In construction and engineering, metal channels serve as building components that are used for a broad range of applications due to their strength and versatility.
They are essential when building bridges, reinforcing skyscraper structures, and are readily available as a reliable solution.
With this information, you will appreciate the different types of metal channels, their numerous uses, and advantages, which will assist you in selecting the metal channel suitable for your intended use.
What is Metal Channel?
Mainly referred to as U or C channels, metal channels are made of high-strength and adaptable metals, which stand the test of time, hence the name C or U-shaped channels.
Metal channels perform efficiently due to their specific shape, which provides excellent structural support across various sectors in construction and engineering.
Alloyed with zinc, brass, or steel according to the requirements, metal channels are roll formed into shapes such as tubes, U, J, or C, serving as the backbone of industrial environments.
Adaptability and strength almost always mean aluminum as a material of choice, making it frequently used in any application where corrosion resistance factors are needed, further to the metals required.
In the building industry, metal channels are used as construction soundproofing between plasterboard layers to help mitigate the transfer of sound. They are particularly useful in controlling sound vibrations.
This is just one example from the many practical uses of metal channels, which are globally recognized for their durability.
Types Of Metal Channels
Metal channels are formed during the high-speed roll forming process in which a metal strand is shaped into a channel. Each of the channels has particular profiles and specific dimensions tailored to corresponding niches.
Metal channels mostly serve to offer continuous support and reinforcement to other structural parts.
In the design stage, metal channels begin with a basic shape known as the web, which has legs on both sides. Strip rolling shapes metal strips into various profiles, which are designed for particular functions.
C channels are some of the most common channel shapes, but the term “C channel” encompasses many profiles and configurations.
#1. C Channel.
C channels are a type of metal channel that is frequently utilized in construction due to their use as a building support, a wall support, a roof support, a ceiling support, and more.
Because C channel is a generic term, it covers a wide variety of channel types, dimensions, and sizes, meeting specific requirements. This is due to the fact that sheet metal can be roll formed into any specific requirements.
Thus, the reason why the name “C channel” was chosen is because of its resemblance to the letter C. Furthermore, channels of this type are made by adding flanges to a base that is U-shaped.
Some may even have their flanges folded back to create a crimped version of the C channel. Regardless, C channels are available in countless variations designed to meet specific requirements.
#2. Hat Channels.
As previously mentioned, hat channels have a base with vertical or angled sides, while the face of the channel is capped at the end with edges that thrust outward. This gives hat the appearance of a wide brim hat that is resting on its crown.
Lastly, just like C channels, it is worth noting that hat channels also start as a U-shaped channel during the roll forming stage as well, which is then bent outward at the top edge.
Hat channels are especially designed for roof framing and are often referred to as hat purlins, which are a major horizontal element in roof systems. While hat channels can be conveniently purchased in a standard length of twenty feet, they can be tailored to specific required lengths.
#3. U Channel.
Forming two right angles to a strip of metal results in a U channel. They can be distinguished by their shape because which can also be altered with different bottom profiles, like round or flat, as well as different sizes ranging from a few inches or several. U channels have bottom widths and side heights that are adjusted depending on application needs.
#4. J Channels.
J Channel is one of the few types that has one side longer than the other, which creates a J outline. Though the basic J channel has various uses, there are many alternative versions created for specific dimensions and applications.
The standard version of a J channel without a hem, a hemmed version, and one that has a flat portion which can be affixed with screws or nails are all common variants of J channels.
Like other channels, J channels are made of metal and come in different sizes, ranging from a few feet to over 20 feet.
How Metal Channels are Roll Formed?
Metal Channels are produced through roll forming, which is a process that involves continuously bending a sheet or strip of metal and passing it through a sequence of rollers or stands.
Each roller has a specific increment for the form of the metal to achieve the desired shape. The shaped channels are then cut to size.
This technique of roll forming is economical for high-volume production of parts that require little finishing or secondary processing. With this method, it is possible to produce an extensive range of metal channel profiles.
CAD Design
Channels and other roll formed parts begin with CAD, which lists the design details like shape, length, and type of metal. It integrates all these factors into a single design so that sustainability can be achieved at production.
In CAD, it is possible to set the parameters or to draw them directly onto the computer. The CAD software produces both nested and separated views of the metal channel, showing its development through each stand in the strip-based automatic rolling mill.
An example is shown below – a CAD-separated view of a hat channel illustrating the roll forming step-wise construction. All the data from these CAD models can be transformed into G-codes ready for a roll forming CNC machine.
Sheet Metal Coil
Roll forming starts with a coil of metal mounted on an uncoiler or decoiler. This device controllably puts the metal sheet into the strip-based automatic rolling mill. The image below illustrates the uncoiler to the right of the roll forming machine.
Pre-Processing Treatment
Parts are typically manufactured with holes, notches, slots, or custom cut patterns by an in-line pre-processing operation step performed prior to metal channel roll forming.
A programmable mechanical, pneumatic, or hydraulic machine exerts a preset force using hardened cutting tools with defined sharp edges to punch the workpiece.
Roll Forming Dies
The roll forming procedure begins by preparing the roll forming machine with a set of distinct dies for each stand, which were manufactured with high precision.
The dies are designed to suit the specifications of the metal channel and its constituents. Each die is mounted on a different station where every roller in that station advances the working metal sheet further down the matrix.
Roll Forming
When these dies are fitted on the roll forming machine, it is connected to the uncoiler, containing a strip of metal. After loading the CAD program, the roll forming process is initiated, which begins by pre-processing the strip and aligning it through an entry guide or table.
This tab ensures the first pass is aligned and orthogonal, forming the desired product geometry. The number of passes required varies with design complexity, ranging from less than thirty passes to upwards of thirty.
Final Cut of Metal Channel
As roll forming processes vary, the cutting of the channel can also involve straightening at the output or input ends. It does not matter how the method is implemented; the channel will eventually pass through a stage where it is trimmed to a predefined size, and afterwards set to a table and some rollers.
What Metals Are Used In Producing Metal Channels?
Metal Channels can be formed out of various metals, but for roll forming, the most popular choices are aluminum, carbon steel, and different classes of stainless steel.
The purpose of the channel determines the selected type of metal, as a channel that is meant to support significant weight would be better made from a dense and tough metal.
In construction, building studs and rafters are made out of steel, while shelf supports and secondary cross members tend to be made of lighter metals like aluminum and brass.
Steel
Metal channels made from steel are incredibly durable due to the strength properties of the material. The structural properties of steel are utilized in construction for building frames, braces, and supports in different types of heavy-duty machinery and equipment.
Aluminum
Metal channels made from aluminum need to be both versatile and strong, which makes this metal an ideal material. Aluminum is not as strong as steel in terms of tensile strength, but it offers ample support when used for applications and devices.
Therefore, aluminum is used widely to make frame extensions and poles for lights, windows, doors, joints, and ladders. Besides those noted, aluminum is also known to have some of the highest conductivity, making it a great conductor and reflector of heat.
Brass
Brass 385, also known as architectural bronze, is one of the well known grades of brass, which is also used for making channels and has enhanced features such as durability and exceptional corrosion resistance.
This grade of brass can be made into desired shapes easily and looks attractive when polished. Therefore, architectural bronze can be used for decorative purposes to make shelves and wall supports for displays. Brass can be manufactured in precise shapes and lengths for use in various devices.
Stainless Steel
Stainless steel roll-formed metal channels have various grades, and each of them has distinct qualities and attributes. As these grades differ, so do their grade’s mechanical properties, corrosion resistance, and appearance.
However, stainless steel is preferred because of its value in resisting corrosion or rust, which is essential in stainless Steel Industries that experience high sanitary requirements.
The most commonly used stainless steels are 304 and 316, the latter being the oldest and the most common.
The resistance of stainless steel is attributed to its alloying elements of chromium and nickel, which increase the rate of oxidation and corrosion resistance. Grade 316 is also known as marine grade and is the second most used type of stainless steel.
Copper
Copper is utilized mostly with increasing arms in roll forming copper due to its ductility, which allows it to be easily roll formed into different metal channel profiles.
Copper is often alloyed with zinc to make brass or with tin to forge bronze. In turn, these alloys upgrade the properties of glass, making it and all copper alloys classified as red metals, which maintain their inherent strength even after roll forming.
Although red metals possess similar formability and resilience traits to red metals, unlike them, they lack strength. Regardless, red metals are appreciated for their endurance. Stains, scratches, and other environmental effects have no impact on red metals once oxidized.
Applications Of Metal Channels
Metal channels are important in providing structural support for walls, ceilings, and roofs, but they can do so much more. With the many available profiles, channels of metal can act as a rigid support beam across multiple dimensions, metal types, lengths, and thicknesses.
Their versatile configuration makes them tremendously valuable towards the advancement and adaptation of evolving technologies.
The versatility of metal channels comes from their many surfaces, which allow for easier connectivity. Channels with notches, holes, and other specialized shapes are readily available and are able to be anchored with ease.
Walls
Metal channels are used to form walls on garages, warehouses, workshops, and steel outbuildings and are made of aluminum or steel. They extend from the bottom to the top plate of a wall and help carry vertical loads.
Unlike wooden studs, metal ones provide much more support in weight and stiffness. To secure the metal channels, bolts and rivets far outperform nails in securing to the metal.
Roofs
Metal channels are used as rafters from the eaves to the ridge and are made from various construction materials to elf the roof deck. They are more compact and lighter in weight when compared to other materials, but still provide the same upper limit of stress they can bear.
Compared to wood, metal channels have a longer lifespan since they do not rot, decay, or get damaged due to moisture. In roofing construction, metal channels can serve as primary supports or as additional reinforcement alongside other materials.
Door Frames
Metal channels can be fitted into door openings to help maintain the desired fit during installation. They serve as guides for a finished grade for the door, which, compared to traditional wood framing, makes it fit in a dusting more precisely and stably. Metal channels are well-suited for use in fire doors due to their sturdy and fireproof construction.
Vehicle Frames
Heavy-duty Aluminum or Steel is used to fabricate custom designed metal channels to suit particular needs in different automobiles. The channels construct the key vehicle frame, while lighter metal channels are for cross framing and reinforcement.
Since these metal rods have a great deal of strength, the channels also give rigidity to the vehicle, preventing excessive flexing while allowing movement for engine torque.
Solar Panel Frame
Solar panels need to be lightweight and yet strong enough to endure harsh environmental conditions, which is why metal channels are a perfect fit for these requirements.
The solar panel channels need to have high tensile strength so that they can withstand the conditions where solar panels are mounted, and at the same time, be lightweight so that flexible installation can be done across different environments.
Industrial Uses for Metal Channels
Construction
Metal channels have found a very big scope of application in construction as there is a growing demand for material to be lightweight, recyclable, as well as strong and durable for multiple uses.
With the gradual decline of using wood in construction, the industry has shifted toward using metal channels, which function much like wood but with added structural strength.
Also, metal channels range in use from scaffolds to walls, they serve as a dependable, strong, and versatile material. Metal channels can be single used and recycled or kept stored for multiple uses.
The weatherproof materials used in metal channels make them a useful and strong alternative to traditional construction methods.
Transportation
In the automobile industry, metal channels have multifaceted usage, such as in window tracks, bumpers, trim, structural components, and even the vehicle’s reinforcement bars. They also help to enable modern vehicle design by alleviating weight, which increases the vehicle’s fuel economy.
Design innovations rely on channels for providing structural supports as well as enabling lightweight frameworks. Metal channels’ adaptability and versatility are some of the fundamental aspects why new concepts and technologies towards the development of transportation readily adopted.
Agriculture
This industry is involved in probably the most challenging sectors in search of a material that is able to endure extreme conditions. In agriculture, metal channels have significant use in the construction of animal enclosures and storage bins.
Metal channels offer a unique solution because most of these materials are liable to come into contact with harsh elements. With metal channels, the grain, animal feed, or fertilizer makes no difference; the equipment provides protection from the environment as well as contamination.
Aside from the fact that they are lightweight, metal channels are strong enough to build these storage units and allow for their relocation whenever necessary. Such flexibility allows for reduced costs of storage and provides producers with equipment that can function in diverse locations.
Aviation
The aviation field focuses on the functionality coupled with lightweight properties of any product or component. Due to the above mentioned reasons, metal channels find widespread application in aviation.
They are generally present in cabin walls, seats, structural supports, and other areas where their reliability and safety are critical.
The aviation industry does require a certain standard when it comes to metal channels and these are usually made of aluminium.
In addition, the weathering, rust, and corrosion resistance provided by this material ensure the safety and durability of an aircraft’s components.
Other Uses
The above examples are underestimating the applications provided for metal channels. Engineers and designers creatively incorporate these metal channels for a number of items ranging from highway signs, bridges, heaters, household appliances, industrial furniture, to even office furniture. These channels are crucial for the functionality and essential support they provide across different industries.
The depletion of natural materials such as wood is one reason why the use of recyclable and durable metal channels is expected to rise further.