Modern metal fabrication is often defined by the advanced technology that dominates high-performance shops. Skills that were once locked inside the heads of craftsmen now have been programmed into control systems. An operator can hit a button and watch as parts are cut or formed on a CNC machine. The only other activity the operator might be involved with is removing parts from and then trashing the skeleton.

That type of CNC is commonplace in many shops, but not all. Some sectors of metal fabricating are still reliant on the wisdom of experienced machine operators. Advanced control technology still has trouble accounting for all the variabilities that come with these jobs. These areas include section, angle and plate rolling. Without the skilled input of someone who has done this type of work, the chances of reworking, or even worse, scrapping, are greatly increased.

The newest addition to Topring Rollers’ shop floor is a Roundo Model 4R3S four roll section rolling machine, which has been supplied by Talmac Machine Tools. Roundo is originally a Swedish company but now is within the Faccin Group. The Roundo Model 4R3S series delivers exceptional performance and outstanding results for small and medium profiles. The four roll machine is a fully CNC programmable section roller

Topring Rollers has provided curved metal components and products to customers since 1989. With that history, the company has developed the skills necessary to deliver the most challenging of shapes on time and within specifications. Topring Rollers was established in 1989 by Pieter and Dot du Toit after Pieter, a tradesman, was retrenched. The first piece of equipment the company purchased was a single Roundo Model R8 section rolling machine that was acquired at an auction and was in a serious state of disrepair. Since then the company has expanded to have over 30 section, plate and bending machines and is still operating from the same premises where it started and is now managed by Sean du Toit, the son of the founders.

Curved metal products can be found in homes, buildings, transport vehicles, stadiums and infrastructure developments. Whether you are looking for balustrading, staircases, roof trusses, flanges, drain pans, pipelines, heat exchangers or artwork you are more than likely going to approach a company that has section, angle or plate rolling capabilities. But like many engineering disciplines they are defined by light, medium and heavy-duty. Most processors will cover most of these areas but a company manufacturing for example tankers and trailers will concentrate on their own requirements.

The Roundo Model 4R3S four roll section rolling machine offers a superior bending solution for crafting body shell components, vehicle chassis components, exterior lighting components, open profile bending (Omega, Channel, etc.), aerospace profile sections, and high-strength material profiles. Although the machine can roll all the standard sections available, this machine will be utilised to curve the various aluminium door, window and curtain wall sections required by architectural detailers and installers

Topring Rollers offers a variety
“We can bend most sections, in mild steel, stainless steel, aluminium as well as speciality steels. These include angle iron, flat bar, channels, beams, pipes, columns and rails,” said Sean du Toit.

“We can roll plates from 0.5mm down to small sizes, right up to 20mm over 3m lengths in mild steel and up to 16mm thick in stainless steel.”

“Our press brake is used mainly for in-house applications, however, we are able to bend 3mm mild steel plate over 2.5m.”

“We have more experience than anyone else in the country when it comes to rolling spiral sections. Our capacity is up to 219mm round tube, 300mm by 100mm channel and 305mm by 102mm beam. We are also capable of rolling up to 250mm by 30mm thick flat bars as spirals.”

“We now have 30 different rolling and bending machines producing all sorts of components. These include section rolls, plate rolls, mandrel benders and pressing equipment. We will do one-offs or reasonable size production runs but limit ourselves to the capabilities of our equipment.”

Topring Rollers can bend most sections, in mild steel, stainless steel, aluminium as well as speciality steels. These include angle iron, flat bar, channels, beams, pipes, columns and rails

“Roll forming still remains a viable method of continuously forming cross sections of metal, even if the jobs of today are measured in hundreds of instead of thousands.”

“Today, roll forming, also referred to as cold rolling or roll profiling, is producing shapes that industry veterans might find hard to believe. The process delivers much more than simple C and U-shaped profiles. In fact, some of these cross sections look like extrusions or even like two pieces of metal that have been welded together. Roll forming is delivering plenty of unexpected possibilities for the metal fabricating community.”

“Each client has their unique profiles. They will supply the material to us to process. We can get the die made for them and where necessary we can design it for them. The manufacture of the dies is costly so great care is taken. Going forward maybe 3D printing will play a role and reduce costs, as you say.”

Topring Rollers’ capacity is up to 219mm round tube, 300mm by 100mm channel and 305mm by 102mm beam. They are also capable of rolling up to 250mm by 30mm thick flat bars as spirals

New Roundo Model 4R3S four roll section rolling machine
“We have recently broadened our scope of capabilities. The newest addition to our shop floor is a Roundo Model 4R3S four roll section rolling machine, which has been supplied by Talmac Machine Tools. Roundo is originally a Swedish company but now is within the Faccin Group, a well-known Italian manufacturer of plate rolls and special rolling machines for larger diameters, thicker plates and challenging shapes.”

“The four roll machine is a fully CNC programmable section roller. The advantages of a CNC controlled four roll design over the more traditional three roll section rollers are that it is safer as the material is securely clamped in the pinch rolls from the start of the rolling process, there is less distortion as the material reforms in the pinch rolls on each pass, and it is also more efficient because the single operator and accurate repeatability due to the machine learning and the CNC programming capability.”

“It is also more versatile because of the simultaneous adjustment of bending rolls, guide rolls and material supports for continuous bending without stops or pauses between the different radii to avoid kinking or distortion on the finished part.”

Topring Rollers can roll plates from 0.5mm down to small sizes, right up to 20mm over 3m lengths in mild steel and up to 16mm thick in stainless steel. The company’s press brake is used mainly for in-house applications, however, they are able to bend 3mm mild steel plate over 2.5m

“The Roundo Model 4R3S series delivers exceptional performance and outstanding results for small and medium profiles. It offers a superior bending solution for crafting body shell components, vehicle chassis components, exterior lighting components, open profile bending (Omega, Channel, etc.), aerospace profile sections, and high-strength material profiles.”

“Although the machine can roll all the standard sections available, this machine will be utilised to curve the various aluminium door, window and curtain wall sections required by architectural detailers and installers.”

“We have specifically purchased the machine to accommodate this growing area of the market.”

For further details contact Topring Rollers on TEL: 918 2490 or visit www.topring.co.za