Short answer: A rack beam roll forming machine forms the horizontal load beam of pallet racking from coil: a step beam is one open section with a step that carries the decking, while a box beam is a closed tube made from two sections, or one section closed by a seam. The line forms and cuts the beam; connector welding is a separate scope. We build it in our Xiamen factory to your drawing and quote within 24 hours.
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We manufacture every Halcyon machine in our factory in Xiamen, China — more than 35 years of roll forming manufacturing experience. Reference projects · trial run before shipment · quotation within 24 hours.
What is a rack beam roll forming machine?
Pallet racking has two main members: the vertical uprights (slotted columns) and the horizontal load beams that carry the pallets. A rack beam roll forming machine makes the beams. Buyers also call it a box beam roll forming machine, step beam roll forming machine, racking beam machine or shelf beam machine. The line forms the section from coil, closes it if it is a box beam and cuts it to bay length; connectors are welded to each end afterwards.
Box beam or step beam?
| Question | Step beam | Box beam |
|---|---|---|
| Section | Open section with a step for decking panels or wire mesh | Closed tube, from two formed halves or one section closed by a seam |
| Line scope to confirm | Roll former + cut-off | Roll former(s) + closing (seam or welding) + cut-off |
| Typical use | Selective pallet racking where decking sits in the step | Selective pallet racking with heavier or longer bays |
| What sets beam capacity | The rack designer's section, steel grade and testing | The rack designer's section, steel grade and testing |
| After the roll former | Connector (end plate) welding to each beam end | Connector (end plate) welding to each beam end |
For the vertical members see our rack upright roll forming machine.
Machines in the line
| Unit | Job | Confirm in the quotation |
|---|---|---|
| Decoiler and leveller | Feeds and flattens the coil | Coil width, weight and thickness range |
| Roll former | Forms the step beam or the box beam section(s) | Beam drawings, number of stations, roll material, changeover between heights |
| Closing unit (box beam) | Joins the two halves or closes the seam | Seam lock, clinching or welding method, as your rack designer specifies |
| Flying or stop cut-off and PLC | Cuts beams to bay length | Length tolerance, PLC brand, voltage |
| Connector welding (separate) | Welds end connectors to the beam | Whether a welding station or robot cell is in scope, or done in your plant |
| Run-out table / stacking | Collects finished beams | Beam lengths, manual or automatic stacking |
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How we quote and test
- You send each beam drawing (every height you make), steel grade, thickness and lengths.
- Our engineering team in Xiamen proposes the line, closing method and scope in writing.
- Before shipment we run the line with your coil; you receive the trial video and measured samples of each beam section.
- FOB China shipment with manual, electrical drawings and installation support.
The trial checks the formed beam against its drawing and the fit of the connector you supply; it does not establish the load capacity of the rack, which is your rack designer's calculation and testing.
What affects the price
- step beam only, box beam only, or both;
- number of beam heights and how they change over (spacers, quick-change rafts or separate tooling);
- closing method for box beams;
- cut-off type, line speed and PLC brand;
- stacking and whether a connector welding station is included;
- delivery terms (FOB/CIF), installation and training.
Rack beam roll forming machine FAQ
What is the difference between a box beam and a step beam?
A step beam is an open roll-formed section with a step along the top edge that holds decking panels or wire mesh. A box beam is a closed tube, usually made from two formed sections joined together or one section closed by a seam. The section, steel grade and load rating are set by your rack designer.
Can one machine make rack uprights and beams?
Do not assume it. Uprights, step beams and box beams use different sections, punching and joining, so they usually need separate tooling or separate lines. List every approved drawing and ask which operations the quotation actually includes. For the upright line see our rack upright roll forming machine page.
Does the line weld the beam connectors?
Usually the roll forming line forms, closes and cuts the beam; welding the end connectors is a separate station or done in your own plant. Tell us which you need and we confirm the scope in writing.
How much does a rack beam roll forming machine cost?
It depends on step or box section, the number of beam heights, the closing method, cut-off type, stacking and whether a connector welding station is included. We do not publish a price range for this line yet: send your beam drawings and we reply with a configuration and price within 24 hours.
What should I send for a quotation?
Beam drawings with tolerances (each height you produce), steel grade, thickness and coating, beam lengths, closing method required by your rack design, connector type, target output and the available voltage.
Related: rack upright roll forming machine, solar mounting roll forming machine, how to choose a roll forming machine.
Send your beam drawings – quotation within 24 hours.
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