Highway Metal Crash Barrier Roll Forming Machine

Highway Metal Crash Barrier Roll Forming Machine (W-Beam & Thrie-Beam)

We are a leading Manufacturer of Highway Metal Crash Barrier Roll Forming Machines, delivering heavy-duty roll forming solutions for producing W-Beam and Thrie-Beam guardrails used in highways, expressways, bridges, industrial zones, and infrastructure safety projects. Our machines are engineered to meet stringent MoRTH, IRC, ASTM, and international road safety standards, ensuring high impact resistance, dimensional precision, and long-term structural durability.

Crash barriers play a critical role in road safety by absorbing vehicle impact and preventing lane deviation. Our roll forming machines are designed using advanced CAD-based tooling systems and structural engineering analysis to produce uniform beam profiles with precise corrugation depth and consistent thickness. The machines are capable of processing high-tensile galvanized steel coils, ensuring compliance with highway load-bearing and impact performance requirements.

The complete production line includes hydraulic decoiler, coil straightening system, servo feeding unit, high-tonnage hydraulic punching system (for slot holes and post holes), multi-station heavy-duty roll forming system, hydraulic cut-to-length system, and automatic stacking unit. Each forming station is reinforced with hardened shafts and precision rolls to ensure accurate beam geometry and minimal tolerance deviation.

Our machines feature PLC-based automation with HMI touchscreen controls, allowing accurate length setting, punching alignment synchronization, and production monitoring. The heavy structural frame design ensures vibration-free performance even when processing thicker materials (2.5 mm–4.0 mm). We also offer optional integration with hot-dip galvanizing lines for complete guardrail production solutions.

Each machine undergoes comprehensive trial production runs, profile inspection, hole alignment verification, load simulation testing, coating thickness compatibility checks, and electrical safety validation before dispatch.

Key Technical Specifications

1. Material Thickness Range: 2.5 mm – 4.0 mm

2. Material Type: High-Tensile Galvanized Steel

3. Profile Type: W-Beam / Thrie-Beam

4. Production Speed: 8–15 meters per minute

5. Forming Stations: 18–26 stations

6. Main Motor Power: 30 HP – 50 HP

7. Hydraulic Power Unit: 15 HP – 25 HP

8. Punching Capacity: Heavy-duty hydraulic punching system

9. Cutting System: Hydraulic Cut-Off

10. Control System: PLC with HMI Touchscreen

11. Drive Type: Gear Drive System

12. Shaft Diameter: 90–110 mm hardened shafts

13. Roll Material: D2 hardened steel rolls

14. Decoiler Capacity: 10 Ton hydraulic decoiler

15. Length Accuracy: ±1 mm

Our Highway Metal Crash Barrier Roll Forming Machines deliver high structural accuracy, impact resistance compliance, heavy-duty performance, and long-term operational reliability—making them ideal for government highway projects and large-scale infrastructure development.