Roll forming technology has revolutionized the industrial sector, enabling the production of precise, high-strength metal shapes for a wide range of applications. This versatile manufacturing process is celebrated for its ability to produce custom-fabricated profiles for OEM applications, supporting varying lengths, hole patterns, and end-use applications. Roll forming is a continuous, high-speed multi-faceted fabrication process that is highly efficient and economical and can support a broad range of thicknesses and material specifications, making it ideal for industrial use. Here, we explore the top roll-formed shapes and their pivotal roles in the industry.

1. Channels

Roll-formed channels are integral to structural frameworks, offering excellent load-bearing capacity and uniformity. These shapes are widely used in construction, commercial building projects, HVAC and Electrical applications, racking, and aerospace industries for their strength and ease of integration into complex structures. Whether for framing or as a part of a support system, channels provide the backbone for many industrial applications.

2. C-Sections

C-sections, or C-channels, are essential in manufacturing and construction. Their unique design offers a high strength-to-weight ratio, making them perfect for beams, braces, and frames. C-sections are commonly used in structural steel components, conveyors, and racking systems, providing both structural integrity and material efficiency. Thicker gauge C-channels can also be used instead of I-beams in some applications – e.g. Solar racking systems could consider using C-sections rather than expensive I-beams for support piles, which are driven into the ground for below-grade support of the photovoltaic panel racking system.

3. Custom Tubes

Roll formed tubing is a custom roll-formed part that is welded in-line to create a closed profile. These tubes are essential for high-strength and high-load applications, commonly used in high bay and pallet racking systems, truck bumpers, automotive components, furniture, decorative handrails, solar torque tubes for tracking systems, and various other commercial and industrial uses. Unlike standard square or round tubes, which are mass-produced commodities, roll form tubes offer unique custom profiles tailored to specific performance needs

Custom roll form tubes are engineered with precise tolerances for specific OEM applications. They can feature pre-notched elements like holes, slots, or embossments, applied before forming and welding. This process eliminates costly secondary operations, reducing production expenses significantly.

4. Hat Sections

Hat sections, characterized by their top-hat like shape, are crucial for creating lightweight yet strong structural components. These profiles are widely used in Solar racking systems, Truck/Trailer, HVAC, and construction applications. Their design provides excellent support and stability, making them ideal for frames, supports and enclosures that require both strength and minimal weight.

5. Z-Sections

Z-sections, or Z-bars, are versatile shapes used extensively in framing, bracing, and support structures. Their design allows for effective load distribution and enhances structural stability. Z-sections are commonly used in construction for wall studs, roof purlins, solar racking, and shelving systems, ensuring robust performance under various loads and conditions.

6. Angles

Roll-formed angles are indispensable in creating corner reinforcements, brackets, and structural frames. Their right-angle design provides optimal strength and support, making them ideal for welding and bolting in construction and manufacturing. Angles are crucial in building frames, machinery supports, and mounting brackets, offering unmatched durability and reliability.

Hynes Industries has a proprietary line of Angles and Slotted Angles for numerous Commercial and Industrial applications, called FlexAngle.

7. Strut

Strut profiles are widely used in commercial and industrial applications, particularly in construction projects. They are commonly employed in HVAC and electrical systems, where trapezes are needed to hang ductwork, conduit, water, and gas pipes. Strut is also frequently used in solar racking as well as material handling racking systems and is prevalent in both residential and commercial construction.

8. T-Sections and Hemmed Profiles

T-sections and hemmed profiles provide additional strength and rigidity along the length of a component, offering crucial support where needed. Roll forming a hem where the metal is folded back over itself, is especially helpful with lighter gauge steel and enhances the part's strength without adding excessive weight. This can help reduce material costs by allowing the use of lighter gauge steel while maintaining the necessary performance  

9. U-Channels

U-channels are commonly used in various industrial applications for their strength and versatility. These profiles are ideal for creating frames, supports, and enclosures, and providing robust structural integrity. U-channels are widely used in the construction, racking, and aerospace applications, where durability and precision are paramount.

>>> Read more: How Hynes Industries Reduced Lead Times by More Than 70% for a Global Commercial Construction Manufacturer

10. Custom Profiles

One of the most significant advantages of roll forming is the ability to create custom profiles tailored to specific industry and unique customer applications. Roll forming custom profiles allows for very specific tolerances and features to be added to the component, which can increase functionality, strength, and reduce overall cost since multiple features can be combined into a single component. From complex shapes that require intricate designs for specialized applications like solar racking, automated material handling, and truck/trailer solutions, custom profiles offer unmatched design flexibility and functionality. This capability ensures that manufacturers can meet unique requirements with precision and efficiency.

Elevate Your Industrial Projects with Roll Formed Shapes

At Hynes Industries, we bring decades of expertise in designing and manufacturing custom roll-formed shapes for diverse industrial applications. Our commitment to quality and innovation ensures that we deliver products that meet the highest standards of performance and durability. Whether you need standard shapes or custom profiles, our team is ready to collaborate with you to enhance your project’s design, streamline production and reduce costs.

Ready to explore how roll-formed shapes can transform your industrial projects? Contact us today to get started!