roll forming machine

Galvannealed and galvanized steels start out similarly. They are both dipped into a hot zinc bath (approximately 850° F), so the zinc bonds to the metal's surface. This coating increases the steel's durability and protects against corrosion. It's the introduction of a secondary process that determines how they differ after the roll forming process. GALVANNEALED VS. GALVANIZED STEEL In order to know which steel you will want to use for your architectural metal design, you'll first want to know the differences between the two. Galvannealed Steel Galvannealed steel goes through an extra processing step. Once the raw steel is coated in zinc, it's then heated to a higher temperature (over 1000° F). This process pulls the iron from the steel, causing it to mix with the zinc coating. Consequently, the coating becomes harder, more scratch-resistant, and more uniform in appearance. Galvannealed steel does not have a spangled appearance. The finish of galvannealed steel is fl

Have you ever heard about 201 stainless steel? It’s a surprisingly nice metal for outdoor projects that demand a blend of power, finesse, and beauty. Part of the 200 series of stainless steels, this metal is known for its use in indoor products like restaurant equipment, appliances, and cooking utensils. But 201 stainless will amaze you with its suitability for outdoor parts, including: Automotive trim Architectural applications Grills and other outdoor appliances And more! 201 STAINLESS STEEL OUTSIDE: THE SPECS 201 stainless steel specifications can be broken down into four main categories: Cost Toughness Resistance Formability Cost  This grade of stainless steel’s relatively low cost is resulting in more frequent use among engineers and architects. Because it’s light in weight, you can pack in more per pound. Toughness  In certain applications (more on these in a sec), you need an extremely hard metal. You’ll get great impact resistance with 201 stainless steel. Its toughness in cold

Architectural design may be functional first and foremost, but it’s still a form of art. One aspect of art and analysis is motif. A motif is like a brand. It tells the viewer “I made this,” or “these designs are connected.” Your motif can be color, form, interior design components, or anything else. One of Frank Lloyd Wright’s design motifs was leaded glass windows. You don’t have to pioneer a design style to put a “signature” in/on your buildings. All it takes is one little component that belongs to you. Custom manufactured tooling can create that signature. CUSTOM MANUFACTURING FOR ARCHITECTURAL DESIGN While we’re most knowledgeable about roll forming tools, almost any manufacturing process can be customized to create a “signature” product. 1.  Full Ownership You own your custom tooling. It may sit in your manufacturer’s facility, but it belongs to you. You can request product from it at any time, and you don’t have to worry about tooling costs. It shortens lead times, and ultimately

HOK'S INSPIRATIONAL USES OF ARCHITECTURAL METAL 1.  Spire London Spire-London-Lobby Images: InHabitat Spire London Exterior Spire London is a “residential tower,” the definition of luxury apartment living. At 771 feet high, it currently stands as the tallest residential tower in Western Europe. It boasts bronze-colored metal detailing on the lower floors, with matching feature fins on its pavilion buildings. The design uses mixed materials, with metal complementing the traditional brickwork and elegant marble.   2.  University of Florida Research and Academic Center University of Florida Research and Academic Center Image: University of Florida University of Florida Research and Academic Center Image: GKD Metal Fabrics The UFRAC uses a mixture of metal mesh, glass, and a steel skeleton to create a beautiful and functional design. The mesh blocks many detrimental effects of direct sunlight, while allowing natural light into the building. HOK worked with GKD Metal Fabrics to realize

So, you want to make something out of metal, put it outside, and make sure it lasts a long time. Easy, right? Engineers have been doing that for centuries and having success. As you ponder your task you ask, “What are my choices?” You need strength to maximize cost. In other words, you want to buy the least amount of metal possible, yet still create a strong design. You need the metal to be ductile enough so your manufacturer can form it. You want metal corrosion protection during all four seasons and along the coast. OUTDOOR METAL CORROSION PROTECTION: YOUR STANDARD CHOICES CONSIDERED outdoor metal corrosion protection.jpg   (Photo courtesy Archiproducts) How about you use gold? It is highly corrosion resistant. In fact, it is the base for which all corrosion is measured in the Anodic Index. Unfortunately, for gold to be a good option, you’d need to A) win the lottery B) magically give gold the rigid strength you need for your project. You could also try bronze or copper. They are bea

Which type of decorative metal trim finish is right for your project? It depends on the basis of the specification. “Form or function?” is the basic question so many architectures have wrestled with over the years, and it applies even to decorative accents. Know this before we continue: Roll forming companies generally don’t do finishing themselves. You may, however, be able to find a metal manufacturer who provides finishing services through a contracted partner. But if you want to take the uniqueness of metal trim a step further, it’s definitely worth a look. DECORATIVE METAL TRIM: SPECIFYING FOR APPEARANCE Are specifying a trim based on the aesthetics you want? There are more ideas and techniques out there than ever before. Here are some of them: 1. Rusted Steel (or Iron!) A few years ago many trend-seeking designers started asking for rusted steel. You can probably see why: In the right style of interior, it would look charming. Examples include: Industrial Weathered wood Other old

Being ahead of the hottest trends is what makes an already qualified and experienced designer stand above the competition. As many modern upscale home and business owners seek to revamp their spaces with materials beyond wood, they are considering the use of strategically placed metal to create impressive architectural touches. An up-and-coming trend with architectural finishes involves a process called intentional corrosion (or forced corrosion). WHAT IS FORCED OR INTENTIONAL METAL CORROSION? Intentional corrosion of metal allows designers to take certain types of metal and transform them into vintage-looking pieces quickly. Want to get that orange-brown rusty finish or enjoy a lovely blue-green patina on your metal accents? There’s no need to stretch the design budget buying true antique pieces or waiting for nature to take its course if you are knowledgeable about the process of intentional corrosion. As a newer innovation in design techniques, requesting this rising trend can put y

Engineers seek out corrosion testing as a way to scope out a problem before shooting with live rounds, so to speak. A corrosion test helps you understand how long a fabricated metal item will hold up under tough conditions. Those conditions include: High temperature High humidity Presence of salt (whether in coastal waters or on roads in cold-weather regions) There are plenty of reasons to conduct a corrosion test and plenty of ways to do it. Let’s investigate. WHY BOTHER WITH A CORROSION TEST? You should use corrosion testing to qualify which material (or chemical, if your heart’s already set on a specific metal) makes sense for your intended use. The real point of the test is to save yourself a buttload of trouble later. Corrosion can render your metal damaged beyond repair. Beyond bruising your ego, this failure could result in: High repair costs Safety risks Production downtime Damage to your professional reputation If you’re creating a product that’ll sustain heavy environmental a

Engineers seek out corrosion testing as a way to scope out a problem before shooting with live rounds, so to speak. A corrosion test helps you understand how long a fabricated metal item will hold up under tough conditions. Those conditions include: High temperature High humidity Presence of salt (whether in coastal waters or on roads in cold-weather regions) There are plenty of reasons to conduct a corrosion test and plenty of ways to do it. Let’s investigate. WHY BOTHER WITH A CORROSION TEST? You should use corrosion testing to qualify which material (or chemical, if your heart’s already set on a specific metal) makes sense for your intended use. The real point of the test is to save yourself a buttload of trouble later. Corrosion can render your metal damaged beyond repair. Beyond bruising your ego, this failure could result in: High repair costs Safety risks Production downtime Damage to your professional reputation If you’re creating a product that’ll sustain heavy environmental a

When you invest in metal materials, you expect them to last. But it’s a mistake to assume metal is immune to degradation from environmental and other factors. Corrosion can wreak havoc on the structural integrity and aesthetics of your parts. That’s why it’s important to know the factors of corrosion -- where it occurs most and what promotes it. Armed with this knowledge, you can account for corrosion when planning your next project. FACTORS OF CORROSION: WHAT PROMOTES IT & WHERE TO FIND IT 1. Weldingfactors of corrosion chrome bumper Welding is the best and most popular way to permanently attach two pieces of metal. But it also creates an environment where corrosion can set up shop and go wild. Every weld creates stress -- we mean in the metal, not the welder. Stress disrupts the structure of metal in ways that allow corrosion to occur. You can see examples of welds leading to corrosion in old chrome bumpers. They always rust where the deepest part of the draw is. Fortunately, you

The oceanfront is a beautiful but expensive place to live. And as it turns out, it’s also one of the most difficult places to use metal in outdoor architecture.  The salt and moisture of the seaside makes long-lasting construction a challenge. The majority of coastal buildings need maintenance every few decades or, depending on the metal used in their construction, they may need to be completely replaced. And while most metals are resistant to corrosion, they are not immune. Those that are immune to corrosion are typically luxury metals that carry big price tags. As you move further inland, all metals survive longer thanks to lower levels of salt in the environment. It won’t save them from the rain and weather, but they stand a better chance. No matter where you build, your architecture will be exposed to wind, rain, and possibly salt and other elements. Deciding on the best metals for exterior applications can be the difference between a long-lasting tribute to your skill and an ugly,

Architectural wood mouldings date back to the early Greeks (like, B.C. early). From temples to homes, wood has been the backbone of most of what we build. And wood trim continues to be the most popular way to accent a room, door, or window. Architectural metal trim is certainly not a new invention of the 21st century, either -- ever since we learned how to melt and shape metals, we’ve been using them in our architecture. One of the first recorded instances of building with decorative metal was in the third century B.C., when the 162-foot-tall Loha Maha Paya temple in Sri Lanka was topped with copper shingles. Even today, copper and other metals remain a sign of luxury and wealth in architecture. Metal is both timeless and modern, while wood is fleeting. So where does that leave wood?  Have interior designers exhausted all of their ideas for wood? Is wood trim outdated now?   IS WOOD TRIM OUTDATED? Maybe wooden mouldings aren't outdated so much as they are tired and primitive (for t