In construction and engineering, the foundation of every great structure lies in the materials used. Steel, known for its strength, durability, and versatility, plays a pivotal role in shaping everything from buildings to complex machinery. GWR specialises in the fabrication of pressed steel sections tailored to meet the unique demands of your projects.
With over 40 years of expertise in the presswork industry, we take pride in our ability to transform raw steel into precisely engineered components used in the logistics, manufacturing, construction, transport and waste sectors. In this blog, we’ll look at pressed steel channel, how it compares to rolled steel channel (RSC), the manufacturing process, and applications.
RSC (Rolled Steel Channel)
RSC, or Rolled Steel Channel, has a C-shaped cross-section with one long, flat side (the web) and two shorter, perpendicular sides (the flanges). It is produced by passing steel through rollers to form this channel shape.
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Pressed Steel Channel
The main difference between pressed steel channel and rolled steel channel is in the manufacturing process. Pressed channels are cold-formed steel sections with a C-shape, similar to rolled steel channels (RSC). However, unlike rolled sections, pressed channels are made by applying pressure to a flat steel plate, bending it into the target shape through a process called cold-forming or press braking. The pressed steel is typically lighter and thinner, making it suitable for applications where weight and cost are factors.
A cold-forming fabrication can shape steel sections at room temperature without heating them. The manufacturing process typically involves the following steps:
- Material Selection: High-quality steel coils are selected as the starting material.
- Uncoiling: The steel coils are uncoiled and flattened to prepare them for the forming process.
- Forming: The steel is passed through a series of forming dies that gradually shape it into the desired channel section.
- Cutting: The formed steel is cut to the required lengths.
- Finishing: The finished product can go through additional finishing processes, such as straightening, trimming, and drilling.
This process offers several advantages over hot-rolling, including:
- Improved Dimensional Accuracy: Cold-forming allows for greater control over the dimensions of the steel section, resulting in more precise and consistent products.
- Enhanced Material Properties: Cold-forming can improve the mechanical properties of steel, such as strength and ductility.
- Reduced Energy Consumption: Cold-forming is a more energy-efficient process compared to hot-rolling, reducing the environmental impact.
Pressed channels can be made from a variety of steel grades, including mild steel, galvanised steel, stainless steel, and other alloys, depending on the required properties. The channels can be left as plain steel or coated with protective finishes like galvanisation, painting, or powder coating to resist corrosion. The size can be adjusted based on the application, allowing for greater flexibility in design. Depending on the strength requirements, they may be produced in shallow and deep sections.
Key Advantages of Pressed Channels:
- Cost-Effective:
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- The cold-forming process used to make pressed channels is generally less expensive compared to hot rolling, which makes these channels more affordable.
- Suitable for light to medium-duty applications where high strength is not essential, reducing material costs.
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- Customisable Design:
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- The pressing process allows for custom channels to be made to fit specific dimensions, including unique lengths, widths, and thicknesses. This flexibility is particularly useful for custom orders and unique construction needs.
- Channels can be produced in various thicknesses, making them adaptable to different applications.
- Lightweight:
- Pressed channels are often lighter than their hot-rolled counterparts, making them easier to transport and install, especially in lighter construction work or for smaller frameworks.
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- Ease of Fabrication:
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- Pressed channels are easier to fabricate, cut, drill, and weld due to the pressing method, which results in smoother surfaces and more consistent thickness.
- Easy Installation:
- Pressed channels are easy to install and can be quickly assembled on-site.
Common Uses of Pressed Channels
Pressed steel channels are available in a wide range of sizes and shapes, allowing for customisation to meet various application needs. This versatility makes pressed channels a popular choice for various construction projects. Many of GWR’s customers use pressed channels as a cost-effective material for roof and floor joists.
- Construction and Building:
- Used for non-load-bearing structures such as wall framing, roof purlins, ceiling frameworks, and partition walls.
- Ideal for light structural supports and secondary framing where heavy loads are not a concern.
- Used as a support structure for cladding and façade materials.
- Often found in fencing, balustrades, and window frames.
- Fabrication and Manufacturing:
- Employed in general fabrication for creating racks, storage systems, and equipment frames.
- Used in shelving units, workbenches, and utility racks in industrial and commercial settings.
- Utilised in vehicle bodywork, especially in areas where light but rigid support is needed, such as in trailers and light-duty vehicles.
- Furniture and Fixtures:
- Popular in the fabrication of metal furniture frames, such as shelves, benches, and table frames.
- Used in shop fittings for display racks, cabinets, and counters.
- Machinery and Equipment:
- Applied in the construction of light-duty machine frames and support structures in machinery and industrial equipment.
- Useful in housing for mechanical components or as brackets for securing components in place.
Steel Selection – it’s horses for courses.
The choice of steel section depends on the specific requirements of the application, such as load-bearing capacity, weight limitations, and aesthetic considerations. Pressed channels serve as versatile and cost-effective steel components such as floor joists, roof joists and uprights, ideal for light-duty structural applications. Our highly experienced team of engineers can advise on your project parameters. If you have any questions or want more information about our pressing services, contact us today by calling 0151 933 3150 or emailing us at [email protected].