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Roll former

How to rollform steel studs and tracks

Industrial roll former used to manufacture stud and trackOne of the most common uses for a roll forming machine is the manufacturing of steel studs and tracks.  Steel framing is commonly used in the commercial high-rise building and construction industry.  Lightweight and easy to assemble this alternative to standard wooden stick framing has gained popularity in the commercial sector.  So how are these common low cost parts manufactured.

7 steps to rollforming studs and tracks

There are 7 basic steps to foll forming studs and track.  Most industrial machines can manufacture all common sizes and profiles used for common drywall construction. The typical configuration for producing high volume parts includes 7 major systems.  Each performs a unique function through the forming process.  From preparation of the metal for bending to cut outs and holes needed for running wires and plumping on the job site.

1) Uncoiler

The uncoiler holds the master coil and feeds in to the line.  Alignment is critical here as any deviation will be amplified through the rolling process causing defects in the final product.

2) Flattener

The flattener add another step to pre-forming quality control.  Having a consistent material thickness as it feeds in to the rollformer is also critical to producing a high quality part.

3) Lubricator

The lubrication unit ensures the metal is easily bent as it passes through each roll stand.  Without this the metal would bind and rip apart as the rolls form the profile of the stud or track.

4) Pre-punch press

Pre-punching is a custom function and is where the holes and notches are made in the stud.  These are located in a common location to allow for wiring and plumping to easily pass through the studs.

5) Mill

The mill is where the forming action takes place.  The roll tooling bends and shapes the sheet metal in to the desired stud or track profile.

7) Cut-off press

The final steps is to cut off to the desired length either a stud or track.  Lengths can vary to fill an order size.

For more information see our stud and track rollforming machine lines.

 

Weather seal rollforming machines

Many products utilize weather seal strips as an integral part of the design.  The difficulty has always been how do you join the weather stripping with the metal framing?

Our latest rollforming advancements now mechanically crimp the weather strip with the profile.  With the introduction of the vinyl weather stripping in to the process of roll forming you can now mechanically fasten the two together.  By combining these two processes in to one machine you now have a superior mechanical bond in an uninterrupted continuous profile.   Your production capacity, efficiency and overall quality have now increased.

Benefits of a weather seal rollformer

  • Single process
  • High strength mechanical fastening
  • Endless lengths
  • Increased productivity
  • Custom design and profiles

Common applications

Some of the most common uses for inline weather seals can be found in garage doors, windows, automotive doors, hotel and office revolving doors and large utility and maintenance doorways.

For more information contact us today.

Purlin

One of the more common building and construction materials manufactured by cold forming steel is the purlin or girt.  This structural steel (versatile) component is an essential part of any building project.   the roll forming machine is a perfect match for purlin production.

Production line considerations for making purlins

C/Z Purlin roll formerBy their very nature purlins are straight uniform designs.  The common profiles include C, Z and Sigma and include common hole and notch placement.  As with many sheet metal materials used in the building industry having this type of uniformity and consistency allows manufacturers to produce high volume low cost products.

Considerations for roll forming purlins

The cold forming of any heavy gauge material such as that used in the fabrication of purlins requires specific machinery.  The rollformer is no exception.  As sheet metal material thickness and hardness increases so do the requirements of all components and auxiliary equipment attached to the forming mill.

Design considerations

  1. Uncoiler design
  2. Uncoiler bracking
  3. In-feed guide system
  4. Mill base and support system
  5. Roll tolling
  6. Tooling stands
  7. Hole punching systems
  8. Cut-off press

Each of these areas within the forming process is critical when manufacturing C/Z purlins.   Minimizing the quality of any of these will result in poor quality product and high re-work costs.

For more information on our purlin roll formers contact us today.

 

 

Solutions for manufacturing steel drywall studs used in steel houses

Rollforming machines used for making steel productsOne of the quickest ways to manufacturing an interior wall is to use steel framing and drywall.  This combination is quick to build and requires little training.  The drywall framing  dimensions are the same as those used in the wooden stick building process and are inherently more flexible.  Scrap material is minimized and recyclable unlike wood products.

Pro’s and con’s of a job site stud rollformer

One of the first things a company that is looking to manufacturer steel building studs is to do so with a portable stud maker.  These machines are small and lightweight my nature and produce a reasonable steel stud.  Here are the basic pros and cons of such a machine.

 

Portable rollformer pros and cons
Pro Con
Speed Not the faster rollformer on the market
Flexibility Can produce what you need when you need it. Requires many manchine changes to switch over product profiles
Capabilities Low volume Not built for long term high volume product
Cost Less than industrial forming machines Ware and tare at a high rate

Industrial stud and track rollformer

Industrial stud and track machines are capable of roll forming a wide range of profile shapes with minimal interruption.  These machines can switch between stud and track with one push of the button.  Changing flange heights and web widths are also quick and easy.

Industrial roll forming machine: pros and cons
Pro Con
Speed  Very fast Requires high volume production to offset costs
Flexibility Can produce any common stud sizes in one machine
Capabilities High volume production and highly flexible profile output
Cost Expensive compared to other machines Large ROI

Prefabricated building machine

A growing market is the prefab or prefabrication market.  This is where wall production and roofing building is all done inside a factory.  The sections are “prefab’d” and sent off to the job site for assembly.  This method reduces some costs of fabrication and increase overall quality.

Pre-fab roll forming machines: pros and cons
Pro Con
Speed Slow speed
Flexibility Can produce all the components needed to assemble a steel stud drywall or roofing Requires specific architectural drawings for each steel house
Capabilities Low volume
Cost Costs can be at par with other roll forming techniques

Read more about our stud and track rollforming machine and how it can help to reduce the cost of manufacturing steel drywall framing components.


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