Metal Roofing and Wall Panel Roll Forming Terms You Should Know

Metal roofing and roll forming are important and common processes in the construction, design, and residential building industries. However, these processes can be quite difficult to understand for those outside the industry or newcomers. The various components of roll forming machines, their functions, the composition of metal roofs, and potential problems when operating these machines can be overwhelming.

These terms play a crucial role not only in equipment operation but also in product design, quality control, and project planning. This comprehensive guide aims to simplify the complex terminology and processes commonly used in the metal roofing and roll forming industry, compiling everything into a single glossary for easy reference. We have included definitions for the following terms:

• Roll Forming Definition: Roll forming process and different roll forming machines
• Metal Roofing Definition: Roofing components and installation accessories
• Other Metal Roofing Definitions: Metal roofing types and related components
• Problems with Metal Roofing and Roll Forming of Metal Coils or Sheets

Roll Forming Definition

Seaming: The process of folding material inwards.

Machinist: A worker who manufactures, assembles, or repairs machinery, a skilled craftsman using machine tools, a person who operates machinery.

Metal Coil: The winding of sheet metal into large coils. Coils are the most efficient way to transport or store sheet metal.

Metal Roll Forming: The process of feeding finished metal, coils, flat metal, or other forms of metal into a series of rollers, where each roller station further processes the metal part into the desired shape.

What is Roll Forming?

Roll forming is a continuous manufacturing process that uses a series of rollers to shape flat metal coils into specific profiles. Each stage progressively bends the material until the final shape is achieved. This process is widely used in the production of roofing panels, wall panels, and structural components.

Roll Forming Process Flow

The process begins by feeding the metal coil into an uncoiler. Then, the material passes through a leveling system to remove any irregularities. Afterward, the material sequentially passes through multiple forming stations, where rollers progressively shape the metal. Finally, the formed panels are cut to the required length.

This method ensures high production efficiency, dimensional consistency, and minimal material waste.

Types of Roll Forming Machines

Different types of roll forming machines are used depending on production needs and panel design.

Standard roll forming machines are used to produce single-profile panels in high-volume production environments.

 

Double-layer roll forming machines allow manufacturers to produce two different panel profiles using a single machine, increasing flexibility and saving space.

Portable roll forming machines are designed for on-site production, allowing for the direct forming of panels on the construction site.

Custom roll forming machines from suppliers such as Metoform can be configured to produce specific roofing or wall panel profiles according to project requirements.

Metal Roofing Definitions

Metal Roof: A roofing system made of metal sheets or tiles, characterized by strong wind/storm resistance, waterproofing, and long service life.

Metal Coil/Sheet Material: Metal roofing material initially exists in the form of metal coils or sheets, which are then rolled, cut, and roll-formed into the panels required for installation. Metal coils are long, continuous strips of metal that have been treated or painted.

Panel: Formed from metal coils through roll forming, creating the desired profile/rib structure that can be stitched together to form a roof.

Profile: The shape of the metal panels; they also determine how the panels are assembled and connected.

Roll Forming Equipment: Machinery that forms coils or sheets into individual panels; this can be a stationary or portable device.

Seam: The side rib that connects two metal sheets.

Metal Roofing Systems

Metal roofing refers to roofing systems made from metal panels or sheets that provide protection against weather and environmental conditions. These systems are known for their durability, long service life, and modern appearance.

Roofing Panels

Roofing panels are the main components of a metal roof. They are formed into different profiles to improve strength and water drainage. Common profiles include ribbed and corrugated designs.

Flashing Components

Flashing is used to seal joints and edges in a roofing system. It prevents water from entering areas such as valleys, edges, and intersections.

Fasteners and Clips

Fasteners and clips are used to secure metal panels to the structure. They play an important role in maintaining system stability and ensuring proper installation.

Other Metal Roofing Definitions

Cold Metal Roof: Painted or coated metal panels that reflect solar energy to dissipate heat.

EPDM Roof: Ethylene propylene rubber, a synthetic rubber used as a roofing material for pitched or flat roofs, commonly found in commercial buildings.

Exposed Fastener Metal Roof: A roofing system in which panels are directly attached to the roof slab or underlying frame via a metal surface and are visible from the top.

Flange: A protruding edge or side of a component, typically narrow and roughly constant in width, used for reinforcement or fastening.

Specification: A unit of measurement for metal thickness. A smaller specification number indicates a thicker metal.

Metal Sheet Joint Type: The shape and manner in which two or more metal sheets are joined perpendicularly.

Panel Profile: The shape and manner in which two or more panels are stitched together.

Ribbed rollers: refer to the “patterns” or stripes rolled onto the seams of metal roofing panels.

Vertical joint metal roof: a concealed fastener metal roofing system characterized by raised vertical seams and a wide, flat area between two panel legs.

Types of Metal Roofing Panels

Metal roofing panels can be classified based on their design and installation method.

Standing seam panels use concealed fasteners and provide a clean appearance with improved weather resistance.

Corrugated panels have a wave like profile and are commonly used in industrial and agricultural buildings.

Ribbed panels offer structural strength and are widely used in commercial construction.

Panel Coatings and Finishes

Metal roofing panels are often coated to improve corrosion resistance and enhance appearance. Coatings also help extend the lifespan of the roof by protecting it from environmental exposure.

Insulation and Underlayment

Insulation is used to improve thermal performance and reduce energy consumption. Underlayment provides an additional protective layer beneath the roofing panels to prevent moisture penetration.

Issues with Metal Roofing and Roll Formed Metal Panels

Issue	Description	Cause	Impact	Solution
Oil Canning	Visible waviness on flat metal surfaces	Internal stress in material or forming process	Affects appearance but not structural performance	Use proper material selection and optimized forming process
Corrosion	Surface deterioration of metal over time	Contact between different metals or damaged coatings	Can reduce lifespan and affect performance	Apply high quality coatings and choose compatible materials
Galvanic Reaction	Chemical reaction between different metals	Direct contact between dissimilar metals	Leads to accelerated material degradation	Use isolation methods and proper material pairing
Denting and Impact Damage	Physical deformation of panels	External impact from debris or objects	Affects appearance and may reduce panel integrity	Use thicker materials and protect exposed areas
Thermal Movement	Expansion and contraction due to temperature changes	Natural response of metal to temperature variation	May cause deformation or fastening issues	Design proper fastening systems and allow movement tolerance

Core Roll Forming Terms in Production

Metal Coil

A metal coil is the raw material used in roll forming. It is supplied in large rolls and determines the final product quality.

Forming Stations

Forming stations are the sets of rollers that shape the metal into the desired profile. Each station contributes to gradual and precise forming.

Cutting System

The cutting system trims panels to the required length after forming. Automated cutting improves accuracy and efficiency.

Control System

The control system manages machine operation, including speed and panel length. Advanced systems improve production consistency.

Conclusion

Understanding roll forming and metal roofing terminology helps improve communication, production planning, and equipment selection. From raw material processing to finished panel installation, each concept plays a role in achieving high quality results.

With the support of advanced roll forming machines from Metoform, manufacturers can produce reliable roofing and wall panel systems that meet the demands of modern construction.