CUSTOM POWER DISTRIBUTION ASSEMBLIES
Samson’s proud to announce its 5th year of being the leading producer of Custom Power Distribution components for the Contract Furniture industry. These Custom Power Distribution Assemblies afford the largest Office Furniture companies in Michigan the flexibility to power their wall systems in a variety of configurations. This translates into unique design layouts for their clients resulting in greater customer satisfaction and increased market share in a fiercely competitive environment.
Samson’s innovative engineering approach has reduced the number of production operations on one particular complex raceway base from six to two, dramatically curtailing labor costs and thus reducing the cost of the raceway assembly. On the mating raceway cover, we eliminated the secondary operation altogether.
In yet another case, Samson converted a brake press operation to a roll form operation saving our new customer 50% over his former supplier.
We are currently working with one of the largest global suppliers of Powered Raceway components to add pre-painted steel raceway components to their considerable catalog.
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LOCK SEAM TUBING
Lock Seam Tubing, also called lockseam or seam lock tubing, is mechanically joined tubing as opposed to electric-welded tubing or laser-welded tubing. Lock Seam Tubing is the tubing of choice for light gauge applications since metal generally is not welded for wall thicknesses less than 0.030”. Consequently, lock seam tubing is used for non-load bearing applications such as residential flagpoles that are made using 0.014” to 0.018” cold rolled steel finished with tinplate, zinc, or paint. Other consumer products using roll formed lock seam tubing include badminton poles, maypoles, shoe racks, tripods for flip charts, shelf supports for displays, etc.
Samson Roll Formed Products Company is one of the largest manufacturers of roll formed lock seam tubing. Contact us by phone (847) 965-6700, fax (847) 965-8950, or: success@samsonmail.com
to learn more about this product or to discuss your roll forming needs.
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SWIMMING POOL SUPPORT
Swimming pool support roll formed by Samson:
Superior support and a 50% cost savings. Note stitching performed automatically by the Samson systems.
Trial and error is not the ideal method for building structures like built-in swimming pools. One manufacturer discovered this and then turned to Samson custom roll forming for the most effective means to keep its customers in the swim. What's more, the company achieved a 50% savings on the superior supports.
The elements of a pool
The pool design in question consists of three main elements: a steel reinforced concrete floor, a concrete footing at the intersection of the floor and the sidewall, and the fiberglass sidewall. When a pool is being built, the sidewall panels are installed with structural supports laminated to the outside at 17" intervals. The supports extend beyond the bottoms of the panels so they can be secured into the footing. Additionally, rods are inserted into the structural supports, then bent back and driven into the unexcavated ground. The objective: to keep the panels perpendicular while the pool walls are back-filled.
Since a typical pool is filled with approximately 23,000 gallons of water, the strength and rigidity of the walls must be at high levels.
The problems of non-support
Initially, the pool manufacturer tried a structural support that was the result of tack welding a 1/2" conduit to a piece of 0.036" cold-rolled steel brake formed to a 90° angle. The pieces were expensive and inefficient. The conduit had a tendency to pull away from the angle during the back-filling.
Next, the company tried a redesign. There were two halves staked together to form a single structural support. Not only were these supports likely to spread apart under pressure, but even getting them ready for installation was a problem. Often, halves had to be reworked so they'd be straight enough to mate. 5% were rejects due to looseness or breakage.
Samson's support solution
After this trial and error approach, Samson engineers were called in. They developed a productive - and economical - solution. It's a one piece, custom roll formed wall support.
The material used is 0.028" hot dipped galvanized steel. Samson engineers, after studying the structural requirements of the component, designed ribs into the piece. The ribs provide an extra measure of strength, which permits the use of this lighter gauge material.
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Operations performed in the continuous roll forming process for the swimming pool support include pre-notching, forming, and cutting to length.
Overall, the Samson roll forming provides a 50% savings to the builder, as compared to the previously used techniques. Download our shape catalog page: Swimming Pool Hardware.
If you think your company might benefit from Samson’s engineering and cost saving innovations, simply click here to have one of our highly trained sales engineers show you how to improve your product and reduce your costs.
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POINT OF PURCHASE STORE FIXTURE SHELF SUPPORT
Roll forming is a continuous process that has distinct advantages over other production methods. It eliminates multiple stage production, finishing or sub-assembly operations.
Secondary operations can be combined continuously with the roll forming operation to speed production and reduce assembly costs. Roll forming permits consistent adherence to close tolerances and provides uniform shapes and dimensions to fit customers' specifications.
The ability to fabricate decorative parts from pre-coated, pre-painted, or pre-plated metal is a distinct feature of roll forming.
Practically all metals can be roll formed, not just aluminum, which is a distinct advantage of roll forming compared to extrusion methods that also require multiple stage production methods. Operations such as notching, punching, and post-painting can be eliminated by using roll forming.
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ROLL FORMING DEFINED
Compared to brake forming, roll forming can produce more parts with greater uniformity and consistency throughout the length of the part. Roll forming also eliminates multiple stage operations, trim scrap, and slitting burrs.
Roll forming is a high-speed production process that converts a flat strip of metal into shapes that are channels, angles, tubes or some variation of these basic shapes. Various kinds of tubes can be made using roll forming including open seam tubing, welded tubing, and Lock Seam Tubing.
Samson Roll Formed Products Company is one of the largest manufacturers of Lock Seam Tubing, which is used in such applications as flagpole kits, shoe racks, badminton poles, maypoles, lawn and garden torches and corrugated shelf supports, to name a few.
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This edition of Roll Forming News features one of these applications. The pictures show an example of a corrugated shelf support that is one kind of P.O.P. (Point of Purchase) store fixture. The corrugated shelves are used to display products such as groceries, cosmetics, greeting cards, etc. in retail stores. The shelves are supported by one-half inch or three-quarter inch diameter mechanically joined tubes called Lock Seam Tubes. These tubes are thin walled tubes that become the tubing alternative of choice for light gauge steel applications. The tubes can be made of almost any pre-finished metal: tinplate, pre-painted, or pre-plated, etc. The tubes are bent and flattened on each end to make them suitable for fitting inside a scored slot on each end of the corrugated display. The corrugated shelf is then lowered on top of these metal shelf supports.
Please contact Samson Roll Formed Products Company for more information about these products.
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SOLAR PANEL ASSEMBLY
Samson Roll Formed Products Company is a contract roll former that serves many different industries including the solar power industry. This edition of Roll Forming News features one of the products that Samson makes for this industry. The part is a parabolic shaped channel that is used in a solar panel assembly called a Compound Parabolic Collector. The collector is used for solar water heating, space heating, industrial process heat and solar cooling projects.
Solar thermal conductors offset energy consumption by concentrating solar energy as heat that is used to heat water in swimming pools, sinks, and showers; it also can be used to heat or cool buildings. This technology is different from the better-known solar photovoltaic panels, which produce electricity from the sun’s energy. Both types of solar technology decrease pollution including greenhouse gas emissions, sulfur dioxide, and mercury.
The technology is based on the mathematics non-imaging optics as developed by a professor at the University of Chicago. Non-imaging optics concentrates light more intensively than traditional optics. In some applications, this technology has proven to be able to concentrate sunlight up to 84,000 times the natural level of sunlight at the Earth’s surface. This exceeds the surface of the sun by 15 percent.
Another advantage is that the collector requires no moving parts unlike conventional solar arrays that must move over a range of 60 degrees from winter to summer in order to collect direct radiation from the sun.
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Samson’s engineers worked with the customer to convert an aluminum extrusion to a roll formed shape using very thin-walled aluminum that has a highly reflective surface, which is protected by PVC during the roll forming process. The roll formed part is the main component of the solar collector. The trough of the channel is designed to accommodate a pipe. The sunlight that is reflected off of the walls of the channel heats the pipe, which in turn, heats the water circulating through it. The solar heated water is then circulated throughout the building to generate heat and cost savings for the occupants.
Please contact Samson Roll Formed Products Company for more information about these products.
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ROLL FORMED FENESTRATION PARTS
Roll formed vinyl window reinforcement parts and roll formed patio door stiffeners shown with examples of roller track caps
Samson Roll Formed Products Company is a contract roll former that serves many different industries including the Fenestration Industry. The word fenestration is derived from the Latin word “fenestra”, which means “openings”. Hence, the fenestration industry is the door and window industry. This edition of Roll Forming News features some of the products that Samson makes for this industry such as cladding for wood windows, nail fin, patio door stiffeners, roller track caps, and vinyl window reinforcements. Some of these parts are illustrated on this page. Other profiles can be seen in Samson’s Shape Book or by visiting our Other Shapes.
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LOCK SEAM TUBING - SHOWER WALL BAR
Samson Roll Formed Products Company serves many industries including the Kitchen and Bath industry. One of the roll formed parts that Samson makes for this industry is a brass stanchion that is roll formed as a Lock Seam Tube. The perforations shown in the accompanying picture are post-punched rather than pre-punched because they are close to the beginning and end of the part. The part is subsequently chrome plated and sold as a kit with mating parts that include end caps, double-sided tape, a plastic slide, and a showerhead. The combination is sold as a premium portable hand-held shower assembly.
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COMMERCIAL AIR FILTERS
Commercial filters come in many shapes and sizes. The filter media is often encapsulated by plastic or metal to give the assembly rigidity. Some are surrounded by frames and others, such as the one depicted here, are supported by two different roll formed shapes and plastic end caps. The two roll formed parts are two unique profiles that are called Steg and Profile. The assembly consists of seven roll formed Stegs and two roll formed Profiles that Samson Roll Formed Products Company roll forms for a major commercial filter manufacturer. (Please go to the pdf document if you would like to see dimensioned drawings of these parts.)
Roll forming is the manufacturing method of choice for these two metal shapes because the economics of roll forming favor large lot sizes. Roll forming typically competes with braking and extruding at lower volumes. Because roll form tooling is generally the most expensive tooling relative to these processes, roll forming does not compete favorably with these processes at lower volumes, but the difference in tooling cost becomes moot as the volume increases because the difference in per unit cost among these processes increases at an incrementally larger rate per unit.
Roll forming also has other advantages over braking and extruding. Compared to brake forming, roll forming can produce more parts with greater uniformity and consistency throughout the length of the part. Roll forming also eliminates multiple stage operations, trim scrap, and slitting burrs.
Advantages of roll forming relative to extrusion methods include: practically all metals can be roll formed, not just aluminum. Also, roll forming can eliminate secondary operations - multiple stage operations such as notching, punching, and post-painting - by combining them in the roll forming process.
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Pre-painted steel can be substituted for post-painting methods and the metal can be perforated prior to roll forming or, if the hole pattern is close to the beginning or end of the part, the formed part can be perforated in the cut-off die. The ability to fabricate decorative parts from pre-coated, pre-painted, or pre-plated metal is a distinct feature of roll forming.
Samson Roll Formed Products Company is one of the oldest and largest contract roll formers in the U.S., located in Chicago in a large industrial facility that houses 40 roll forming lines and an array of ancillary equipment. Stamping, bending, parting, and assembly are some of the other services in Samson's arsenal of value-added options. Samson has stock tooling for more than 2,000 shapes, many of which are featured at other roll-formed shapes.
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