Roll forming process involves continuous bending operation of a long strip of sheet metal which is passed through consecutive sets of rolls, each performing incremental parts of the bend until the desired cross-sectional profile is achieved. This process is widely used in various industries due to its efficiency, precision, and versatility. In recent times cold-formed steel has been a game changer in the construction industry where the thin-walled sections are used as structural elements of a building saving significant time and money thereby optimising the traditional framing process.

Below, we explore the major operations involved in the roll forming process and their use cases and how Scottsdale Construction Systems and Knudson by Scottsdale roll formers, a leader in advanced roll forming technology handles these steps within the roll forming process.

Roll Forming: Key Processes

The key processes in roll forming are summarized below

• Rolling
• Cutting
• Notching
• Punching
• Swaging
• Flattening
• Dimpling

Each of these operations involves a series of tool sets are also detailed in this article.

Rolling

The rolling process is the foundation of roll forming, which is a continuous process used to create long metal shapes with specific cross-sectional profiles. This process involves the gradual deformation of metal sheets or strips through a series of precisely engineered rollers. The various individual entities within the roll former contribute to its efficiency and precision. These include:

• Rolling stations
• Decoiler
• Hydraulics
• Electricals
• Software
• Tool Head

Overview of various components of a roll former are presented in below image.

Rolling stations

The number of rolling stations determine the type of profile that gets produced by a roll former. Rolling stations help in forming various bends within the roll former and also in producing the stiffeners along the profile web. During this stage, the metal strip is fed through a series of rollers that gradually shape it into the desired profile. The rollers are strategically designed and spaced based on the principles of roll forming to ensure precision and consistency while optimizing the production output. Typical roll cage is shown in image below.

Decoiler

The automatic decoiler stores and unrolls the steel coils into the roll formers in a seamless manner without the need for manual interventions thereby helping in achieving a constant input of steel into the roll formers for production. Scottsdale and Knudson by Scottsdale have decoilers with their respective capacity varying from 1500 kg to 4500 kg. Customers have the option of choosing from a variety of decoilers based on their usage and needs.

Hydraulics

Hydraulics are an essential component of the roll-forming process. Operations such as cutting, notching, and punching are powered by the hydraulic unit within the roll former. The speed, efficiency, and precision of these operations rely heavily on the performance of the hydraulic system. A typical hydraulic pump and motor setup within the Scottsdale roll former is shown below.

Hydraulics in roll forming are typically integrated with electrical systems and controlled by bespoke software packages, enabling automation of essential operations such as cutting, notching, and punching. These advanced software systems provide precise control, enhancing efficiency, repeatability, and overall productivity in manufacturing processes. However, there are situations where these operations can also be executed manually, offering flexibility and adaptability when automation is not feasible or necessary. Scottsdale stands out in this field by excelling in both the design and manufacture of high-performance roll formers and the development of state-of-the-art software packages. These integrated solutions ensure seamless automation and exceptional functionality, delivering superior outcomes in roll-forming applications.

Electricals

Electrical systems are the nerves of any roll former, acting as the communication and control hub that ensures the smooth operation of the entire machine. Just as nerves transmit impulses for the human body to perform its functions, a robust electrical system is essential for coordinating the various components of a roll former. These systems manage motor drives, sensors, PLCs (Programmable Logic Controllers), and safety devices, ensuring synchronization, precision, and safety during operation. A well-designed electrical system minimizes downtime, enhances productivity, and provides adaptability for different production requirements. The electrical cabinet, typically housing these critical components, exemplifies the intricate control network necessary for seamless roll-forming performance. A typical electrical cabinet within the roll former is shown below.

Software

Bespoke software packages are needed to automate the roll-forming operations. This includes cutting the profile to length, punching holes at specified locations, making dimples at specified angles for connecting members, notching members for intersecting connections, swaging the ends to make a bearing connection etc. These intelligent operations at predetermined locations are cumbersome to perform manually in a roll former and henceforth software packages play a crucial role in communicating these operations to the roll former.

The integration of software and hardware is key to achieving optimal performance of the roll formers without slowing down the production process. The software must communicate effectively with the electrical systems within the roll formers thereby establishing a seamless connection and coordination during the roll forming process. Scottsdale produces bespoke software called ScotRF to communicate with the roll formers. Support for other third-party software packages such as MWF Pro Metal plugin for Autodesk Revit and Vertex BD are also facilitated within the ecosystem.

Learn more about Scottsdale ecosystem here – Click here

Learn more about ScotRF software and capabilities here – Click here

Roll forming operations and Tool Heads

Multiple tool head options are available within the Scottsdale product lineup and are discussed in detail in their respective sections. Tools heads that are available within the Scottsdale and Knudson by Scottsdale series if roll formers include the following

• Cutting
• Notching
• Punching
• Swaging
• Flattening
• Dimpling
• Coping

Cutting

Cutting is a critical process in roll forming, where the formed profile is precisely cut to the required lengths to meet specific design and structural needs. This operation is typically performed using a guillotine positioned at the exit stage of the roll former. The intelligent ScotRF software enhances this process by enabling the roll formers to cut profiles accurately to the required dimensions, facilitating the production of various structural elements such as studs for wall panels, and components like top and bottom chords, webs, and other elements for trusses. The cutting operation can be executed in two ways: as a static cut, where the profile comes to a complete stop, or as a dynamic operation with variable speed, allowing for high-speed continuous production without interruptions. This flexibility ensures efficiency and adaptability to diverse production demands. A typical guillotine tool, designed for this purpose, is shown below, highlighting the technology behind precise and efficient cutting in roll forming.

Notching

Notching is a vital process in roll forming that involves creating precisely positioned slots, holes, or indentations in the material to enhance its functionality and usability. This step is essential for enabling assembly or integration of the formed profiles with other structural components. Depending on the design and manufacturing requirements, notching can be performed either before the rolling process begins or after the profile has been formed.  Notches are commonly introduced to allow a main member to pass through or to facilitate connections within a structural assembly. These features play a critical role in ensuring secure and efficient construction. Typical examples include creating a notch in a stud to allow for a connection to a continuous nogging, or forming a T-intersection in the truss top chord for a heel connection. These applications underscore the importance of precision and accuracy in the notching process. The image below illustrates a notch on a C-section web, highlighting its functional design and application in structural assemblies.

Punching

Punching involves creating holes or slots in the material using a die and counter punch. This process is essential for adding features like bolt holes, plumbing and service holes. Punches are often made on the flanges and webs of the section and can vary in size and shape. Various punches and use cases are discussed below.

Image below shows bolt and rivet hole punches made on the webs and flanges of the Hat and C-section respectively.

Holes made on the flanges are generally slots are cuts to accommodate various secondary members. Slots are punched on top plate of the wall to stud connection allowing for the vertical movement in buildings. The slots can be single or multiple in nature. Flange cuts on the other hand are not common but used in rare cases accommodate end / intersection connections in C-section. Image below shows slots and flange cuts in the C-section profile. These slots are generally made in the flat state of the coil before the rolling process.

Punches are also made on the profile webs in various shapes and sizes. This includes slots and tabs. Image below shows some of the commonly used slots and tabs.

An overview of the applications of some of the punches is detailed below.

• Circular punches are used for service holes and HVAC ducts in the web of the C-section. These holes vary in size depending on the application.
• Single slot holes on the webs also vary in size and depth and are often used as plumbing holes and slotted screw holes on the top track of non-load bearing walls to accommodate in plane movements in buildings.
• Key slot holes are predominantly used for proprietary clipped noggings to provide in-plane buckling resistance of C-section members.
• Single and Multiple tabs are often used in C-section bearers to connect the joists thereby forming floors.

Swaging

Swaging is a process that crushes the profile thereby reducing the width of the profile. It is achieved by applying compressive forces through rollers or dies. Swaging is done on profiles to get a closer fit in the connection to enhance the load transfer between structural elements thereby achieving better connection capacities. In some cases, swages are used in the end of the wall studs to form end bearing connections wherein the connection capacity is overridden by the bearing capacity of the stud. This is particularly useful in designs with higher axial load demands thereby reducing the dependency on the structural adequacy of the connections which are generally lesser than the bearing capacity of the profile. Image below shows commonly made swages within the C-section webs at the middle and end of the member.

Flattening

Flattening is used predominantly in C-sections to flatten the formed lips of the profile. This ensures a T-intersection connection is made with another C-section. The flattening tool can also be used to form an unlipped C-section which can also be used as a U-track OR Top plate on walls. The image below shows a continuous flattening operation within the SCOTPANEL roll former.

Dimpling

Dimpling involves creating small indentations or depressions in the material. This process is often used around the connection holes such as rivet/screw holes. Dimples in the connection allow for the connector to stay in place during shear action thereby reducing connection slip which can inherently reduce the connection capacity. Dimples are also helpful in reducing the protrusion of the connector such as screws and rivets within a wall panel thereby reducing the bulge in the cladding. This helps in achieving a much cleaner and smoother finish and avoids the risk of cracks due to bulging. The image below shows dimples on a double rivet C-section profile.

Coping

Coping is the process of removing the lips within a profile. These can be of varying lengths and angles depending upon the application. Copes in C-sections are generally used to connect perpendicular members. This is an alternative to flattening as discussed in previous sections. Angled copes are often used in the web members of C-section trusses oriented about the major principal axis. Image below shows various coping options for C-section profile lips.

Roll Forming Automation: Efficiency Meets Innovation

Scottsdale Construction Systems integrates advanced roll-forming processes into cohesive, automated solutions that redefine modern construction. Our cutting-edge roll formers are designed to deliver unparalleled precision, speed, and versatility, enabling the rapid production of steel components that consistently meet the most stringent quality standards. Scottsdale’s dedication to innovation ensures our systems not only streamline manufacturing processes but also support sustainable practices by minimizing material waste and optimizing energy consumption.

With a wide range of customizable options, our roll formers are capable of producing optimized cold-formed steel sections tailored to meet diverse project needs. Whether it’s for residential housing, commercial developments, or industrial structures, Scottsdale’s roll-forming technology offers exceptional efficiency, customization, and cost-effectiveness. Our solutions empower construction professionals to bring their designs to life with unmatched accuracy and reliability.

As the trusted steel framing partner for construction professionals worldwide, Scottsdale is committed to delivering systems that consistently exceed expectations. By choosing Scottsdale, you’re investing in proven solutions, cutting-edge technology, and a partner dedicated to building stronger, smarter, and more sustainable structures for the future.