Top roll former designs for manufacturing steel framing studs

Steel framing studs are used in almost all commercial building and construction projects.  They are lightweight versatile and relatively inexpensive to manufacture.  There are many steel framing advantages that can be used in residential projects too.  So what roll forming design works best for steel stud and track manufacturing?

The top roll forming machine design features

When looking for a steel stud machine you'll find that they are grouped in to two main categories.  The first is job site systems that produce metal studs where you build, on the job site.  These machines provide low volume and generally lower quality products.  They have a place in the market but when it comes to large production runs they simply don't measure up.

The second group of roll forming machines are the industrial grade systems.  These produce large volumes of studs or tracks with various features such as knock out holes for plumbing and electrical wiring.  Investing in this roll former is a serious proposition.  You not only require the mill itself you'll need both feeder and discharge equipment to handle the large scale production.

The design of a rollforming line is generally determined by the profile of the final product.  The more complex the design is the more stands and roll tolling you'll need.  This in turn increases the foot print in the plant and auxiliary equipment to support it.

What rollforming designs work best for steel framing studs?

Although there are many ways to manufacture steel studs in general the best method is large scale production.  This process will scale both in quantity of studs manufactured and in profile designs.  Many industrial grade roll formers can switch over to different stud and track profile designs allowing manufacturers the flexibility to meet market demands.

For further details on steel stud and track roll forming equipment check out the rest of this blog.

How lightweight steel framing roll forming machines increase productivity

The metal framing industry produces a large volume of steel studs and tracks every day.  To keep up with this demand suppliers must utilize high speed roll forming machines that are capable of producing large quantities of high quality parts.

Types of light steel framing machines 

There are several types of systems on the market today for producing light gauge steel framing.  They are often broken down in to 3 categories.  Some of the world's best steel framing machines can fit in to multiple categories.

Portable roll formers - These systems are found on the job site of many small building projects.  Capable of producing many common sizes needed these low cost machines produce low volume and generally low quality parts.

Industrial roll forming machines - This is the high volume high quality rollformer that can produce a large number of profiles at high speeds and high quality levels.  The cost is also very high and will generally pay for itself if the market demands can meet it's output.

Pre-fab systems - This is somewhat of a cross between portable and industrial roll forming.  The key here is having the ability to produce each component needed in sequence for assembly of the building.  Manufactures can kit together all the parts in order so that at the job site assembly can build as fast as possible.

Regardless of what type of rollforming system you are looking to purchase each comes with a clear benefit and risk.  Before you purchase a cold forming machine check with a top manufacturer to get the full story.

Steel Framing : Its Benefits and Effective Technique of Fabrication

Framing of a construction project is the basic structure around which the other materials rely for support. The strength, durability and endurance of steel make it a good choice for framing.

The construction of super structures, bridges and high rise buildings has been made possible with steel framing roll former. Steel framed buildings are designed to withstand adverse weather, wind and seismic loads caused by hurricanes and earthquakes. A building with a 'heart' of steel is indeed designed to stand the test of time.

Some typical benefits of steel framing include:

• Short and predictable construction schedule
• Higher strength to weight ratio than most other building materials
• 100 percent recyclable nature
• Inorganic material that does not rot, warp, split, crack or creep
• Stable dimensions that do not expand or contract with moisture content
• Consistent Quality

The cost effective technique that can be used to create high strength steel for framing, is roll forming. It is a continuous metal forming process used to fabricate shapes of identical cross section. Roll forming augments the metal with rigidity and strength and has distinct advantages over alternative metal forming methodologies like brake pressing, stamping and folding. Some of these are:

• Ability to create longer dimensions for the metal.
• Consistency and uniformity of profile.
• Very close and tight tolerance.
• Inclusion of all secondary operations in same process.
• Superior surface finish

With roll forming, the production of high strength structural steel for a variety of engineering applications, is made simple and cost effective.

C Channel Roll Machine

Stud and Tracks in Steel Framing

Steel framed buildings are made to effectively withstand adverse weather, wind and seismic loads caused by hurricanes and earthquakes. For light steel framing used in interior wall partitions, the metal is fabricated in different shapes, thicknesses, sizes and finishes. Every steel component used in framing has a specific function in the wall assembly. Choosing the correct size and thickness for the component depends primarily on the spacing of the framing members and height of the wall. Typically, the centre to centre stud spacing for interior applications is 12 inches, 16 inches or 24 inches. Other considerations in the selection process include the makeup of the wall finishes, whether the wall finishes are to be applied on one or both sides, and impact resistance requirements, if applicable. Generally the interior walls of a public space may require more resistance to impact than those of a private office or home.

The typical framing components for an interior wall system include:

• C-shaped stud

• U-shaped track

• Furring channels

• L- headers

The studs and tracks for light steel framing are roll formed from oxidation resistant galvanized steel. The C shaped studs used to support wall panels are of a regulated cross-sectional size and configuration and usually the stud elements are disposed to extend between track elements that in turn are of channel cross-section. The U-shaped track is fixed by fasteners to the floor and ceiling of a building, and the studs are then extended between the floor and ceiling tracks and joined to the track. The internal flange to flange width of the tracks usually corresponds to the exterior width of the studs so that the studs are closely fitted with the tracks.

The track and studs with thermal break are joined together by welding or by power driven self-drilling and tapping screws and this too is made largely possible by the roll forming machines.

Roll Forming Equipment

Metal Stud Channels: Roll Forming Machines

The strength and durability of metal framing makes it the ideal process used in construction of bridges, buildings and various machines. A metal stud channel is used for framing in a number of ways. These channels can also be constructed with inward flanges to add extra strength to the structures. The flanges are used to mount special nuts, braces, connecting angles to join lengths of metal channels and connect pipes, wires, bolts and rods into the channels structural system.

Forming Machine for Metal Studs

Steel stud channels can also be equipped with channel covers that snap or slide on to form a duct for wiring or a cable. Holes can be drilled in steel stud channels during their fabrication through the roll forming process. These facilitate interconnection and fastening a stud underlying building structures.

Used Roll Formers

The use of steel stud channels including C channel and U channel used in steel framing proves to be very cost effective as they can be assembled very rapidly with minimal tools by moderately trained labour. Modification and additional installation in metal stud systems is also fairly easy.

Steel stud channels can be produced with quite a few metal fabrication techniques such as stamping, extrusion and press brake bending but roll forming is considered the most efficacious process for producing high strength and quality rich steel studs.

Metal stud and strut continue to replace angle iron and other conventional metal shapes and it is therefore essential to retain the integrity of the support system by continuing to use structural grade materials. A typical stud building machine that employs roll forming technique makes cost effective production of such metal parts largely possible.

Benefits of high quality roll tooling

The fabrication of steel studs and tracks has become almost common place.  From portable lines to high-speed fully automated machines steel framing components are now produced at great numbers.

How to increase production of roll formed products?

Many steel building components are manufactured through the process of cold forming.  This process uses 'cold' sheet metal coils feed through a rolling mill where roll tooling bends and shapes the flat metal in to a specific shape.  Although simple in theory the process is quite complex.  One of the easiest ways to increase production rates is by having quality roll tooling engineered for rollformers.

Roll former roll tooling

Understanding the specific heat, vibration and wavering requirements of tooling used in the roll former lines is key to manufacturing high quality tooling.  Companies that manufacture both the equipment and tooling and stands have a better capability of supplying the correct parts for your machine.

The benefits of quality machined roll tooling are:

• Reduced web rippling
• Longer life
• Lower maintenance
• Improved 'fit'

The key is having a roll tooling supplier who understands the requirements of rollforming.  Not all machine shops are capable of producing precision tooling for the metal forming process.

Roll forming deck line machinery adds strength to steel framing projects

Steel framing buildings are designed to take advantage of the inherent benefits of metal components.  One such component is the steel decking.  Steel deck is manufactured through a cold forming process called deck line roll forming.  Sheet metal coils are feed in to a forming mill with progressive roll tooling stands that bend and shape the flat coil sheet in to a specific profile.  Steel deck material is engineered to take advantage of both the depth of the deck as well the ribbing of the deck walls.

Advantages of roll forming decking materials

Manufacturers of metal decking materials are always challenged with how to improve their product.  Providing improved structural integrity, design flexibility and just in time delivery are all major concerns for buyers.  Having the ability to switch between different design requirements such as material thickness and deck depth and width can mean the difference between staying in business or selling your equipment on the used market.

Top features

1. Wide range in material thickness
2. Narrow and wide profile designs
3. Easily replaceable tooling with cassettes or rafts

Learn more on how roof, floor, bridge and composite decking material is roll formed from Metform International.