{"id":605,"date":"2018-03-22T14:38:09","date_gmt":"2018-03-22T06:38:09","guid":{"rendered":"https:\/\/believeindustry.company\/?page_id=605"},"modified":"2026-11-10T10:29:09","modified_gmt":"2026-11-10T02:29:09","slug":"%d0%bb%d0%b8%d1%81%d1%82%d0%be%d0%b3%d0%b8%d0%b1%d0%be%d1%87%d0%bd%d0%b0%d1%8f-%d0%bc%d0%b0%d1%88%d0%b8%d0%bd%d0%b0-ibr","status":"publish","type":"page","link":"https:\/\/believeindustry.company\/ru\/roll-forming-machine\/metal-sheet-roll-forming-machine\/ibr-sheet-roll-forming-machine\/","title":{"rendered":"\u041f\u0440\u043e\u0444\u0438\u043b\u0435\u0433\u0438\u0431\u043e\u0447\u043d\u044b\u0439 \u0441\u0442\u0430\u043d\u043e\u043a \u0434\u043b\u044f \u043b\u0438\u0441\u0442\u0430 IBR"},"content":{"rendered":"

Short answer:<\/strong> An IBR sheet roll forming machine turns galvanized coil into the Inverted Box Rib roof and wall profile used across South Africa. A standard line runs 0.4 to 0.8 mm strip through 18 to 22 forming stands at 10 to 12 m\/min, then cuts each sheet with a profile-matched hydraulic die. Two drawings set the tooling: IBR 686 and IBR 890. Both keep the 37 mm rib height.<\/p>\n

The profile is simple to describe and hard to make well. Trapezoidal ribs, a stiffener in every valley, and a side lap that has to seal on site. A mill that gets the rib height right can still fail on lap shape or cut length.<\/p>\n

We have built roll forming lines since 2005 and shipped them to 50+ countries. This page stays with the IBR sheet roll forming machine: tooling, layout, cut-off, changeover and pre-shipment checks. For profile geometry and South African standards, read What Is IBR Roof Sheeting?<\/a>. For supplier and price comparisons, use the roofing sheet roll forming machine buy guide<\/a>.<\/p>\n

What an IBR sheet roll forming machine makes<\/h2>\n

IBR stands for Inverted Box Rib. Trapezoidal ribs are pressed up from a flat valley, with a small stiffener rib inside each valley. Roof fixings go through the narrow flute, wall fixings through the wide flute. One roll set produces both applications.<\/p>\n

An IBR sheet roll forming machine does not make fasteners, closures, ridge caps or flashings, and it does not slit coil. Coil has to arrive at the width the profile drawing calls for. That drawing is the first thing to settle on the enquiry.<\/p>\n

An IBR sheet roll forming machine normally feeds 0.4 to 0.8 mm galvanized or pre-painted coil. Colour coated coil needs polished rolls and a slower first pass, because a rough roll surface marks the paint. Our coil selection guide<\/a> covers the trade-offs, and the metal coil calculator<\/a> sizes the coil for a production run.<\/p>\n

IBR 686 and IBR 890: the drawings that set the tooling<\/h2>\n

IBR 686 is the standard South African sheet. IBR 890 covers more area per sheet and suits large roofs where fewer side laps matter. Both use a 37 mm rib height, but pan count and coil width differ, so the roll sets are not interchangeable.<\/p>\n

\"IBR
IBR 686 drawing: 740 mm overall, four pans at 686 mm effective cover, 37 mm ribs at 171.5 mm pitch.<\/figcaption><\/figure>\n
\"IBR
IBR 890 drawing: 938 mm overall, five pans at 890 mm cover, same 37 mm rib height.<\/figcaption><\/figure>\n

These are the drawings we build tooling to. The 686 sheet shows 740 mm overall, 686 mm cover, a 171.5 mm rib pitch and a 35 mm crown. The 890 sheet shows 938 mm overall, 890 mm cover and a 33 mm crown. The valley stiffener appears in both and is easy to miss on a low-cost roll set.<\/p>\n\n\n\n\n\n\n\n\n\n\n\n
Item<\/th>\nIBR 686<\/th>\nIBR 890<\/th>\n<\/tr>\n<\/thead>\n
Overall width<\/td>\n740 mm<\/td>\n938 mm<\/td>\n<\/tr>\n
Effective cover<\/td>\n686 mm<\/td>\n890 mm<\/td>\n<\/tr>\n
Pan count<\/td>\n4<\/td>\n5<\/td>\n<\/tr>\n
Rib height<\/td>\n37 mm<\/td>\n37 mm<\/td>\n<\/tr>\n
Rib pitch<\/td>\n171.5 mm<\/td>\n178 mm edge, 112 mm valley<\/td>\n<\/tr>\n
Rib crown<\/td>\n35 mm<\/td>\n33 mm<\/td>\n<\/tr>\n
Strip thickness<\/td>\n0.4 to 0.8 mm<\/td>\n0.4 to 0.8 mm<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Cover width is not coil width. The gap between overall width and cover width is the side lap. A supplier quoting without the profile drawing attached is quoting a guess. Ask for pan count, crown width and stiffener dimension, then have the rolls drawn from it. This is why an IBR sheet roll forming machine built for 686 cannot be turned into 890 by moving spacers. The entry guide, every stand and the cut-off die are sized for one strip width.<\/p>\n

Coil width, grade and coating to specify first<\/h2>\n

South African roofing sheet is normally a thin high-strength grade. ISQ 550 is the local designation, in the same strength class as G550 and S550GD. Softer DX51D or S350GD coil forms more easily and is used where the engineer allows it. Grade changes forming force, springback and roll finish, so it belongs on the order sheet.<\/p>\n\n\n\n\n\n\n\n\n\n
Coil option<\/th>\nTypical use<\/th>\nEffect on the line<\/th>\n<\/tr>\n<\/thead>\n
GI, Z180 zinc, 0.4 to 0.8 mm<\/td>\nInland roofing<\/td>\nBaseline roll gap and power<\/td>\n<\/tr>\n
GI, Z275 zinc, 0.5 to 0.8 mm<\/td>\nCoastal roofing<\/td>\nPolished rolls, wider gap<\/td>\n<\/tr>\n
Galvalume AZ150, 0.4 to 0.6 mm<\/td>\nCoastal and industrial<\/td>\nCareful roll finish<\/td>\n<\/tr>\n
PPGI, 0.4 to 0.6 mm<\/td>\nResidential and commercial<\/td>\nClean rolls, soft stacker supports<\/td>\n<\/tr>\n
High-strength 550 MPa grade<\/td>\nLong spans<\/td>\nMore stands, more motor power<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Coating matters more than colour in coastal work. Inland jobs use Z180, coastal sites call for Z275 or aluminium-zinc. The American Galvanizers Association<\/a> publishes coating guidance, the National Regulator for Compulsory Specifications<\/a> covers the South African compulsory specification framework, and the SANS standards catalogue<\/a> is where to confirm the current SANS 994 and SANS 121 editions. Specify the coating before the roll gap is set, because a heavy coating in a tight gap flakes at the rib crown.<\/p>\n

Pre-painted coil needs clean rolls, a guarded entry table and a stacker with soft supports. An IBR sheet roll forming machine that handles bare GI well can still scratch PPGI on the first shift if the run-out table has bare steel rollers.<\/p>\n

Decoiler to stacker: the line layout<\/h2>\n
\"Two
IBR lines in the workshop. Forming stands run left to right, with the hydraulic cut-off press at the exit.<\/figcaption><\/figure>\n\n\n\n\n\n\n\n\n\n\n
Station<\/th>\nStandard build<\/th>\nWhy it matters<\/th>\n<\/tr>\n<\/thead>\n
Decoiler<\/td>\n3 to 5 t, manual or hydraulic<\/td>\nSets coil change time<\/td>\n<\/tr>\n
Entry guide and leveller<\/td>\n7 or 9 rolls<\/td>\nRemoves coil set on thin strip<\/td>\n<\/tr>\n
Forming mill<\/td>\n18 to 22 stands<\/td>\nBuilds ribs and valley stiffeners<\/td>\n<\/tr>\n
Hydraulic cut-off<\/td>\nProfile-matched die, 4 kW pack<\/td>\nKeeps rib shape at the cut<\/td>\n<\/tr>\n
Run-out table<\/td>\n6 to 12 m<\/td>\nSupports the longest sheet<\/td>\n<\/tr>\n
Auto stacker<\/td>\nOptional, 15 to 25 m\/min<\/td>\nCuts labour on long sheets<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

A standard IBR sheet roll forming machine starts with a 3 to 5 t decoiler. A hydraulic expansion mandrel with a coil car cuts coil change to about 10 minutes, against 20 to 30 minutes on a manual mandrel. On a 10 m\/min line that difference beats a small speed increase. Our auto stacker<\/a> page shows the stacking options for long sheets.<\/p>\n

\"Single
Hydraulic expansion uncoiler at the mill entry, with the first forming stands behind it.<\/figcaption><\/figure>\n

The leveller is often left off a low-cost quotation. On 0.4 mm coil, coil set shows up as a twisted sheet at the exit. Seven or nine leveller rolls before the first stand are cheap insurance. The roll forming machine line<\/a> overview shows where each station sits, and the metal sheet roll forming machine range<\/a> lists the other profiles we build mills for.<\/p>\n

Why 18 to 22 forming stands matter<\/h2>\n
\"Twenty
Twenty forming stands on a long base, with the four column hydraulic cut-off press at the exit.<\/figcaption><\/figure>\n

Each stand bends the strip a little. A 37 mm rib formed over 18 to 22 stands takes roughly 2 mm of bend per stand. Compress that into 12 stands and the bend doubles, causing springback at the crown, coating cracks and a sheet that will not sit flat on the purlins.<\/p>\n

An IBR sheet roll forming machine with 20 stands is the normal build for 0.4 to 0.6 mm coil. Thin 0.3 mm coil or 550 MPa grades need more stands, not fewer. Rolls are GCr15 or equivalent, hardened and polished, on shimmable bearing blocks. Ask for stand count and roll hardness in writing.<\/p>\n

On an IBR sheet roll forming machine, chain drive is standard on economy lines and needs regular tension checks. Gear drive holds register better at 15 to 20 m\/min. Neither changes the profile drawing, only how long the profile stays in tolerance. We have completed 500+ machines, and stand count is the item we refuse to cut for a lower price.<\/p>\n

Cut-off: die shape, length tolerance and edge quality<\/h2>\n
\"Profile-shaped
Profile-matched cut-off die. The blade follows the rib shape so the crown is not crushed at the sheet end.<\/figcaption><\/figure>\n

The cut-off die has to match the rib profile. A flat blade crushes the crown and leaves a flared end that will not lap. A profile-matched die closes around the formed sheet, so ribs keep their shape right up to the cut. On an IBR sheet roll forming machine, stop-and-cut hydraulics with a 4 kW pack suit 10 to 12 m\/min.<\/p>\n

An encoder on the forming stand sets length. Expect plus or minus 1 mm on a 6 m sheet and plus or minus 2 mm on a 12 m sheet. Larger drift usually means encoder slip or a worn die guide, not a software problem. Measure three sheets at the start of a run and three at the end.<\/p>\n

Ask for a flying shear only above 20 m\/min. It keeps the strip moving and gives the cleanest end, but costs more and needs more maintenance than a stop-and-cut press. For most roofing plants it is not the right spend.<\/p>\n

Curving and crimp options for long roofs<\/h2>\n

Cranked or curved sheets need a curving station after the mill. It is a separate three-roll machine, not a setting on the IBR sheet roll forming machine. Buying it later is possible, but the mill exit height has to match it, so settle the layout before the quotation is signed. Crimping rolls stiffen the overlap on low-slope roofs. Both options add line length, so measure floor space including the run-out table for the longest sheet.<\/p>\n

Changeover between 686, 890 and a second profile<\/h2>\n

A single-profile IBR sheet roll forming machine has one roll set, one cut-off die and no changeover. It is the cheapest and the most repeatable. A plant selling one profile in volume should buy it.<\/p>\n

For two profiles, the common answer is a double layer roll forming machine<\/a> with two roll sets on one frame and a shared decoiler. The upper set makes IBR, the lower set makes corrugated sheet<\/a> or a box profile. Changeover is a clutch selection and a die swap, roughly 5 to 15 minutes. A standing seam roll forming machine<\/a> is a different layout and belongs on its own line.<\/p>\n

686 and 890 are not a double-layer pair. The overall widths differ by almost 200 mm, so the guide, every stand and the die all change. Plants needing both sizes run two lines, or buy a cassette mill where the forming section lifts out. A cassette costs more up front but keeps one decoiler, one hydraulic unit and one control system.<\/p>\n

Power, control and site requirements<\/h2>\n

A 20-stand IBR sheet roll forming machine at 10 to 12 m\/min typically uses a 5.5 kW main motor, a 4 kW hydraulic pack and about 12 kW connected load. Confirm the plant supply before the panel is built. 380 V 50 Hz, 415 V 50 Hz and 220 V 60 Hz are all common in the markets buying this machine. The IBR machine shipped to South Africa<\/a> case shows a 380 V 50 Hz build.<\/p>\n

PLC and HMI brands belong in the contract, with the inverter, encoder and switchgear. Ask for a ladder diagram and a spare parts list. Chain guards, an emergency stop at both ends and a lockable isolator are the minimum safety items. Every IBR sheet roll forming machine we ship carries an ISO 9001 build record and CE-marked electrical components.<\/p>\n

Acceptance tests before the machine ships<\/h2>\n

Before an IBR sheet roll forming machine ships, run the factory acceptance test on the coil the plant will actually use. A line tuned on soft DX51D behaves differently on 550 MPa coil. Measure the profile, run a full shift, then measure again.<\/p>\n\n\n\n\n\n\n\n\n\n\n
Check<\/th>\nTarget<\/th>\nHow to measure<\/th>\n<\/tr>\n<\/thead>\n
Cover width and rib height<\/td>\nAgainst the signed profile drawing<\/td>\nCalliper on three sheets<\/td>\n<\/tr>\n
Cut length<\/td>\nPlus or minus 1 mm at 6 m<\/td>\nTape on first, middle, last sheet<\/td>\n<\/tr>\n
Side lap shape<\/td>\nTwo sheets nest by hand<\/td>\nDry assembly on the bench<\/td>\n<\/tr>\n
Valley stiffener<\/td>\nPresent in every valley<\/td>\nVisual, both sheet edges<\/td>\n<\/tr>\n
Surface and coating<\/td>\nNo cracks or flaking at the crown<\/td>\nVisual after 30 pieces<\/td>\n<\/tr>\n
Long run stability<\/td>\nSame dimensions after 8 hours<\/td>\nRepeat the first three checks<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

Keep the signed samples as the reference for any later dispute about profile shape. An IBR sheet roll forming machine video<\/a> of the test run helps people who could not travel, and the request a quote<\/a> form is where to send the coil grade, profile drawing and plant supply.<\/p>\n

Frequently asked questions about IBR sheet roll forming machines<\/h2>\n

Q: How many forming stands does an IBR sheet roll forming machine need?<\/strong>
\nA: Plan on 18 to 22 stands for 0.4 to 0.8 mm coil, with 20 as the usual build. Fewer stands force each pass to bend too far, causing springback at the crown and cracks in the zinc coating.<\/p>\n

Q: What coil width does an IBR sheet roll forming machine need for 686?<\/strong>
\nA: The drawing calls for 740 mm overall to give 686 mm effective cover. IBR 890 needs 938 mm overall for 890 mm cover. Confirm both against the drawing supplied with the machine, because the guide and cut-off die are cut for one width only.<\/p>\n

Q: Can one IBR sheet roll forming machine make both 686 and 890?<\/strong>
\nA: Not with a spacer adjustment. The strip widths differ by almost 200 mm, so the guide, all stands and the die must change. Plants run two lines or a cassette mill. A double layer machine pairs profiles sharing a coil width, such as IBR and corrugated.<\/p>\n

Q: How fast does an IBR sheet roll forming machine run?<\/strong>
\nA: A standard 20-stand line runs 10 to 12 m\/min and makes about 3,000 linear metres in an 8 hour shift after coil changes. Economy lines run 6 to 8 m\/min. Lines at 15 to 20 m\/min need gear drive, a flying shear and an auto stacker to pay back.<\/p>\n

Q: What cut length tolerance should an IBR sheet roll forming machine hold?<\/strong>
\nA: Plus or minus 1 mm on a 6 m sheet and about plus or minus 2 mm on 12 m, from an encoder driven stop-and-cut press. Measure three sheets at the start of the run and three at the end, not one in the middle.<\/p>\n

Q: Does an IBR sheet roll forming machine need a curving unit?<\/strong>
\nA: Only if the plant supplies cranked or curved sheets. A curving station is a separate three-roll machine downstream of the mill, so decide at the order stage while the mill exit height and run-out table can still be matched to it.<\/p>\n

Q: Which coil grade and coating belong on the order?<\/strong>
\nA: ISQ 550 is the common South African high-strength grade, in the same strength class as G550 and S550GD. Use Z180 inland and Z275 or aluminium-zinc near the coast. SANS 994 and SANS 121 set the local requirements, so confirm current editions before the roll gap is machined.<\/p>\n

Q: What should the factory acceptance test include?<\/strong>
\nA: Run at least 30 sheets from the production coil, then check cover width, rib height, cut length, side lap fit and coating at the crown. Assemble two sheets by hand to prove the lap closes, repeat the measurements after an 8 hour run, and keep the samples.<\/p>\n

Last updated: 2026-11-08
\nArticle Changelog
\n2026-11-08: Rebuilt the page from 316 words. Added the IBR 686 and IBR 890 profile drawings, four specification tables, eight FAQs, six workshop photos, cut-off and changeover details, and a factory acceptance checklist.
\nNext Review Triggers
\nSANS 994 or SANS 121 is revised and profile tolerances or coating minimums change
\nA cassette mill or flying shear becomes a standard option on the IBR line
\nA new IBR pan count or cover width enters the Southern African market<\/p>\n