What is a good metal? Unless you are willing to learn about metallurgy, this is not easy to answer. But, to put it simply, the production of high-quality metals depends on the type and quality of the alloys used, heating, cooling and processing procedures, and a proprietary system that belongs to the company’s confidentiality.
For these reasons, you need to be able to rely on the source of your coil to help ensure that the quality and quantity of the metal you think you ordered is consistent with the quality and quantity of the metal you actually received.
Owners of roll forming machines that are portable and in-store fixed machines may not know that each specification has an allowable weight range, and not considering this when ordering may lead to unexpected shortages.
Ken McLauchlan, Director of Sales at Drexel Metals in Colorado, explains: “When the pounds per square foot are within the allowable range, it can be difficult to order roofing materials by pound and sell by square feet.” “You might plan to roll the material. Set at 1 pound per square foot, and the coil sent is within a tolerance of 1.08 pounds per square foot, suddenly, you need to complete the project and get paid for the material shortage by 8%.”
If you do run out, did you get a new volume consistent with the product you have been using? McLauchlan gave an example of his previous work experience as a major roofing contractor. The contractor changed the middle of the project from using prefabricated panels to roll forming his own panels on site. The coils they ship are much harder than the ones used and required for the job. Although high-quality steel, harder steel can cause excessive oil cans.
Regarding the issue of oil cans, McLaughlin said, “Some of them may be [roll forming] machines-the machine is not adjusted correctly; some of them may be coils-the coil is harder than it should be; or it can be a consistency : Consistency can be grade, specification, thickness, or hardness.”
Inconsistencies may arise when working with multiple suppliers. It is not that the quality of steel is poor, but that the calibration and testing done by each manufacturer meets its own machine and its own requirements. This applies to steel sources, as well as companies that add paint and paint. They can all be within industry tolerances/standards, but when mixing and matching suppliers, changes in results from one source to another will be reflected in the final product.
“From our point of view, the biggest problem for the finished product is that [process and testing] must be consistent,” McLaughlin said. “When you have inconsistencies, it becomes a problem.”
What happens when the finished panel has problems on the job site? Hopefully it will be caught before installation, but unless the problem is obvious and the roofer is very diligent in quality control, it is likely to appear after the roof is installed.
If the customer is the first to notice the wavy panel or color change, they will call the contractor’s first person. Contractors should call their panel suppliers or, if they have roll forming machines, their coil suppliers. In the best case, the panel or coil supplier will have a way to assess the situation and begin the process of correcting it, even if it can point out that the problem lies in the installation, not the coil. “Whether it is a big company or someone who works outside his house and garage, he needs a manufacturer to stand behind him,” McLaughlin said. “General contractors and owners are looking at roofing contractors as if they have created problems. The hope is that the trend is that suppliers, manufacturers, will provide additional materials or support.”
For example, when Drexel was called in, McLauchlan explained, “We went to the job site and said, “Hey, what is causing this problem, is it the substrate (decoration) problem, the hardness problem, or something else?; We’re trying to be Back-office support… when manufacturers show up, it brings credibility.”
When the problem does appear (it will definitely happen one day), you need to check how to deal with the many problems of the panel from point A to point B. Equipment; Has it been adjusted within the tolerances of the machine; is it suitable for the job? Have you purchased the right specification material with the right hardness; are there tests for the metal to support what is needed?
“No one needs testing and support before there is a problem,” McLaughland said. “Then it’s usually because someone says,’I'm looking for a lawyer, and you won’t get paid.’”
Providing a proper warranty for your panel is a way to assume your own responsibility when things get worse. The factory provides a typical base metal (red rust perforated) warranty. The paint company provides guarantees for the integrity of the coating film. Some vendors, such as Drexel, combine warranties into one, but this is not a common practice. Realizing that you do not have both can cause severe headaches.
“Many of the guarantees you see in the industry are prorated or not (including substrate or just film integrity guarantees),” McLaughlin said. “This is one of the games the company plays. They will say that they will give you a film integrity guarantee. Then you have a failure. The metal substrate supplier says it’s not metal but paint; the painter says it’s metal because it won’t stick. They point to each other. . There is nothing worse than a group of people on the job site accusing each other.”
From the contractor who installs the panel to the roll forming machine that rolls the panel, to the roll forming machine used to manufacture the panel, to the applied paint and finishes to the coil, to the factory that manufactures the coil and manufactures steel to make the coil . It takes a strong partnership to solve problems quickly before they get out of control.
McLauchlan strongly urges you to establish strong partnerships with companies that provide the best services for your panels and coils. Appropriate guarantees will be passed to you through their channels. If they are good partners, they will also have the resources to support these guarantees. McLauchlan said that instead of worrying about multiple warranties from multiple sources, a good partner will help collect the warranty, “so if there is a warranty issue,” McLauchlan said, “this is a warranty, a person calls, or as As we say in the industry, a choked throat.”
Simplified warranty can provide you with a certain degree of sales confidence. “The most important thing you have is your reputation,” McLaughlin continued.
If you have a reliable partner behind you, through the review and resolution of the problem, you can speed up the response and alleviate the overall pain points. Instead of yelling at the job site, you can also help provide a sense of calm as the problem is being addressed.
Everyone in the supply chain has the responsibility to be a good partner. For roll forming machines, the first step is to buy quality products from reliable sources. The biggest temptation is to take the cheapest route possible.
“I have been trying to improve cost-effectiveness,” McLaughland said, “but when the cost of the problem is 10 times higher than the cost saved, you can’t help yourself. It’s like buying a 10% discount on material and then 20% interest will be deposited into your credit card.”
However, it is useless to have the best coil if it is not handled properly. Good machine maintenance, routine inspections, correct selection of profiles, etc. all play an important role and are all part of the roll machine’s responsibilities.
Make sure you fully meet the expectations of your customers. “Suppose you have a coil that is too hard, or it is not divided correctly, or the panel is deformed due to unevenness, it will depend on who turns the raw material into a finished product,” McLaughland said.
You may be inclined to blame your machine for the problem. It 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; cut/retracted/improperly handled; stored outdoors; wet; or damaged?
Do you use a sealing machine at the work site? The roofer needs to make sure that the calibration matches the job. “For mechanical, enclosed panels, it is very important to ensure that your sealing machine is calibrated with the panel you are running,” he said.
You may be told that it is calibrated, but is it? “With a sealing machine, many people buy one, borrow one, and rent one,” McLaughlin said. problem? “Everyone wants to be a mechanic.” When users start to adjust the machine for their own purposes, it may no longer meet manufacturing standards.
The old adage of measuring twice and cutting once also applies to anyone who uses a roll forming machine. Length is important, but width is also important. A simple template gauge or steel tape measure can be used to quickly check the profile size.
“Every successful business has a process,” McLaughland pointed out. “From the perspective of roll forming, if you encounter a problem on the production line, please stop. The things that have already been processed are difficult to repair… Willing to stop and say yes, is there any problem?”
Going further will only waste more time and money. He uses this comparison: “The moment you cut 2×4, you usually can’t bring them back to the lumber yard.” [Rolling Magazine]
Post time: Aug-14-2021