{"id":7435,"date":"2026-11-08T09:00:00","date_gmt":"2026-11-08T01:00:00","guid":{"rendered":"https:\/\/belirollforming.com\/deep-vs-shallow-deck-roll-forming-machine\/"},"modified":"2026-11-08T11:32:58","modified_gmt":"2026-11-08T03:32:58","slug":"deep-vs-shallow-deck-roll-forming-machine","status":"publish","type":"post","link":"https:\/\/belirollforming.com\/ru\/deep-vs-shallow-deck-roll-forming-machine\/","title":{"rendered":"\u0413\u043b\u0443\u0431\u043e\u043a\u0438\u0439 \u043f\u0440\u043e\u0444\u043d\u0430\u0441\u0442\u0438\u043b \u043f\u0440\u043e\u0442\u0438\u0432 \u043d\u0435\u0433\u043b\u0443\u0431\u043e\u043a\u043e\u0433\u043e: 7 \u0441\u0440\u0430\u0432\u043d\u0435\u043d\u0438\u0439 \u043e\u0441\u043d\u0430\u0441\u0442\u043a\u0438"},"content":{"rendered":"\t\t
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A deep deck roll forming machine<\/strong> is not a shallow deck line fitted with taller rolls. Rib depth changes the force path, the pass count, the shaft size and the cutoff stroke. A deep profile on a shallow frame twists at the rib root and will not hold tolerance past the first coil.<\/p>\n

Shallow deck means 38 mm (1.5 in) or 51 mm (2 in) ribs. Deep deck starts at 76 mm (3 in) and runs to 125 mm (5 in). Span and gauge selection belongs to the long span floor deck rib depth rules<\/a>. Here we compare seven machine specs.<\/p>\n

Figures assume 0.8 to 1.5 mm (22 to 16 ga) galvanized sheet to ASTM A653 SS Grade 50. Tolerances follow ANSI\/SDI NC1.0<\/a>, design checks use AISI S100<\/a> and EN 1993-1-3. The American Iron and Steel Institute<\/a> publishes the sheet grade data.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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1. Stand Count and Bend Angle Per Pass<\/h2>\n\n

Stand count is the first number that separates the two lines. A 38 mm shallow profile forms cleanly in 14 to 18 stands. A 76 mm deep profile needs 24 to 30. A 100 to 125 mm section pushes that to 30 to 36.<\/p>\n

Keep each pass to about 10 to 15 degrees at the rib root. A 76 mm rib formed in 16 stands asks for 25 degrees or more per pass, and the outside of the bend starts to thin and spring back. Extra stands are how the metal survives.<\/p>\n\n
Machine spec<\/th>38 mm shallow deck line<\/th>76 to 125 mm deep deck line<\/th>Why it changes<\/th><\/tr>\n
Forming stands<\/td>14 to 18<\/td>24 to 30 (30 to 36 for 100 mm plus)<\/td>Bend angle held to 10 to 15 degrees per pass<\/td><\/tr>\n
Shaft diameter<\/td>60 to 75 mm<\/td>80 to 100 mm<\/td>Higher forming force and longer roll face<\/td><\/tr>\n
Stand plate thickness<\/td>35 to 45 mm<\/td>55 to 70 mm<\/td>Frame deflection kept under 0.05 mm at the gap<\/td><\/tr>\n
Roll blank diameter<\/td>180 to 260 mm<\/td>260 to 360 mm<\/td>Larger wrap angle around a taller rib<\/td><\/tr>\n
Drive power<\/td>30 to 45 kW<\/td>75 to 110 kW<\/td>Torque rises with rib depth and gauge<\/td><\/tr>\n
Line speed<\/td>25 to 40 m\/min<\/td>12 to 25 m\/min<\/td>More passes and a longer cutoff stroke<\/td><\/tr>\n
Changeover time<\/td>2 to 4 h with shim sets<\/td>6 to 10 h, or 2 to 3 h with cassettes<\/td>More stands and heavier rolls to reset<\/td><\/tr>\n<\/table>\n

Tooling guides from The Fabricator<\/a> describe the same stand count logic. A deep deck roll forming machine<\/strong> spends its budget on stands before anything else. Rib shapes are covered in floor deck profile types from dovetail to deep rib<\/a>.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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A 38 mm shallow deck line runs 14 to 18 forming stands and 60 to 75 mm shafts.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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2. Shafts, Bearings and Stand Rigidity<\/h2>\n\n

Deep ribs load the frame harder. Forming force at the rib root runs two to three times the shallow figure, and torque per stand climbs from 1.5 to 2.5 kN\u00b7m to 4 to 8 kN\u00b7m.<\/p>\n

Shafts grow from 60 to 75 mm to 80 to 100 mm. Bearing centres move closer, because a long unsupported span lets the shaft bow and opens the gap on one side. Stand plates go from 35 to 45 mm to 55 to 70 mm, with preloaded tie rods holding the shafts parallel.<\/p>\n

Set a 0.05 mm target for shaft movement at the last stand, measured under load. Anything above that drifts across the sheet width. The roll forming tooling<\/a> page lists the shaft and bearing options we build to.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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3. Roll Blank Geometry and Tool Steel<\/h2>\n\n

A deep rib needs a bigger blank, from 180 to 260 mm up to 260 to 360 mm. The larger radius eases the contact angle at the rib root and stops the strip being pinched on entry.<\/p>\n

Deep profiles also need split and side rolls. One solid roll cannot form a 76 mm rib with an undercut dovetail. Top, bottom and side components each get their own shim stack. Steel is D2 or Cr12MoV at HRC 58 to 62, polished to Ra 0.4 \u00b5m for coated stock.<\/p>\n

Springback rises from 1 to 3 degrees on shallow sections to 3 to 6 degrees on deep ones. Put the overbend in the last two stands. Gap settings are in roller gap clearance rules<\/a>.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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4. Drive Torque, Line Speed and Power<\/h2>\n\n

More stands mean more driven axes, and every axis needs torque. A shallow line runs one motor and a geared distribution shaft. A deep line splits into two drive groups, one for the first half of the mill and one for the finishing stands.<\/p>\n\n
Rib depth \u00d7 gauge<\/th>Stands<\/th>Total drive power<\/th>Practical line speed<\/th>Drive layout<\/th><\/tr>\n
38 mm \u00d7 0.9 mm<\/td>14 to 16<\/td>30 to 37 kW<\/td>30 to 40 m\/min<\/td>Single motor, geared shaft<\/td><\/tr>\n
51 mm \u00d7 1.2 mm<\/td>18 to 20<\/td>40 to 55 kW<\/td>25 to 35 m\/min<\/td>Single motor, two gearboxes<\/td><\/tr>\n
76 mm \u00d7 1.2 mm<\/td>24 to 28<\/td>75 to 90 kW<\/td>18 to 25 m\/min<\/td>Two drive groups<\/td><\/tr>\n
100 mm \u00d7 1.5 mm<\/td>30 to 34<\/td>95 to 110 kW<\/td>12 to 20 m\/min<\/td>Two drive groups, individual stands<\/td><\/tr>\n<\/table>\n

Speed is the trade buyers notice first. A deep line runs at half the metres per minute of a shallow line, because the cutoff die clears a taller rib and the embossment rolls need dwell time. Precision Metalforming Association<\/a> material on mill drives covers the same torque split. Do not quote a deep line at shallow line rates.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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A 24 stand mill shows the stand count a 76 mm deep rib needs, with two drive groups.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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5. Embossment, Punching and Cutoff Stations<\/h2>\n\n

Composite deck needs embossments for concrete bond. A shallow profile runs 3 to 6 kN per rib. A 76 mm rib needs 8 to 15 kN in a separate reinforced housing. Load that station into a light frame and the mill prints a periodic rib depth error.<\/p>\n

Shear tabs, pour stops and cell closures are punched before the last forming stands on a deep deck roll forming machine<\/strong>, with a servo feed tracking line speed. Bond design values are in floor deck embossment and bond strength<\/a>.<\/p>\n

A flying shear needs a stroke equal to rib depth plus 20 to 30 mm. A 38 mm profile clears in 60 mm, a 125 mm profile in 150 mm. That means a heavier shear, a longer servo cycle and a slower line. Blade clearance stays at 5 to 8 percent of sheet thickness.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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The flying shear stroke must clear the full rib depth plus 20 to 30 mm.<\/figcaption>\n\t\t\t\t\t\t\t\t\t\t<\/figure>\n\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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6. Straightening, Exit Handling and Tolerance<\/h2>\n\n

Deep sections leave the last stand with more stored stress. A shallow line uses 4 to 6 straightening rolls, a deep line 6 to 9 plus an adjustable twist head. Deep ribs also scuff if stacked too fast, so the stacker needs a slower drop. Measure the finished profile cold, 30 minutes after the line stops.<\/p>\n\n
Acceptance check<\/th>Method<\/th>Limit<\/th><\/tr>\n
Rib depth across width<\/td>Calliper at 5 points on a 1 m sample<\/td>\u00b10.8 mm from drawing<\/td><\/tr>\n
Cover width and squareness<\/td>Tape measure and square on a 3 m length<\/td>\u00b11.0 mm width, 1 mm per metre out of square<\/td><\/tr>\n
Longitudinal bow and twist<\/td>Straightedge over 3 m, feeler gauge<\/td>3 mm bow, 1 degree twist<\/td><\/tr>\n<\/table>\n

These limits sit inside SDI NC1.0 manufacturing tolerances. The SDI standard roll forming tolerances<\/a> article explains how they interact with gauge and coating. If the profile passes cold but drifts after an hour, go back to shaft deflection and roller wear patterns<\/a>.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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7. Changeover Time and Frame Adjustment<\/h2>\n\n

A shallow deck line with two or three widths changes over in 2 to 4 hours using shim sets. A deep line has more stands, heavier rolls and a split drive, so the same job takes 6 to 10 hours.<\/p>\n

Cassette tooling is the answer when the mix is wide. The frame stays put, the roll set comes out as a unit, and a prepared cassette goes back in within 2 to 3 hours. Quick changeover practice<\/a> covers the sequence. The same approach is used on cellular floor deck lines<\/a>, where two rib heights share one frame.<\/p>\n

Record every shim stack and stand position at sign-off. A deep line set by eye never returns to the same tolerance twice.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Acceptance: Three Checks Before Sign-off<\/h2>\n\n

Run the test on the production coil, not a clean strip. Check rib depth at five points on a 1 m sample, cover width and squareness on 3 m, then bow and twist once the part cools.<\/p>\n

Log stand positions, roll gaps, drive current and cutoff stroke. Those four numbers explain a drift three months later. Guard the forming zone and shear to OSHA 1910.212 rules. Precision Metalforming Association<\/a> guidance covers the same points.<\/p>\n

If a buyer wants one frame for both families, say what it costs. A steel decking machine<\/a> sized for 125 mm ribs will form 38 mm stock, but carries deep line power and floor space on every shallow order.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Conclusion<\/h2>\n\n

Seven numbers decide the purchase: stand count, shaft diameter, roll blank size, drive power, embossment load, cutoff stroke and changeover time. All seven scale with rib depth, so a deep deck roll forming machine<\/strong> is a different capital item. The floor deck roll forming machine buying guide<\/a> covers the commercial side.<\/p>\n

Beli Rollforming builds roll forming machines<\/a> and floor deck tooling with over 15 years of experience, installed in more than 20 countries across the US, Europe and Australia. Send us your rib depth, gauge range and target output, and we will size the stands and the frame before quoting.<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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FAQ<\/h2>\n\n

1. How many forming stands does a deep deck roll forming machine need?<\/strong> 24 to 30 stands for a 76 mm rib, and 30 to 36 for 100 to 125 mm ribs. A 38 mm shallow profile needs 14 to 18. The extra passes keep each bend to 10 to 15 degrees.<\/p>\n

2. Can a shallow deck line be upgraded to make deep deck?<\/strong> Rarely. Shaft diameter, stand plate thickness, drive power and cutoff stroke are sized at build time. Replacing those parts costs more than a purpose built line.<\/p>\n

3. Why is shaft diameter larger on deep deck lines?<\/strong> Forming force at a deep rib root is two to three times higher. Shafts grow from 60 to 75 mm to 80 to 100 mm to hold gap deflection under 0.05 mm.<\/p>\n

4. What drive power should I budget for 76 mm deck?<\/strong> 75 to 90 kW for 1.2 mm sheet at 24 to 28 stands, usually split across two drive groups. A 38 mm line at 0.9 mm needs 30 to 37 kW.<\/p>\n

5. Does deep deck run slower than shallow deck?<\/strong> Yes. Expect 12 to 25 m\/min against 25 to 40 m\/min. More stands, a longer shear stroke and embossment dwell time set the ceiling.<\/p>\n

6. What tool steel is used for deep deck rolls?<\/strong> D2 or Cr12MoV hardened to HRC 58 to 62, polished to Ra 0.4 \u00b5m or better for coated coil. Deep ribs need split and side rolls, not one solid blank.<\/p>\n

7. How much does springback increase with rib depth?<\/strong> Shallow sections show 1 to 3 degrees, deep ribs 3 to 6 degrees. Build the compensation into the final two stands.<\/p>\n

8. What tolerance should a deep deck profile hold?<\/strong> Rib depth \u00b10.8 mm, cover width \u00b11.0 mm, bow under 3 mm over 3 m, twist under 1 degree. Measure cold, 30 minutes after forming.<\/p>\n

9. Can one machine make both 38 mm and 125 mm deck?<\/strong> It can, with cassette tooling. The frame must be sized for the deepest rib, so shallow orders carry the higher power and floor space cost. Changeover takes 2 to 3 hours with prepared cassettes.<\/p>\n

10. Which standards apply to the finished deck profile?<\/strong> ASTM A653 for the galvanized sheet, ANSI\/SDI NC1.0 for noncomposite floor deck tolerances, and AISI S100 or EN 1993-1-3 for cold formed steel design checks.<\/p>\n

Last updated:<\/strong> 2026-11-08<\/p>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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Article Changelog<\/h2>\n\n
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  • 2026-11-08: First publication. Seven tooling and frame comparisons between deep and shallow floor deck lines, with a spec table, a gauge and power table and three acceptance checks.<\/li>\n<\/ul>\n\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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    Next Review Triggers<\/h2>\n\n
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    • Revision of ANSI\/SDI NC1.0 tolerances or ASTM A653 grade designations<\/li>\n
    • New field data on shaft deflection or embossment roll load for 100 mm plus ribs<\/li>\n
    • A cassette changeover system changes the 2 to 3 hour swap time quoted here<\/li>\n<\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t
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