What is high-quality metal? Unless you are willing to learn about metallurgy, this is difficult to answer. But, to put it simply, the manufacture of high-quality metals depends on the type and quality of alloys used, heating, cooling and treatment processes, and secret proprietary systems protected by the company.
For these reasons, you need to be able to rely on coil resources to help ensure that the quality and quantity of the metal you think you ordered is the same as the quality and quantity actually received.
What the owners of portable and in-store stationary roll forming machines may not be aware of is that each specification has an allowable weight range, which may cause unexpected shortages when ordering.
Ken McLauchlan, Director of Sales at Drexel Metals, based in Colorado, explains: “It can be difficult to order roofing materials by pound and sell by square feet within the per square foot allowable range.” “You may want to plan the coils per square foot. For one pound, the tolerance of the coil sent is within 1.08 pounds per square foot, and suddenly, the materials you need are 8% less than the materials needed to complete the project.”
If you do run out, will you get the same new volume that you used? McLauchlan gave an example of the work he experienced while working for a large roofing contractor. The contractor changed the mid-term work of the project from cooperation with prefabricated panels to rolling their own panels on site. The coils they transported are much more difficult than previously used and completed work. Although it is high-quality steel, harder steel will produce too much oil cans.
Regarding the topic of oil cans, McLaughland said: “Some of them may be [roll forming] machines, that is, the machine is not adjusted correctly; some of them may be coils-coils are harder than they should be. It can also be consistency: consistent Sex can be grade, it can be specification, it can be thickness, it can be hardness.”
Inconsistencies may arise when working with multiple suppliers. It is not that the steel is of poor quality, but that the calibrations and tests performed by each manufacturer meet their own machine and their own requirements. This applies to steel resources and companies that add paint and paint. They can all meet industry tolerances/standards, but when mixing and matching suppliers, the final difference from one source to another can be reflected in the final product.
“For our finished products, from our point of view, the biggest problem is that [process and testing] must be maintained continuously,” McLauchlan said. “When you have inconsistencies, it becomes a problem.”
What should I do if there is a problem with the work site on the panel? Hopefully it will be caught before installation, but unless the problem is obvious and the roofer is working diligently on quality control, it will most likely not show up until the roof is installed.
If the customer is the one who notices the wavy panel or color change, the contractor they will call first. Contractors should call their sheet suppliers, or, if they have roll forming machines, they should call their coil suppliers. In the best case, the panel or coil supplier will have the ability to assess the situation and initiate a correction process, even if it can point out that the problem lies in the installation rather than the coil. McLaren said: “Whether it is a large company or someone who works in a house and garage, he needs a manufacturer standing behind him.” “The general contractor and the owner are looking at the roofing contractor as if they caused it. The problem is the same. Hope the trend is the supplier and the manufacturer will provide additional materials or support.”
For example, when Drexel was called, McLauchlan explained: “We went to the work site and said,’Hey, this is the cause of the problem, is it the substrate (decoration) problem, the hardness problem, or something else.; We try to provide backstage support… …When manufacturers appear, they bring credibility.”
When a problem does occur (it will definitely happen one day), we will discuss how to deal with a series of problems of the panel from point A to point B. For the roll forming machine, the following questions will be asked: where do you purchase your product equipment; have you adjusted within the machine tolerances; is it suitable for the job? Have you purchased the right specification material with the right hardness; has the metal been tested to support the required material?
McLaughland said: “Unless there is a problem, no one needs testing and support, and then usually because someone says,’I'm going to find a lawyer, and you won’t get paid.’”
Preparing appropriate guarantees for the panel is a way to assume your own responsibility when the situation deteriorates. The rolling mill offers a typical base metal (red rust perforated) warranty. The paint company provides film integrity assurance. Some vendors (such as Drexel) will combine warranties into one, but this is not a common practice. Realizing that you do not have both can cause severe headaches.
McLauchlan said: “Many of the guarantees you see in the industry are distributed proportionally or disproportionately (including substrate or film integrity guarantees). This is one of the games companies play. They will say they will give you movies Integrity guarantee. Then you fail. The metal substrate supplier says it’s not metal, but paint. Painters say it’s metal because it won’t stick. They point their fingers at each other. There’s nothing like having one on the job site It’s even worse for people to blame each other.”
From the contractor of the production line to the roll forming machine that installs the panel, to the roll forming machine used to manufacture the panel, to painting and finishing, the production process of the problem panel involves many processes. To the coil, then to the factory that creates the coil and creates the steel to make the coil. It takes a strong partnership to quickly resolve any issues before they are resolved.
McLauchlan strongly recommends that you establish a strong relationship with a company that provides the best service for your panels and coils. Appropriate guarantees will be passed to you through their channels, and if there are good partners, they will also have resources to support these guarantees. Good partners don’t have to worry about multiple warranties from multiple sources, but will help organize the warranty. “So when there is a warranty issue,” McLauchlan said, “It’s a warranty, one person can call, or just like us As the industry said., a throat choked.”
Streamlined warranty can provide you with certain sales confidence. “The biggest thing you have is your reputation,” McLauchlan continued.
If you have a reliable partner behind you, you can speed up response and reduce overall pain through problem review and resolution. You do not need to yell at the work site, but can solve the problem, so it can provide calming effect.
Everyone in the supply chain has the responsibility to be a good partner. For roll forming machines, the first step is to purchase high-quality products from reliable sources. The biggest temptation is to take the cheapest route.
McLauchlan said: “I’m going all out to save costs, but when the cost of the problem is 10 times higher than the cost saved, you’re overwhelming. It’s like buying materials that are sold at a 10% discount and then 20% interest will be placed on your credit card.”
However, if not handled properly, the best coil is useless. Good machine maintenance, routine inspections, correct profile selection, etc. all play an important role, and all of these are part of the roll forming machine’s responsibilities.
Make sure you fully meet the expectations of your customers. McLauchlan said: “Assuming that your coil is too hard, or is not split correctly, or uneven and deforms the panel, it will fall on the person who turns the raw material into the finished product.”
You might be tempted to blame the computer for the problem. This may make sense, but don’t rush to judge, first look at your own process: Did you follow the manufacturer’s instructions? Is the machine used and maintained correctly? Did you choose a coil that is too hard? Too soft; seconds; slit/recoil/incorrect handling; stored outside; wet; or damaged?
Do you use a seaming machine on the job site? Roofers need to ensure that calibration meets job requirements. He said: “For closed mechanical panels, it is very important to ensure that your sealing machine has been calibrated according to the panel you are running.”
It may tell you it is calibrated, but is it? McLaughlin said: “With the seaming machine, so many people bought one, borrowed one, and rented one.” Question? “Everyone wants to be a mechanic”, and when users start to adjust the machine to suit their use, it may no longer meet manufacturing standards.
The old adage is to make two measurements, and one cut applies to anyone who uses a roll forming machine. Length is important, as is width. A simple template gauge or steel tape measure can be used to quickly check outline dimensions.
“Every successful company has a process,” McLauchlan pointed out. “From the aspect of roll forming, if you have a problem (online), please stop. It is difficult to fix what has been processed…Willing to stop and say good, what is going on?”
Going on will only waste more time and money. He used this comparison: “The moment you cut 2×4, it is usually impossible to bring them back to the logging yard.” [Rolling Magazine]
Post time: Jan-13-2021