the most popular types of products and other factors.

When developing a development strategy, it would be useful to think about the vector of work of the future enterprise for the production of corrugated sheets. So, in accordance with the nature of demand, you can focus on construction companies or private customers. Clients of the first group need profiled sheets of various profiles (8-114 mm) and consume about 60% of the total production volume. IN individual construction“low” profile sheets (8-21 mm) are more often used, and the main selection criteria are not high price and acceptable quality of products.

Registration moments

For this business, it is better to choose first, because An individual entrepreneur is liable for the company’s obligations with his property.

When registering a company, you can indicate the following OKVED :

• 27.33 “Production of bent steel profiles»,
• 51.53.24 " Wholesale others building materials»,
• 52.46.73 " Retail metal and non-metallic structures, etc.”

Corrugated sheeting is not subject to mandatory certification, but it is recommended to adhere to the standards of GOST 24045-2016.

Raw materials for making corrugated sheets

For the production of corrugated sheets, rolled metal of the first or highest categories is used. It can be either ordinary galvanized steel (GOST 14918-80) or metal with polymer coating different colors(GOST 30246-2016). In some cases, corrugated sheets are made from coated aluminum-zinc steel.

To enterprises equipped with automated lines, raw materials are supplied in rolls. Manual profiling is performed using ready-made rolled sheets. A large share of the metal raw material supply market falls on domestic manufacturer. Rolled metal from China is also in demand, South Korea, England, Germany, Slovakia.

Equipment for the production of corrugated sheets + Video on how to make them

On the territory of the Russian Federation, corrugated sheets are not subject to mandatory certification. However, many customers prefer to deal with a product manufactured in accordance with GOST 24045-94.

Depending on the level of mechanization of the equipment, the production of corrugated sheets can be carried out automated, semi-automatic and manually. Technologies differ in line performance and cost.

Production on automated lines

Basic benefits automated production of corrugated sheets - high productivity (about 1000 m² per shift), wide range and ideal geometry of products. The equipment is simply configured to any parameters and practically does not require minimal human intervention; one employee is enough to control the process.

Among the disadvantages of the lines is the high cost of the units themselves and their maintenance.

Stages of the production process

Raw materials for corrugated sheeting are supplied to the enterprise in the form of rolled steel. Next, the workpiece goes through several processing stages.

1. The roll is placed on the unwinding device. The free edge of the metal is fixed on the filling stand of the rolling mill and then fed from set speed for processing.
2. The profile height and width parameters are set depending on the requirements for the final product. The width of the profiled sheet is limited by the size of the roll. The length of the corrugated sheet can be any, however, as a rule, no more than 12-13 meters, which is due to the dimensions freight transport.
3. Sheet metal under the influence of rolling rollers of the working shafts during the production process it acquires the necessary geometry. Moreover, rolling of all corrugations is carried out simultaneously, which allows us to obtain products of the highest possible quality and level of accuracy.
4. After forming is completed, the rolled sheet is cut using guillotine shears.
5. The finished corrugated sheet arrives at the work table, where it is formed into bundles and sent to the finished product warehouse.

Video how to do it:

Composition of automated lines

The main manufacturers of units are the Russian Federation, China and Germany. A typical set of equipment for the production of corrugated sheets includes five basic machines:

• software control unit, through which product parameters are set and units are controlled;
• unwinder in the form of a shaft on which rolls are placed, with a lock;
• a forming machine, where the formation of corrugated sheets of corrugated sheets is carried out directly;
• guillotine scissors for cutting the finished profile into sheets of a given size;
• receiving table for stacking and packaging products.

To purchase such a line you will need from 1,000,000 rubles. Over time, the production can be retrofitted, for example, with a heeling table or a unit for removing scraps. This will make it possible to speed up the production process and thus increase the productivity of the organization.

Production of corrugated sheets using manual equipment

Machines of this type can be found in small enterprises with a capacity of up to 400 corrugated sheets per shift. IN in this case All operations are performed manually, which requires serious physical effort on the part of the staff.

The production line is a single unit in the form of a frame with symmetrical pairs of shafts, which form the corrugation by mechanical pressure. Only galvanized sheets can be used here as raw materials for the production of corrugated sheets. The equipment also allows you to produce roofing elements.

Among the advantages of the solution it should be noted low cost, low maintenance, quick payback, the ability to corrugate corrugated sheets different shapes at a constant height.

Disadvantages include low productivity, high percent defects and high labor costs - at least two operators will be required to service one mill. It is also not recommended to work with painted metal. In addition, there are strict restrictions on the types of products produced. Thus, the length of the sheet cannot exceed 2 m, the thickness of the metal is 1 m, and the height of the corrugation is 15 mm.

Most of manual equipment for the production of corrugated sheets on the market is of Russian origin, and its cost starts from 70,000 rubles. In most cases, construction companies purchase such machines for coating. own needs.

Production of corrugated sheets using semi-automatic equipment

In many situations, this option turns out to be the most cost-effective for a beginning manufacturer of corrugated sheets, since with relatively low initial costs and high quality products (compared to the manual method) allows you to significantly increase the volume of the product produced.

To ensure the operation of the workshop, 2-3 qualified operators will be required per mill. Also, the production owner needs to take into account the presence of a moderate amount of defects due to the influence of the human factor at the stage of cutting products.

Semi-automatic line includes:

• unwinding machine;
• guillotine shears;
• rolling machine;
• table for cutting sheets.

The operating principle of a line for the production of corrugated sheets is similar to an automated one, with the difference that metal cutting is done manually. The dimensions of the equipment make it possible to produce corrugated sheets up to 10 m long. The maximum productivity of the equipment is about 700 m² of metal products per shift. The cost of units starts from 700,000 rubles.

Workshop equipment

For the production of corrugated sheets, it makes sense to rent a premises with an area of ​​at least 300 m². Here it is necessary to provide a production area (150 m²), storage space for raw materials (50 m²) and storage of the finished product (100 m²). It is optimal to have a flat floor and at least two gates: for receiving rolled metal and shipping profiled sheets. In addition, you will need to connect communications, including heating and 380 V power supply. To service production processes, you will need specialized equipment with a lifting capacity of 5 tons or more - a beam crane or a monorail.

Packs are formed from ready-made corrugated sheets and laid on wooden pallets and secured with foam or metal straps. Wooden spacers are placed in the places where the sheets come into contact with the constriction and in the corners to prevent deformation during transportation.

Storage and transportation of corrugated sheets

Requirements for storage and transportation of profiled sheets are regulated by GOST 15150.

Packs are formed from ready-made corrugated sheets, placed on wooden pallets and secured with polypropylene or metal belts. Wooden gaskets are placed in the places where the sheets come into contact with the constriction and in the corners to prevent deformation and mechanical damage coatings during transportation. Loading and unloading operations are performed using soft slings.

In warehouse and in the back vehicle packs are placed in one tier, except for cases where 1 m² of products weighs less than 3,000 kg/m². Products can be stored on open areas.

Staff

To ensure work small line for the production of corrugated sheets, a minimum of four employees will be required: a master equipment operator, two auxiliary workers, as well as a director, who at this stage assumes responsibilities for ensuring the supply of raw materials, searching for customers and other aspects of the enterprise’s activities.

Sales market

Sales of corrugated sheets can be carried out in three directions. Wholesale and retail sales involve cooperation with warehouses, supermarkets, as well as the involvement of dealers. You can arrange wholesale supplies to large enterprises through participation in tender procedures and auctions. In some cases, production/work “to order” with clients who require profiled sheets of non-standard sizes turns out to be profitable.

The specialized PKF "Metinvest-Service" sells rolled metal products in an assortment. The company organizes the production of corrugated sheets to order. We organized the production of corrugated sheets in the Moscow region on an automated line (CNC), with control at every stage production process.In particular, rolling speed. This allows for optimization of all process parameters.

Prices are indicated for informational purposes and under no circumstances constitute a public offer as defined by the provisions of Article 437 of the Civil Code of the Russian Federation.

The information on the site is for informational purposes only. Please check with our managers for current prices and delivery conditions.

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Production of corrugated sheets (corrugated sheets) is located in Moscow and the Moscow region

Our technical capabilities allow us to organize the production of corrugated sheets with the characteristics required by the customer. The production line includes:

A special device that allows you to secure and unwind rolled products;
. Roll forming mill;
. Guillotine type cutting mechanism;
. Receiving node.

If necessary, it is possible to connect additional equipment(stamp, device for packaging finished products, perforation block).

We offer to buy corrugated sheets from the manufacturer

Our customers have the opportunity to buy corrugated sheeting from the manufacturer with the required geometry:

According to the height of the completed profile (corrugations):

• low or medium (8.0 mm - 21.0 mm), which is ideal for cladding and wall work, and is also the best option for fences and fencing;
• medium or high (44.0 mm - 75.0 mm) is in demand for roofing work;
• high (75.0 mm - 114.0 mm) acts as a load-bearing element.

Profiled sheet from a manufacturer in the Moscow region At Metinvest-Service you can select by type of protective coating:

• polymer (in a wide range) color scheme). This material is in demand by clients, the priority criterion for which is appearance object;
• zinc. The products belong to the category of budget building materials.

Using profiled sheet from the manufacturer, the buyer has the opportunity to qualitatively cover the roof of any configuration in a short time.

Capabilities of the plant for the production of corrugated sheets

Possibility of quick changeover production line allows, within the agreed time frame, to fulfill any order for production of profiled sheets. For ease of selection, products are labeled according to standard 27772-88 (as amended on 06/01/89):

• “N” - the product is intended for laying coverings. Has significant load-bearing capacity with low weight.

• “NS” - ​​for any enclosing structures (wall and floor). Has special grooves on the shelves, which give the product additional rigidity

• “C” - only for making wall fences. With a shelf width of 50 mm, the product has excellent decorative properties.

If it is needed buy profiled sheet from the manufacturer, the quality of which is guaranteed to comply with the provisions of current standards, contact Metinvest-Service. All products are manufactured in accordance with the provisions of current regulations:

• Galvanized rolled thin sheets - in accordance with standard 14918-80* (GOST valid as amended on 06/01/86). These products are not specially marked;
• Sheets that have an aluminum-zinc coating and are produced in accordance with specifications from thin-sheet rolled products are marked “AC” according to standard 14-11-247-88;
• We have established production of profiled sheets in Moscow and the Moscow region(according to specifications) from rolled products with an aluminum-silicon coating, or aluminized thin sheets (14-11-236-88) are marked with the letters “KA” and “A”, respectively;
• If the corrugated sheet is made in accordance with the technical specifications from rolled metal with an applied zinc electrolytic coating (TU 14-1-4695-89). It is marked "EOTSP".

In cases where paintwork materials are not applied to the finished product, no additional markings are affixed. And when they are applied, in accordance with the standard 30246-2016 (GOST), the designation of the paintwork materials used is affixed.

To organize the production of profiled sheets you need:

• 1) premises, production equipment, staff;
• 2) warehouse stock of metal (for the current month) + metal in transit (paid for the next month);
• 3) sales of products, advertising.

Brief production requirements

Room

The room must be spacious (for installing lines, organizing a warehouse for rolls and finished products), with a flat floor and a crane beam with a lifting capacity of 5 tons or more.

To ensure a range of products, it is advisable to install several lines in the workshop at once (for example, the most popular profiles of corrugated sheets C8, C21, MP20, metal tiles “Monterey”, “Cascade”).

The following personnel are required to work in the workshop:

• 1 person per line,
• storekeeper,
• one or more auxiliary workers depending on production volumes (loading and unloading).

Metal warehouse stock

Metal is ordered from large dealers or directly from metallurgical plants (large deliveries). To produce profiled sheet metal in rolls must be available in at least four popular colors (chocolate, green, blue, cherry).

The workshop should have enough metal for at least a month of work. Metal for the next month must be ordered and paid to the supplier in the current month.

Calculation of profitability of corrugated sheet production

Corrugated sheets are sold by linear meters, so we will calculate the cost per linear meter. The metal is sold in rolls, usually weighing about 5 tons. The number of linear meters per ton depends on the thickness of the metal and is indicated in the table.

Sales price of C8 corrugated sheet (NLMK steel) in Lipetsk in December 2014.

Conclusion

In Lipetsk, the markup on the cost of metal (the cost of rolling corrugated sheets) is 11%. In other regions, the markup varies from 10% to 25% and depends on the state of the local market.

According to statistics, during an 11-hour shift, one line on average profiles from 13 to 16 tons of rolled products, and on long sheets - up to 24 tons. It all depends on the sizes ordered and the number of colors.

Calculation of profitability of metal tile production

The cost of producing metal tiles is calculated similarly. It, unlike corrugated sheeting, is sold by square meters, which are calculated by the total width.

Overall width - 1 170 ±8 mm
Step height - 21 mm
Step between steps - 350 mm

Prices for December 2014 for NLMK steel with paint coating (after price increases)

For the production of 1 l.m. m/tiles required 1 063 mm of smooth sheet, because in one linear meter 3 steps of 21 mm.

Thus, for metal tiles with a thickness of 0.5 mm:

• cost price 1 p.m.- 238 * 1.063 = 253 rubles,
• cost price 1 m2 - 253/1,17 = 216 rub.(total width - 1,170 mm).

Conclusion

The selling price in Lipetsk in December is 240 rubles/m2 (thickness 0.5 mm), which means the markup per 1 m2 will be 240-16 = 24 rubles or the same 11% markup on the cost of metal.

According to statistics, one line produces from 3 to 5 tons of metal tiles per shift. Performance depends on the specified lengths and number of colors.

Ways to deceive consumers

There are several ways to deceive end consumers by unscrupulous suppliers.

• According to the documents, 0.5 mm metal is shipped, but in fact it is thinner.
• According to the documents, NLMK metal is shipped (a certificate is usually attached), but in fact it is metal from another manufacturer (for example, cheaper Chinese metal).
• Sales of products in rubles for square meter. In this case, inflated figures are included in the price calculation. For example, instead of a total width of 1,190 ± 8 mm, 1,200 mm is indicated. With such figures, the price per m2 is lower than that of competitors.

These methods allow unscrupulous manufacturers to reduce prices and make high profits to the detriment of the buyer.

Profiled a metal sheet- This coiled steel, the surface of which, as a result of processing on special equipment, has acquired a wavy or corrugated shape.

The purpose of this operation is to increase the longitudinal stiffness and bearing capacity source material. This allows the use of cold-rolled steel of relatively small thickness for the manufacture of various building structures, including those subject to significant static and dynamic loads.

Machine for making corrugated sheets using simultaneous rolling technology

Modern corrugated board produced from steel with a thickness of 0.45 to 1.2 mm. Depending on the purpose, metal profiled sheets are divided into two main groups - load-bearing and wall. They differ in profile shape and metal thickness. The corrugated sheet has high performance characteristics at a relatively low cost, which makes its production quite an attractive and profitable investment.

Technology for the production of corrugated sheets - a brief description of the main stages of manufacturing profiled sheets

The production technology of corrugated sheets is quite simple. It is based on the method of cold rolling of thin sheet metal. By using special equipment, from a roll of galvanized steel or steel with a polymer coating is obtained metallic profile with a given surface geometry.

There are two methods of metal profiling: simultaneous and sequential (or combined).

In the first case, the corrugated sheet manufacturing technology involves rolling all the corrugated sheet corrugations simultaneously, starting from the first stand of the rolling mill. At the same time, production space is significantly saved, since a machine for simultaneous rolling is approximately 1.5 times smaller than equipment for sequential or combined method obtaining a profiled sheet. In addition, the first method of metal processing profiles the sheet more evenly, eliminating the possibility of defects at the edges of the original workpiece.

The profiled sheet production line includes:

• unwinder;
• cold rolling mill;
• hydraulic guillotine shears;
• receiving device.

The coherence and continuity of operation of the equipment is ensured by an automated control system, which ensures that the technology for producing corrugated sheets is not disrupted. Such lines are designed for the production of corrugated sheets from galvanized steel in accordance with GOST 14918 and from thin sheet steel with a polymer coating in accordance with GOST 30246-94, GOST 9045, GOST 1050.

From a roll installed on the unwinder, thin sheet steel is fed into a forming machine, where the metal surface is profiled. Then the finished sheet of corrugated sheeting falls on hydraulic shears, which cut the product in accordance with the specified dimensions. The profile of the profiled sheet is curled from the shape of the rollers installed on the rolling mill.

Corrugated sheet production technology - standard production line layout

All stages of the production process are controlled by a control system, which allows you to set the rolling speed, as well as the length and number of corrugated sheets. After cutting, the finished sheets of corrugated sheets fall into the receiving device.

Thus, the production of corrugated sheet steel consists of the following steps:

• Roll of galvanized steel or steel with polymer protective coating installed on an unwinder that ensures correct and uniform feeding of the sheet.
• The end of the sheet is inserted into the forming machine of the rolling mill.
• System automatic control basic parameters are set, such as rolling speed, length and number of corrugated sheets.
• The equipment is launched and the process of making corrugated sheets is carried out.

The finished product is taken out of the receiving device, labeled and packaged for shipment to the consumer.

Main equipment of the corrugated sheet production line, its purpose and design

Below I will dwell in detail on the functions of each individual unit of the machine for the production of corrugated sheets.

Cantilever hydraulic decoiler

This device is designed to feed rolled sheet steel into a forming machine. Like all mechanisms of the corrugated sheet production line, the unwinder is controlled by automated system management. In addition, the unwinder has its own automation system, which, using braking device synchronizes the feed speed of the metal strip with the speed of metal rolling.

Metal cutting device

It is installed after the unwinder and is used for cutting metal if it is necessary to replace, for example, a roll of galvanized steel with polymer-coated steel to complete another order.

Rolling mill (forming machine)

This - main element any production line for the production of profiled sheets. It is this that is the key link in the corrugated sheet manufacturing technology and turns a smooth metal sheet into a corrugated profile. Surface profiling is carried out by rolling the metal through specially shaped rollers, the choice of which depends on the required corrugation shape of the sheet being profiled. The formation of corrugated sheet metal begins with the first stand, and the number of stands depends on the complexity of the corrugated shape of the profiled sheet.

By design, molding machines can be pneumatic or hydraulic. In a pneumatic rolling mill, a metal sheet is pressed into a die using a punch under the influence of compressed air. A pneumatic forming machine can produce profiled sheets up to 2.5 m long, with a bend angle of the profile corrugation up to 90° from metal, up to 1.5 mm thick.

The operating principle of a hydraulic rolling mill forming machine is the same as that of a pneumatic forming machine. But hydraulically driven rolling mills are more powerful and can produce profiled sheets of any length, which is limited only by the convenience of transporting the finished product to the consumer.

The program specified by the control system of both pneumatic and hydraulic rolling mills, allows you to automatically change punches and dies by selecting their configurations when viewing a graphic model of a profiled sheet, as well as set any operating rolling speed.

They are used for cutting the finished profiled sheet according to the specified dimensions automatic system management. Cutting is carried out with a knife, the shape of the blade exactly repeats the shape of the corrugation of the profiled sheet.