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ROLL FORMING NEWS
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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 break 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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LOCKSEAM TUBING |
 Lockseam
tubing, also called lock seam 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, lockseam 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 rollformed lock seam tubing include badminton
poles, maypoles, shoe racks, tripods for flip charts, and 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 (-8950), or
e-mail 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.
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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. |
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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.
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 |
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 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 the 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 such as notching, punching, and post-painting -
operations that can be eliminated using roll forming.
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 lockseam tubing (also called lock seam tubing,
lokseam tubing and seam lock tubing)
Samson Roll Formed Products Company is one of the largest
manufacturers of
lockseam 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.
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 lockseam 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 |
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 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.
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.
Read all our previous Roll
Forming News stories by clicking here |
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ROLL
FORMED FENESTRATION PARTS |
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LOCKSEAM TUBING - SHOWER WALL
BAR |
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 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 lockseam
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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