When ordering angles you will need the following information:
Size of angle and material type:
The size of the material and material type is very important when rolling angles. Angles need to have room to expand and material like Aluminum will easily break during this expansion. The size of the legs are also important. Knowing if an angle will break or not requires an experienced roll man that knows the behavior of material during the process. Make sure to give us a call before ordering to make sure your requirements do not need special processing like heat treating or a modification to material thickness.
Angle methods of rolling and diameters
Angles can be formed two different ways. Easy way and Hard way. The following sections will detail how a angle roll method is described and will show cross sections to help you request angles over the phone or email without the requirement of a drawing.
Unequal Angles
Angles can also be formed with obtuse legs sizes or unequal angles. When ordering these types of angles you must declare if you wish to use the Easy Way or Hard Way method plus you must specify which leg points to the inside of the diameter for Hard Way and the outside of the diameter for Easy Way
Easy Way
An Easy Way or EW angle will have its leg pointing out as shown in the image below. This will give you one inside diameter and 2 outside diameters. This means that an inside diameter size should be given when ordering EW angles.
Hard Way
Also listed as HW, Hard way angles are a much more difficult form of rolling angle due to the limited amount of pressure angles can handle using this method. Hard way angles have the leg facing in has shown in the following image. This creates one outside diameter and two inside diameters. When ordering HW angles make sure to use the outside diameter.
When ordering channels you will need the following information:
Size of Channel and material type:
Channel sizes are classified by the type, size, and weight per foot. An example would be C6 x 8.2#. The is a “C” Standard Structural Size Channel with a 6″ Depth and a weight of 8.2 lbs per foot. This allows us to communicate the web thickness and flange length which is important for roll forming. The standard sometimes varies especially for Aluminum Channels that use a different standard.
Channel methods of rolling and diameters:
Channels can be formed with three different roll methods. The standard Easy Way (EW) and Hard Way (HW) methods are the most common, but channels can allow be rolled on edge. When selecting material if is important to consider web thickness when rolling on edge and flange widths when rolling EW or HW. When placing an order the weight of the channel may be changes to prevent deformation.
Easy Way
The Easy Way or EW roll method has one inside diameter dimension and two outside diameter dimensions. Make sure when ordering to use the proper diameter to make sure your requirements are met.
Hard Way
The Hard Way or HW rolled channel has one outside diameter and two inside diameters. Make sure when ordering to use the proper diameter to make sure your requirements are met.
On Edge Channel
On-Edge rolling of channel is one of the most difficult methods to roll form channel. This may cause deformation of the channel include a twist. This sometimes requires the channel to be flatten after forming. Due to the even number of outside and inside diameters a drawing is required to make sure your requirements are met.
When ordering flat bar you will need the following information:
Size of Flat Bar and material type:
The size of the material and material type will determine how flat a flat bar will be after rolling and the possible amount of deformation. Flat bars are limited by the roll machines ability to hold the bar square as it rolls. Make sure to give us a call before ordering to make sure your requirements do not need special processing like heat treating or a modification to material thickness.
Flat Bar methods of rolling and diameters:
Flat bars can be rolled in two different methods. Easy Way (EW) or Hard Way(HW).
Easy Way
An Easy Way or EW flat bars are shaped like a “wedding band”. This method of rolling allows us to use breaking equipment and methods to roll most bars all the way to the end. This eliminates waste and time required to cut.
Hard Way
Hard Way or HW flat bars are shaped like a “washer”. Hard way flat bar require tangent to allow for flat ends created by the roll machine. The amount of flatness depends on the material size, type, and diameter.
When ordering tubing you will need the following information:
Size of Flat Bar and material type:
The size of the material and material type dictates the tooling and machine needed to form the required part. Make sure to give us a call before ordering to make sure the thickness is enough to avoid producing a ripple or concave. Extra material for the machine to grab the piece called tangents will also vary depending on the specific machine being used.
Tubing methods of rolling and diameters:
Tubing can be formed two different ways. Easy way and Hard way. The following sections will detail how each method is described and will show cross sections to help you request tubing over the phone or email without the requirements of a drawing.
Easy Way
An Easy Way or EW tubing will have the widest part of the material profile horizontal with the working plane.
Hard Way
An Hard Way or HW tubing will have the widest part of the material profile perpendicular with the working plane. Due to the decrease in support on the wider length this method increases the possibility of rippling on the inner face.
Special instructions (Pitching and taper)
Rectangular tubing as the ability to form with a pitch or an taper. In order to form a pitched tubing the following information is required.
Using this information Carolina Rolling Company can calculate the required diameter and angle needing to achieve the proper helical profile. Unfortunately square tubing does not have that ability.
When ordering pipe and round tubing you will need the following information:
Size of Flat Bar and material type:
The size of the material and material type dictates the tooling and machine needed to form the required part. Make sure to give us a call before ordering to make sure the thickness is enough to avoid producing a ripple or concave. Extra material for the machine to grab the piece called tangents will also vary depending on the specific machine being used. When mandrel bending tight bends only specific thickness may be used for the designed tooling.
Diameters
Diameters are very simple for round profiles. The only thing require is the diameter and which diameter you would like to use. Choices include inside diameter, outside diameter, and center line diameter. It is important to not mistaken diameter and radius when ordering.
Special instructions
Pipe and round tubing have the ability to be pitched and coiled. For pitching the only information required is the ground diameter, pitch, and direction. The same information can be used with coiled. In place of pitch you may request the distance from the inside or center of each ring on the coil.
When ordering I-Beams you will need the following information:
Size of angle and material type
I-Beams are classified by Size and Weight. An example would be a S5 x 10#. This is a standard I-Beam with a 5″ flange signified by the S5. 10# allows us to check the thickness dimensions which is .214″ for our example. Aluminum I-Beams do not follow this standards with uncommon sized I-Beams.
I-Beam methods of rolling and diameters
I-Beams can be formed two different ways. Easy way and Hard way. The following sections will detail how an I-Beam roll method is described and will show cross sections to help you request I-Beam over the phone or email without the requirement of a drawing.
Easy Way
An Easy Way or EW I-Beam will have its leg pointing towards and away from the center of the diameter as shown in the image below. A drawing is required since I-Beams have multiple Easy Way and Hard Way diameters.
Hard Way
Hard Way or HW flat bars are shaped like a “washer”. Hard way flat bar require tangent to allow for flat ends created by the roll machine. The amount of Also listed as HW, Hard way I-Beams apply pressure directly to the weakness part of the I-Beam. The thickness of the webbing is very important when forming I-Beams with this method. Hard way I-Beams have many inside and outside diameters measurements so a drawing is required to meet your requirements.
When ordering plate you will need the following information:
Thickness, blank size, and material type:
The thickness of the material will allows Carolina Rolling Company to select the correct machine required to make your part.
As thickness increases and decreases we become limit in the length and diameter of the upper dies for each plate forming machine. We house a variety from 1” x 24”, 14ga x 144”, and up to 1.25” x 120”.
Each machine has definite strengths and weaknesses. It is best to require a quote for ordering material in case a change of thickness is required or if extra material is required the ends. Most equipment we have is able to pre-form the ends of plate so no cutting is required mid process.
Material type is required even tack welding is needed for transport. This will help the parts to survive transportation with minimal changes in tolerance.
Roll direction and diameter
The roll direction is required to make sure the parts are made to the required specification. The best method to communication which direction the piece is rolled is based on weather the arc length that runs along the machine is the longest or the shorts arc length. If the shortest length is parallel with the machine dies then this is considered easy way. If the hardest length is parallel with the machine dies then this is considered hard way.
Diameter can be specified as inside, outside, or centerline.
Special instructions
Cone: Using specialized roll accessories and cutting the plate to a correct profile we are able to roll plate up to 1.25” thick into conical shapes. The only information require will be the diameter of the small end, diameter of the large end, and total height of the transition. The height is measure perpendicular to the work plane in relation to the cone. If it best not to confuse the measurement that runs around the cone which is considered the slope height.
This shapes can be either concentric or eccentric. Concentric cone’s diameters share the origins x and y values. Eccentric cones offset these values. Normally this is to allow one flat edge and maintain the taper only on one side. We do offer custom layouts so the offset can be defined.
Eccentric cones require extensions on the small diameter end to allow our cone rolling equipment to maintain the angle of taper during rolling. Without this extension the cone will not be able to achieve standard tolerances. The required extension must be stitch cut to the small end. This gives a path for cutting the final edge.
Transitions: Carolina Rolling Company offers design software that allows us to create specialized transitions. This includes square to round, elbow, tee, and wye. Our forming capabilities for these profiles are up to 5/16” thick carbon steel.
Pitch: If you need side plating or would like to make a plate style stair stringer Carolina Rolling Company has you covered. Using custom made pitch inspection jigs we are able to roll and check to make sure you plate is flat with the perpendicular plane of the pitch profile. We offer pitch plating up to 120” travel and up to 3/4” carbon steel.
Roll direction and diameter
The roll direction is required to make sure the parts are made to the required specification. The best method to communication which direction the piece is rolled is based on weather the arc length that runs along the machine is the longest or the shorts arc length. If the shortest length is parallel with the machine dies then this is considered easy way. If the hardest length is parallel with the machine dies then this is considered hard way.
Diameter can be specified as inside, outside, or centerline.
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