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FAQ

Here, we answer some frequently asked questions about Bendiro and roll forming. Also, please feel free to contact us directly.

Frequently asked questions about roll forming and Bendiro

On this page, we answer some common questions about roll forming and our company, Bendiro.
If you can’t find what you’re looking for, please contact us via this page

Production

How does roll forming work?

In roll forming, a flat strip is reshaped into a sheet metal profile by progressive profile bending. The metal passes through a series of shaft pairs with consecutive form-changing tools.

What is meant by roll forming being a ‘gentle processing method’?

Since forming takes place in a large number of steps, where only the folded corner is worked gradually, the rest of the profile is unaffected. This is ‘gentle’ on the material, and means less power and energy can be used to perform advanced forming of tough materials.
 
One positive side effect of gentle forming is that the tools and dies have a long life span.

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What are the biggest profiles Bendiro can roll form?

Bendiro can manufacture profiles up to widths of just over 300 mm finished profile (max. input width 450 mm), and heights of just over 100 mm.

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What are the longest profiles Bendiro can manufacture?

There are essentially no limits on profile length in roll forming. Practically speaking, Bendiro can produce and deliver profiles in lengths from 200 mm up to 12000 mm

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Is there a minimum order?

As a production method, roll forming is exceptionally cost-effective when manufacturing volumes of more than 10,000 m. As standard Bendiro offers a minimum order limit of 5,000 m, but smaller volumes can be discussed where necessary.

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Which production methods can roll forming replace, and what are the comparative benefits?

Roll forming is in many ways a unique production method that can combine many of the advantages of edge pressing, extrusion of aluminium profiles, and tool-bound pressing of profile-like products.

There are many benefits of roll forming:

  • Naturally automated production with integrated punching.
  • The ability to manufacture advanced profile shapes in large volumes.
  • Integrated cutting to the customer’s required length.
  • Tool-bound production with good repeatability.
  • The ability to manufacture laser-welded, tube-like profiles.
  • “Holes free of charge”. The punching stage is an integrated part of the roll forming process.

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What kind of businesses and industries does Bendiro deliver to?

Bendiro makes profiles for a wide range of companies and areas, including:

  • Renewable energy
  • Automotive
  • Construction
  • Furniture
  • Shop interiors
  • Transport
  • Warehouses
  • Farming

In what way is roll forming cost effective?

  • Material efficient => high material utilisation
  • Energy efficient => forming in the cold state

Where does Bendiro manufacture its products?

In Falkenberg on Sweden’s West Coast. Falkenberg, south-west Sweden. Strategically located on the E6 Highway and the West Coast Line (railway). High capacity with potential for Just-in-Time deliveries to your work site.

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What does ‘Bendiro Complete’ entail?

Bendiro offers a range of additional services alongside roll forming of profiles, which is still our core business. Some examples of additional services:

  • Lacquering
  • Warehousing
  • Grading of profile ends for specific customisation
  • Assembly
  • Bending
  • Cutting

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Materials

What kinds of materials can be roll formed?

All bendable materials can be roll formed. This essentially means that any material that can be coiled can be roll formed. Even extremely strong materials, or materials with very limited forming properties, can be roll formed.

Examples of materials roll formed at Bendiro daily:

  • Aluminium, EN-AW 1050 and EN-AW 5754
  • DC01, S235J, S355J, Ymagine D1 and other untreated standard materials
  • DX51d, S220GD and other metallic coated standard materials
    o S280–420GD, HC340–420LA, HX340–420LAD and other high-strength materials
  • HCT780X, Docol DP1200M and other ultra high-strength materials
  • Ferritic and austenitic stainless and acid-resistant materials
  • Special materials such as copper, nickel and titanium

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Can surface-treated material be roll formed?

Yes. All types of metal-coated materials (galvanized, zinc-magnesium, aluzinc). Also pre-lacquered materials are good for roll forming, as are foiled materials.

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What material thicknesses can Bendiro roll form?

Bendiro can roll form material thicknesses from 0.3 mm up to 3.0 mm

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Sustainability / Energy

How does roll forming perform in terms of sustainability?

Roll forming allows high material utilisation, generally >95%, so it is a good, long-term sustainable production process. High material utilisation offers several benefits, such as:

  • Less ore from the mine
  • Less steel that needs to be made
  • Less transport requirement
  • Less need for recycling
Roll forming can shape profiles in high-strength materials, which makes it possible to build strong structures that weigh less. Overall this allows for the same positive sustainability properties as high material utilisation.
Steel itself is an extensively recyclable material, which is a crucial aspect of the circular economy of which Bendiro and roll forming are parts.
Steel, which will be manufactured increasingly by fossil-free methods in the future, is ideal for roll forming.

How energy demanding is the roll forming process?

Roll forming at Bendiro is an energy-efficient production method:

  • All forming takes place in the cold state (no need for energy-demanding heating).
  • The gentle forming process means that roll forming uses minimal energy during the forming
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