Fully Automatic Highway Guardrail Rolling Forming Machine

Two Wave and Three Wave Guardrail By One Machine Rolling Forming Machine

Description:Automatic two wave three wave highway guardrail roll forming machine makes standard W-beam and thrie-beam guardrail panels. Online punching, servo flying cut, PLC control, meets AASHTO M180, EN1317 road safety standards.

Two Wave & Three Wave Highway Guardrail Roll Forming Machine

The two wave and three wave highway guardrail roll forming machine is a heavy-duty continuous cold roll forming line for manufacturing corrugated steel crash barrier panels for road infrastructure. It can produce both standard two-wave W-beam guardrail and high-strength three-wave thrie-beam guardrail by changing roller cassettes, widely used on highways, national roads, mountain roads, bridge median dividers and high-risk roadside zones.

Road safety contractors and traffic facilities manufacturers need stable, dimension-consistent guardrail panels that pass crash test standards. This guardrail forming line eliminates bending distortion, uneven hole spacing and out-of-tolerance wave height common with old semi-automatic equipment. Finished panels fit standard posts, spacers and connection hardware directly without secondary correction.

Machine Composition & Production Process

A complete highway guardrail roll forming line includes hydraulic uncoiler, coil guiding unit, heavy leveling station, servo feeding, online hydraulic punching station, multi-pass roll forming groups, servo flying cutting system and automatic stacking table.

Hot-dip galvanized Q235 or Q355 steel coil feeds continuously. The strip goes through progressive forming rollers to create W-beam or thrie-beam corrugations. The integrated punching unit pre-drills all bolt holes for splicing and post mounting inline. The PLC touchscreen sets target length, batch count and hole pitch. After flying cut, finished guardrail beams slide onto the stacking table automatically. Only one operator is required to monitor the whole production cycle.

Difference Between Two-Wave W-Beam and Three-Wave Thrie-Beam Guardrail

Two-wave W-beam is the mainstream general-purpose guardrail, finished width around 312 mm. It is lightweight, economical and used for common highway shoulders, provincial roads and low-to-medium speed traffic sections.

Three-wave thrie-beam has three corrugations, finished width around 506 mm. Its thicker cross-section delivers higher impact resistance and energy absorption capacity. It is specified for steep embankments, bridge approaches, sharp curves, heavy truck lanes and high-risk median barrier projects.

Our interchangeable roller cassette design lets one base machine switch between these two profiles, which helps factories accept mixed orders and reduce separate equipment investment.

Core Machine Advantages

Heavy-duty forming rollers: Rollers are made of Cr12MoV or GCr15 steel, vacuum heat treated and hard chrome plated. Hardness reaches HRC 58–62, long service life under continuous heavy steel forming.

Strict dimensional tolerance: Beam width, wave depth and hole position tolerance are controlled within ±2 mm, fully compatible with AASHTO M180, EN1317 and other international guardrail specifications.

Integrated online punching: Punching station completes all mounting holes in one pass, no extra stamping press needed. Hole pitch stays uniform for easy field assembly.

Servo flying cut: Non-stop flying cutting keeps production continuous, avoids speed loss and cut-end deformation compared with stop-cut designs.

High stable production speed: Working speed 8–16 m/min, adjustable according to material thickness (2.0–4.0 mm galvanized steel).

Robust welded machine frame: Thick steel plate main frame reduces vibration during heavy forming, keeps precision after years of high-volume production.

Main Application of Finished Guardrail Panels

Panels from this machine supply road safety projects worldwide: highway roadside barriers, road median separation barriers, mountain hazardous section guardrails, bridge edge protection, tunnel entrance safety barriers and industrial park perimeter crash barriers.

Hot-dip galvanized guardrail beams have excellent anti-corrosion performance, suitable for coastal rainy areas, high-altitude cold zones and harsh outdoor environments. We support custom profile development if you need special local standard guardrail drawings for Africa, Southeast Asia, Middle East, Europe and America.

Technical Parameters Reference

Available profiles: 2-wave W-beam guardrail, 3-wave thrie-beam guardrail

Suitable material: Q235 / Q355 hot galvanized steel

Material thickness: 2.0–4.0 mm

Control system: PLC + touch screen

Punching: Hydraulic inline punching

Cutting system: Servo flying cut

Drive: Gearbox heavy transmission

Power supply: Customized voltage (380V, 415V etc.)

Roller stations: Configured for W-beam or thrie-beam

After-Sales Service Package

We provide machine layout drawings, foundation drawings, electrical diagrams, operation manuals and operation training videos. Overseas engineer commissioning and operator training are available on request. We keep common spare parts in stock: forming rollers, cutting blades, hydraulic seals, punching dies and electrical components for quick delivery.