What a T-16 TDF Flange Former Does
A TDF flange former T-16 is a heavy-duty roll-forming machine that forms the TDF (Transverse Duct Flange) profile along the two long edges of a rectangular duct panel. The formed edge replaces the traditional angle-iron frame: panels lock at the corners with cleats and seal with gasket, with no welding and no riveting. The T-16 designation marks the heavy frame and roller class — in the Preda lineup the T-16 handles up to 1.6 mm galvanized sheet, where the T12 class stops at 1.2 mm.
For shops fabricating larger trunk ducts, higher-pressure systems, or simply running thicker stock on the same line, the T-16 class keeps flange geometry repeatable. This guide covers the specifications that matter, the roll tooling, setup, throughput math, inspection points and the checks to run before releasing a purchase order.
T-16 vs T-12: What Actually Changes
The two machines share the same flange concept, but the engineering differences decide which gauges each can form without roller deflection. Roller deflection is the failure mode buyers underestimate: when shafts bend under load, flange height drifts along the panel and corners will not close square.
| Specification | T-12 class | T-16 class |
|---|---|---|
| Galvanized sheet range | 0.5–1.2 mm (18 ga) | 0.5–1.6 mm (16 ga) |
| Stainless capability | ~0.8 mm | ~1.0 mm (20 ga) |
| Main motor | 2.2–3.0 kW | 3.0 kW (duplex T-16-2: 5.5 kW) |
| Roller steel | 45# steel, quenched | GCr15 bearing steel, quenched and tempered |
| Forming speed | 10–12 m/min | 8–12 m/min |
| Machine weight | ~840 kg | ~840 kg single / ~2,200 kg duplex |
| Typical duct segment | Light commercial | Trunk duct, heavy gauge, larger panels |
Read the table this way: if 80% of your work is 0.5–0.8 mm galvanized, the T12 class forms faster at lower cost. The moment 1.2–1.6 mm sheet becomes routine — thicker trunk sections, industrial ventilation, retrofit jobs where stiffness is specified — the T16 stops being an upgrade and becomes the correct tool.
Roll Tooling: Steel Grade, Hardness and Bearings
Roller material and heat treatment
Forming rollers are the wear parts. In the heavy class they are made from GCr15 bearing steel, quenched and tempered to high hardness, then ground. The metallurgy matters more than the label: high contact-fatigue strength and dimensional stability after heat treatment keep the profile true over years of daily production. Lower-grade rollers lose profile tolerance after a few hundred tonnes of sheet and the flange bead starts to open.
Shafts and bearings
Ask the supplier which bearings are fitted. Ball bearings, rather than traditional needle bearings, handle the combined radial and thrust load of edge forming far better and show dramatically longer service life. Also ask about roller and axle replacement: a credible manufacturer supplies replacement rollers and axles for the whole life of the machine — this single answer separates real factories from trading companies.
Installing the T-16: Power, Footprint and Workflow
A single-head T-16 needs a 3 kW three-phase supply and roughly 2,550 × 700 mm of floor space; the duplex T-16-2 runs on 5.5 kW and occupies about 2,450 × 2,250 mm. Plan the infeed and outfeed tables at working height, and leave a 1 m service corridor behind the machine for roller changeover. Position the machine next to your shear or plasma table so cut panels flow one way — every U-turn an operator makes with a panel costs seconds and edge damage risk.
Throughput: Speed, Gauge and Real Output per Shift
Published line speed for the T-16 class is 8–12 m/min, and it is not a constant. Forming speed has to come down as gauge and profile complexity go up: 1.6 mm galvanized at 12 m/min will stress both the rollers and the operator. A realistic planning number is 8–10 m/min on mixed gauges.
Work the math from the panel, not the motor. A 1,200 × 500 mm duct panel needs two passes — one per long edge — so roughly 3.4 m of formed edge per panel. At 9 m/min effective speed plus handling, one operator produces roughly 150–200 formed panels per shift. Compare that with manual flange fabrication, where a single angle-iron flange takes a fitter many times longer, and the machine pays back primarily in labor and dimensional consistency, not just speed.
Flange Quality: What to Inspect on Every Panel
- Flange height at panel start, middle and end: variation should stay within ±0.3 mm along a 2 m panel.
- Bead closure: the formed bead must be fully closed with no slit or orange-peel on the bend radius.
- Edge burr direction: burrs should face outward so corners close without interference.
- Corner relief: notched corners must clear the flange at 90° without filing.
- Surface: no roller marking, scratching or galling on pre-painted or stainless sheet.
- Gauge setting: check the roller gap matches the actual gauge running — 0.5 mm sheet on 1.6 mm gaps produces a loose, unusable profile.
Common Faults and How to Fix Them
Flange height drifting along the panel is almost always roller gap or infeed setting, not a motor problem. Re-shim the roller gap for the gauge in use and check the infeed guide pressure. Bead opening at the ends points to insufficient forming passes or a worn final roller — measure the profile against a new sample. Abnormal noise after long service means bearings: stop and inspect, because running a failed bearing scores the shafts. Sheet slipping in the rollers usually indicates worn knurling or too light an infeed pressure on thin gauge.
Preventive maintenance is simple and non-negotiable: clear swarf from the roller area daily, apply lubricating oil to the working rollers on schedule to prevent rust and wear, and log every gauge change together with its roller gap setting.
Factory Acceptance Checklist Before You Order
- Run your heaviest gauge (e.g. 1.6 mm GI) and your most common gauge (0.5–0.8 mm) during the same visit — watch both, not a demo on one material.
- Measure flange height at three points on a 2 m test panel; ask for the numbers to be recorded on the inspection report.
- Confirm roller steel grade and heat treatment in writing (GCr15, quenched and tempered, ground).
- Confirm bearing type and that replacement rollers and axles are supplied for machine life.
- Check the control panel wiring, emergency stop placement and CE documentation for your market.
- Verify lead time and stock status — standard TDF machines are commonly stocked, with delivery in days after order confirmation.
- Agree payment terms (typically 20% TT deposit, balance before shipment) and the packing method — wooden case with channel-steel chassis for machines of this class.
FAQ
Can the T-16 form 1.6 mm stainless steel? No. The 1.6 mm rating applies to galvanized steel; stainless is limited to around 1.0 mm because of its higher yield strength.
Can I run 0.5 mm sheet on a T-16? Yes, but re-set the roller gap for light gauge. Running thin sheet on heavy-gauge settings gives a loose profile and edge wave.
Does the T-16 produce TDC profiles too? The single-head T-16 forms the TDF profile; duplex versions add a second forming head so both TDF and TDC can be produced on one frame.
How many operators does it need? One at the machine plus one at the outfeed table is typical; the duplex T-16-2 needs two because throughput doubles.
Choosing between T12 and T16 is a materials question before it is a price question. List every gauge your shop ran last quarter, find the heaviest recurring gauge, and size the machine so that gauge sits comfortably inside the middle of its range — not at its limit.