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Rollforming

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.

 

Uncoiler

Uncoiler or decoiler for master coil handlingEvery rollforming line requires some method of feeding sheet metal to the rolling mill.  The uncoiler (also known as the decoiler) is the most common auxiliary piece of equipment purchased when buying a roll former.  Our uncoilers are available both in standard designs and custom configurations.  Engineered to meet rigorous use within all industries including, stud and track, automotive, shelving and racking, appliance and all metal parts manufacturing industries.  Competitively priced our uncoilers meet the demands of global fabricators.

Engineered for your industry; reliable and durable uncoliers

A complete line of uncoilers designed and engineered to meet the demands of your industry.  Optional coil cars combinations are available to help increase production work flow.  Integrated hold down arms and braking systems offer an increased level of security and operational performance.   Built to last these reliable uncoiling systems make easy work when handling large master coils.

Reduce downtime with dual and multihead designs

Having the ability to pre-load a coil in order to minimize change over time is critical for many operations.  The dual head and multihead designs do just that.  Now you can load up to 5 coils of any width and material type to keep your production flowing smoothly.

Capabilities

  • Traversing base designs up to 14″
  • Powered feed rewind and unwind
  • Single and double end coil stations
  • Capacity range 2,000 lb up to 45,000 lb
  • Coil safety hold downs
  • Rotating base and expanding hydraulic design

Options

  • Powered – power feed
  • Hydraulic braking
  • Hold down arm
  • Multihead design

Contact us today for more information on uncoiler equipment for your steel material handling needs.

 

Machines for manufacturing metal products

Rollforming machineOne of the most common places you will find a rollforming machine is in the fabrication of building and construction materials.  A wide range of common building materials are manufactured through the roll forming process.  The machinery is generally single function in nature producing one specific profile or small variations with in it.

Standard configuration of a rollforming line

Most metal forming machinery setups use a common line configuration.  At the start of the process uncolier (also known as decoliers) hold the master coil and fed the line.  Depending on the profile requirements and the quality of the steel coil a flattener may be need to bring material thickness consistency to the mill.  Lubrication is also added at this stage to reduce friction through the bending process.  When forming a more complex or heavy gauge material lubrication can be added at critical locations within each stand.

Many manufacturers of steel products can benefit from quick change over tooling. One of the most common ways to achieve this is through rafting or cassette roll tolling.  This second set mounted on a base plate can be easily removed and ‘changed over’ in order to manufacture a new steel profile.

Cold forming machine

Once the continuous steel sheet enters the rolling mill powered tooling pulls the sheet in and progressively forms and bends the steel in to the desired shape and profile.  The number of stands needs for any roll former is dependent on the  complexity of the shape.  The forming of metal places large stresses on the overall design and construction of a mill.  Careful consideration and engineering is required in order to construct a long lasting machine.

Once the sheet metal leaves the mill it is often in its final shape.  Now presses are used to cut to length continuous strips of metal specific to customers orders.  The best roll forming machines offer a range of punch and cut off dies and designs allow for an endless combination.

For more information about our full line of rollforming machines 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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