The rollforming machine

One of the most common building and construction materials is the steel stud and track.  The machine that is used to form these steel studs and track is the "Stud and Track Roll Forming Machine".  The common configuration includes advanced features such as automatic material thickness (gauge) control and material handling systems.  Production rates as much as 500 fpm the fabrication of studs and tracks must roll out without failure.  The rollfromer is an integral part of the success of any stud supplier and is often the heart of the operation.

Drywall Machine

Industrial building and construction projects rely on drywall steel stud systems.  The quick installation and light weight characteristics of steel framing makes this an ideal product.  Many job site forming machines lack the ability to produce stud and track to the right tolerances.  The installation of drywall requires the use of the correct drywall tools.  These tools are engineered to match standard stud sizes used in commercial building.   The drywall machine, or rollformer, must continuously produce the same sizes regardless of the steel coil used.

Stud Rollformer Equipment

The most common installation for stud rollforming includes a number of auxiliary equipment.  This equipment aids in the forming of the sheet metal into the correct studs and channels.  The equipment required in rollform studs includes; 

• Uncoiler
• Flatenner
• Sheet Metal Lubricator
• Pre-cut Dies
• Pre-notching Press
• Rolling Mill
• Roll Tolling Stands
• Post Cut Press
• Flying Cut-off

Option Accessories

Many installations operate at very high speeds.  For stud and track roll forming it’s common to reach line speeds of 500fpm or more.  For the overall operation to be successful manufacturers must keep in mind the post production requirements.  As the forming machine discharges the stud at a high speed material handling equipment is required to stack and package the steel sticks in to bundles.  Automated conveyor systems such as the following are typically required.

• Stacker
• Bundler
• Wrapper

Rollforming Machine Features

Integrating the rollforming machine in to your material handling software is critical to minimizing material waste.  These two systems can ‘speak’ to each other in such a way that loading of specific coils and steel material types are selected.  Having automated features within the roll former such as, auto web width, auto material thickness and auto flange height greatly increase the build to order process.  With pulse generators and photo eye alignment sensors throughout the rolling mill PLC programs constantly monitor the high speed operation of the line.

There are two types of rollforming machines used to manufacture stud and track.  The more common machine is the stud and track rollformer that is used to manufacture drywall studs.  These machines produce studs and very high rates allowing you to produce at a lower per part cost.

The second type of rollforming machine is the structural steel rollformer.  This machine is engineered to handle the larger material and is built “heavy duty”.  The overall functionality is the same as the drywall stud machine however speeds are reduced as a result of the material thickness.

The world leaders that manufacture industrial grade steel stud and track rollforming lines all have installations with the largest suppliers and producers of steel studs.

Learn more about the Stud & Track Rollformers and how they work

Read more about the various features and functions on the stud maker machine in our rollformer blog.

Drywall Stud Machine Lines

Watch the stud and track rollformer in action in this product video

• Drywall Stud Rollforming Video

Stud Rollforming Machine

The cost of steel stud framing is a critical consideration when designing a steel home.  In order to be cost effective manufacturers of light steel framing products utilize high-speed rollformers.  These machines are engineered for high volume production which directly impacts the per part cost.  The second critical factor affecting the metal stud and drywall calculation is the material specifications.   The rollforming machine line speed can reach as high as 550FPM while running non-load bearing 20-25 gauge (GA) galvanized steel coil.  At these speeds the rollformer can maintain specification tolerances on length accuracy of +/- 0.032”

Steel Structural Lines

The manufacturing of structural steel products requires a specialized stud and track rollforming machine.  The material standards, requirements and shape dimensions are all critical when producing load-bearing products.  Typical material thicknesses for floor joists and stud or tracks is 12, 14 and 16 gauge (GA) with a minimum 55 yield stock.  Structural lines include rapid change over designs with integral pre-cut and post-cut dies.  This allows for continuous operation and the ability to change over the flange height and web width virtually with the touch of a single button.

Full integration with high speed automated packaging systems including bundlers, stackers and strapping systems reduce labor costs and per unit costs.  The heavy duty design and construction allows for 24/7 operation under any circumstance.

Custom Roll Tooling Design Services

Many drywall studs require specialized “proprietary” patterns on the web or flange in order to deliver the required structural requirements.  Also, suppliers may want to ‘brand’ their products with embossing their name or product number in to the steel.  All of this requires specialized tooling within the rollformer.   Many of the leading manufactures for steel studs partner with a rollforming machine company that is capable of assisting them in the development and design of their unique roll tooling stud requirements.

Stud and Track Rollforming  Video

• Drywall Stud and Track Machine Video

Rollformers

• Bradbury Stud Mills
• Sen Fung Model SF-240L
• Gasparini C/U Machine
• Samco Greenfield
• Samco Studmaker™
• Samco Workhorse

System Specifications and Capabilities

• Fully Automated Profile Selection
• High Speed Production Rates
• Quick Change Over Tool Design
• Turnkey Software Integration
• Master Bundler and Stacker Packaging Systems
• Automated Material Handling Conveyor Systems

Our History

With over two decades of experience in the industrial machinery business we have built a reputation as knowing your business.  Our industrial equipment experience spans many industries and includes a range of product specialties such as rollforming, uncoilers, punch presses and conveyor metal detection equipment.

Industry Stewardship and Position in the Market

Building equipment is only part of the commitment we bring to the industry.  Our approach is to deliver both what our customer needs and engage with the industry as a whole to improve the future.

• Industry Leadership
• Innovative Designs
• Development and Research 

Rollforming Customers 

Companies that use rollforming systems in the manufacture of their drywall stud and tracks

• Clark Dietrich
• Bailey
• Imperial Group
• Studs Unlimited
• California Expanded Metal Products Co.
• Custom Stud, Inc.
• MarinoWare

The Samco Greenfield Studmaker is an industrial leader in the manufacturing of steel framing channels.

The Samco Studmaker has been designed to manufacture studs from 3 5/8" to 14" in width with flange heights ranging from 1 3/8" to 2 1/2".  Material thickness can range from 20 (.039) to 12 (.112) with 3" rollformed deep leg tracks.  All of this can be manufacturered without shear's or dies.

Samco Roll Forming

The "Samco Roll Forming" machine Studmaker is designed for quick change-overs, typically under 20 minutes, which in turn allows you to manufacture 24/7.  This high speed capability and size change speed is another innovative design first introduced by Samco Machinery ltd.

Piercing and Cutt-Off

Optional pre-pierce and pre-shear hydrex dies can be provided on the Studmaker.  If you have an older model you can benefit from the upgrade of these accessories.

The manufacturing of steel stud and track used in today's industrial construction relies heavily of through-put.   A highly commodity based industry the manufacturing of steel framing is all about cost.  The cheaper you can pump out the sticks the better off you are, plain and simple.  Some manufacturers design their light gauge framing components with special ribbing or knurling to separate themselves in the marketplace.  Now, this could very well be a highly valuable feature when constructing interior steel walls.  However, at the end of the day most builders will decide largely based on cost.

How to manufacture steel framing studs with a roll former.

This is where the stud and track roll former such as the Samco Greenfield come in.  These machines can manufacture virtually all of the sizes required for conventional steel stick framing.  They can also integrate special features such as knurling or 'stampings' in to the web of the stud.  With the ability to produce high volumes, special features and custom sizes industrial level rollforming allows produces of steel framing to increase margins while being competitive.

Interior Construction of Office Buildings 

The most common wall manufacturing technique used in today’s modern office tower is that of steel stud and track.  Speed, cost and weight are the driving forces for this preferred building method.  Having the ability to cut quickly and join simply any interior wall design makes the C channel and U channel steel framing product the only choice.

How do they make steel stud and track?

Stud and Track Wall Roll Former

Large heavy duty stud and track roll formers manufacture with a high degree of accuracy all of the common profiles.  Some manufacturers even offer stud and track wall machines that automatically switch between profile sizes.  This allows manufactures of steel framing products the ability to produce ‘made to order’ bundles of products.  Having this capability along with the capacity to produce thousands of pieces makes the building material highly cost effective.

Onsite Stud and Track Wall Fabrication

Some builders prefer to manufacture the steel framing studs on site.  The rollformer is a lower grade the its industrial cousin however it allows for even higher flexibility.  On some projects the roll forming machine is raised to the floors where it’s needed.  This allows the construction crew to manufacture on demand the materials they need.

Steel framing solutions are ideal for construction of strong buildings in high wind speed and seismic zones including the US eastern seaboard, the Gulf coast states, California and Hawaii. 

Commercial steel framing lowers the construction costs as: 

• Warranty costs are minimized – steel does not shrink, split or warp. Due to this, there are no nail pops or drywall cracks to fix once the structure is completed. 
• Consistent quality implies that scrap is drastically reduced. As against cold formed steel, there are costs involved in jobsite culling of wood materials, haul off costs and the disposal of discarded material. 
• Discounts on builders risk insurance for buildings constructed with light steel framing result in significant cost savings for builders.

Light gauge steel framing is easier to handle and consumers also recognize steel as a superior framing product for its fundamental characteristics including low maintenance costs and high resistance to rot, mould, termite and insect infestation. Steel framing has proven performance in high wind and seismic zones. 

Roll forming is the most effective metal fabrication process for the production of light gauge steel framing members. Structural-quality sheet steel is formed into shapes by roll-forming the metal through a series of dies. Unlike hot-formed structural I-beams, the process does not require heat to form the shape and therefore fabricates “cold-formed” steel. Steel stud roll forming machines typically fall in two categories – outboard and inboard mills. Outboard mills have housings that support both ends of roll tooling shafts. If the shafts are supported only at one end, the roll forming mill is said to be of inboard variety. 

Light gauge steel products produced by roll former machines are stronger, faster to produce, and cost less than their hot-formed counter-parts. They prove to be the most suitable and cost effective solutions for commercial steel framing. 

These two leaders in the metal framing business offer a broad range of products.  There innovative approach and excellent customer service positions them well for the market recovery.

About ClarkDietrich Building Systems LLC


ClarkDietrich Building Systems LLC is a joint venture combining ClarkWestern Building Systems with Dietrich Metal Framing. The joint venture manufactures a full line of drywall studs and accessories, structural studs and joists, metal lath and accessories, and shaft wall studs and track. ClarkDietrich Building Systems combines quality manufacturing, a broad product line, engineering services, responsive customer service and strong management as the industry leader of light gauge steel framing in the United States.

About Marubeni-Itochu Steel America Inc. (MISA)


MISA is a fully integrated network of metal processing and manufacturing facilities and sales and service offices strategically located in the United States, Canada and Mexico. Founded in 2001, the company is a recognized industry leader in all aspects of supply chain management and processed metals for the automotive, construction and other major industries.

About Worthington Industries


Worthington Industries is a leading diversified metals manufacturing company with 2010 fiscal year sales of approximately $1.9 billion. The Columbus, Ohio based company is North America's premier value-added steel processor and a leader in manufactured pressure cylinders, such as propane, oxygen and helium tanks, hand torches, refrigerant and industrial tanks, camping cylinders, alternative fuel storage, and scuba tanks; light gauge steel framing for commercial and residential construction; framing systems and stairs for mid-rise buildings; current and past model automotive service stampings; steel pallets and racks; and through joint ventures, suspension grid systems for concealed and lay-in panel ceilings, and laser welded blanks. Worthington employs approximately 6,500 people and operates 67 facilities in 11 countries.

Roll forming used to manufacture steel studs

The steel stud industry utilizes roll forming equipment to manufacture the wide range of profiles required for this industry.  As a leader in this field Samco Machinery is well known for their leading edge technologies.  The Greenfield roll former encompass all the necessary advanced features required by many of the leading steel stud manufactures. 

Steel framing members like metal studs offer great advantages to home building contractors while remodeling or making a home addition. While wood is extremely combustible, steel is not. Here we will discuss some of the advantages of metal framing (metal studs): 

How steel framing can benefit your business

Metal Studs offer Earthquake Resistance: Metal framing have proved to be a better option in earthquake prone areas. When it comes to hurricanes and tornadoes, metal framing are far better than the wood frame construction.     

Mold, Mildew, and Termite Proof: With metal frame construction, termite damage is a thing of past. Also, metal studs don't harbor the moisture that mold and mildew need to exist and spread.

Environment Friendly: As steel can be recycled, it can be reused rather than taking up the space in landfill. Also, it reduces the need to cut down trees and all the logging expenses. Additionally, it results in less scrap and waste at the construction site.    

Home owners Insurance Discounts: Because of its fire-resistance and superior performance in hurricanes, and earthquakes, some insurance companies have marked steel as superior construction material. That's why they offer discounts on home-owners insurance and builders risk. 

Reduce construction costs with new framing techniques

Benefits During the Construction Process: Apart from above points, steel framing also offer several other benefits when it comes to assembly and construction process. Labour time is also minimised in several cases. Although heavier gauge studs and track used for exterior walls are cut with a sliding, light gauge studs used for interior partitions are simply cut with aviation snips, that saves time on each cut. 

With so many advantages, metal framing are definitely a better choice over the  conventional wood framing.

With its durability and strong characteristics, steel is a popular material for construction. Earlier, steel frame buildings were commonly found in industrial or storage situations, they are used for residential purposes as well. Steel frame designs are the best options for those looking forward to build or buy a new home. But before buying or building a steel frame home, always go for an architect who is experienced in constructing steel frame homes. Also, measure all the pros and cons of steel frame houses, before settling for an option. 

Benefits of Steel Framing vs Wood Framing

One of the major advantages of using steel in residential building is its longevity and durability. While wooden frames often involves problems such as rotting or warping, steel frames do not pose any problems like that. 

Wooden frames often need to be replaced which can be quite costly. Steel frames on the other hand, need not to be replaced, which means, you need not to fork out any money to replace any parts of the structure. So, if you are looking forward to stay in your house for a long time then a steel frame design can really save you money spent on repairs.

In wooden homes, there is always a possibility that bugs like termites may damage the structure of the house which is not the case with steel frame houses. Therefore the steel frame homes don't face structural damage that pests often cause to wooden frames.

Another advantage a steel house has is that they are very sturdy and can withstand even the most severe weather changes. With so many advantages, steel frame homes are definitely a better choice! 

Steel framing process utilizes advanced roll forming technology

Nowadays, many home-owners and builders are choosing steel frame design for their houses and buildings. There have been many advantages of using a steel frame for your next home or building. Here we will discuss a few of them. While building any a home or any other kind of facility, the major concern is the cost of the building. Anything that can reduce the cost, will be advantageous. Here comes the role of steel frame designs. This is a cheaper and more cost-effective option than the typical lumber and wood frames. Steel framing not only allows you to save on money, but the construction process is also much easier. Another major advantage of using steel frame designs is that, you don't have to worry about weather disruptions. As all the pieces can easily fit together, smaller teams can tackle larger projects in less time.

If you are worried about the quality, rest assured as steel house frames are sturdier and stronger than their wooden counterparts. They won't be affected by weather changes and environmental conditions. Apart from quality and longevity, another benefit of steel framing is you need not to worry about termites. With so much convenience and flexibility in offering, steel frame designs allow you much more open space without intrusion, and you can create any look, design or feel that can make your home unique, and spacious. Another benefit of steel framing homes is that they are environment friendly. Yes, no trees are felled for its manufacturing. This creates a positive impact on environment. With so many advantages steel house framing is definitely a better choice.