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Roll Forming Capabilities

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* All Products are produced to order. No Stock Products.

Download PDFs of roll forming capabilities charts:

Standard Sizes Chart - Recently Produced U & J Channels

Standard Sizes Chart - C-Channel, Box-Channel, Rectangular & Square Open Seam Tubing

Standard Sizes Chart - Lock Seam Tubing

Standard Sizes Chart - Open Seam Tubing

Standard Sizes Chart - Split Seam Tubing

Roll Forming since 1948

Johnson Bros. has specialized in Roll Forming since 1948 for Custom, Standard, and Contracted Parts. We use over 20 Roll Forming Machines with up to a 28 station capacity can Roll Form the most complex Profiles. We use Thicknesses of .005" up to .188" and coil widths .187" up to 20". Minimums are generally 2,000ft on Straight Lengths and 500pcs on Channel Rings and Angle Rings, Rims, and Clamps.

We have Existing Tooling for most Roll Formed Channels, Angles and Lockseam Green Tubing. Many Profiles and Openseam Tubing have Existing Tooling or Partial Tooling available. Johnson Bros. Roll Forming can utilize more than 2 Presses (prepunch & Cutoff-Postpunch) for many different "Inline" Punching & Fabricating Variations on the Roll Formed Parts. We use Die Accelerators & Die Boosts with modern Encoders & Servo-Drives. Inline Ring Bending at the end of the Roll Forming Line with a special Inline Cut-to-Length Ring Press provides Rings being produced in One Operation from raw material to finished product.

Since our beginnings, Johnson Bros. has been producing parts with "Prefinished" material. Johnson Bros. Roll Forming in Chicago is very experienced in Adhesive Application, and Rubber and Plastic Molding or Magnet Strip Insertion into the Roll Formed part. Cladding Different Materials by Forming them Together is also done. We are an environmentally friendly company providing green energy products.

Some of the Roll Forming Products we Manufacture are:

Channels(U, J, C, Hat, & Box), Profiles, Mouldings, Special Shapes, Trim, Edging, Rails, Tracks, Slats, Louvers, Strips, Zees, Continuous Hinge Sections, Panels, Slides, Framing, Brackets, Gasketing, Stiffeners, Extrusion Covers, Hats, Wirework-(Straightening, Skyving, Edge Rolling, Cut-to-length, Light Extruding & Ring Forming), Openseam Tubing, Splitseam Tubing, Flanged Seam Tubing, Slot Seam Tubing, Lockseam Tubing, Poles, Posts, Railings, Rings, Rims, Flanges, Hoops, Boots, Clamps, Bands, Shields, Shrouds, Purlins, Subgirts, DIN-Rails, Cable Trays, Busbars, Raceways, Wireways, Snap-On Sections, Struts, Fins, Heat Transfer Plates, Scuff Plates, Lagging, Roof Bows and so much more.

Roll Forming Materials include:

Steel, Stainless, Aluminum, Brass, Copper, Galvanized, Titanium, Special Alloys, Martinsite, Foil, Bronze, Wire Cloth, Perforated, Expanded, Clad, Wire, Embossed, High Strength, High Yield, Cor-Ten and more.

Finishes provided with Prefinished(less expensive than Post Finishing), and Post Finishing. Johnson Bros. forms the following Prefinished Metals: Pre-Painted, Pre-Anodized, Pre-Plated, Pre-Polished, Pre-Galvanized, Pre-Perforated, Pre-Lacquered, Pre-Laminated Vinyl, Clad, Pre-Embossed, Strippable-PVC.

Secondary Fabricating of Roll Form parts is also provided in a separate area and by outside vendors.

Dun & Bradstreet and ownership information:

We have a 5A1 rating in D&B, and our Dun's Number is 00-511-0580. Our financial condition is strong. Ownership consists of President & CEO-Edwin Johnson Jr., his wife-Marian Johnson, and son Sr. Vice President and G.M.-Brad Johnson. Close relations between owners, management and shop personnel is constantly maintained for our working family.

Special Facilities & Packaging:

Johnson Bros. roll forming in Chicago has 4 Dock loading areas, including an indoor recessed dock, that can be used in its over 37,000sqft. facilities. Certified in-floor scales, in the shipping/receiving zone, are used for all incoming and outgoing products. Certified capacity, Product, Raw Material and Die storage racks are widely used. A 6,000# max overhead crane is used which travels the entire shop floor and does loading in the recessed dock. 9 overhead hoists and jib cranes from 4,000# through 1,000# capacity, load coils of metal onto our 21 coil reels. These hoists and jib cranes are shared between several roll forming machines, each. Several 6,000# electric forklifts and one 3,000# electric forklift are used for loading, unloading and handling, as well as powered & unpowered pallet movers, die carts and other portable handling equipment. Our packaging department handles many sizes of: Skids( 2x4 framing), Wood Crates, Triwall(corrugated) Crates, Platform Pallets, Cartons with Assembly, and many other special and custom packaging requirements. Our experienced, professional staff at Johnson Bros. Roll Forming ensures that products are shipped with the best chance to prevent damage, caused by the freight company, from occurring. How containers should be stacked in your facility is an important concern that customers need to discuss with our contact person. Special packaging requests, bar code labeling, dimensions and capacities should be given to your contact person with your inquiry and/or order. Johnson Bros. Roll Forming. have experienced packaging designers for your needs. Reusable containers are encouraged on higher volumes. Other manufacturing Departments: In-House Engineering & CAD dept., Machinery-Maintenance, Rebuilding, Guarding, Controls and Design dept., Our own In-House Tool Room, Material Handling, Storage, Shipping & Receiving dept., Parts & Safety Inspection, Testing, Blueprint (not many blue any more), ISO-9002, SPC, dept., Die Storage dept., Oils, Coolants, waste & scrap dept., Pressurized Cylinder dept., Welding dept., Assembly dept., Secondary Fabrication dept., and a Shop and Safety Supplies dept. These departments insure the greatest care is taken and the most thorough handling of your orders on our shop floor. In our offices are the: Sales dept., Purchasing dept., Financial dept., Reception, Personnel & Records dept., Cafeterias, and our Management dept.

Progression of your Purchase Order throughout our Company:

Written orders are received by mail, fax, or email. Your salesman is the first one to have your order brought to him, by the office assistants. Your salesman verifies the price you used, or informs you and requotes it if it is not correct or current. When the price is mutually agreed on, the salesman brings your order to the Work Order entry assistant. The Work Order information needed, is retrieved from our computer network's memory. This information shows on the work order: how your part should be produced, special instructions, tolerances, packaging, QC Gages used, Die Numbers used, Part numbers, Print numbers, metal characteristics & requirements, etc. Of course, P.O. numbers, due dates, etc, are entered manually on the work order. Once this work order is created, your order is attached. The work order goes back to the salesman with copies made for the purchasing dept and the shop. The salesman double checks the Work Order data entry, with your order attached, and brings it to the Vice President who develops a schedule and where your order can fit into it. Once scheduling is done, the P.O., work order, and the copies, are brought by the Vice President to the Purchasing dept. for metal purchasing or stock allocation. Once metal is received or allocated the Purchaser delivers your order and a sales work order copy, attached to it, to an alphabetical file in the salesman's office where it stays until the parts are ready to ship. The Purchaser also brings a shop work order copy to the shop where the assistant foreman puts it into the shop work order alphabetical file. It remains there until the Vice Presidents schedule tells them to take it out and bring it to the machine with the print designated by it, and to go over it with the Setup man and/or operator, that will be setting up the dies and/or producing the parts at the machine that needs to be used. After the setup man shows the work order to the tool room to have the correct press dies brought to him, and uses it to obtain the correct rolls needed, the work order copy and print are placed in a permanently designated holder at that machine for review by Setup man, Operator, Inspector, Sales and Management, and Shipping Foreman, at any time during the production process. Once your order is produced the shop work order copy is brought to the shipping foreman by the operator, who then brings it to the traffic manager with all of the final totals of weight, quantity, container counts, etc. The traffic manager goes to the salesman's file to retrieve your Purchase order attached to the sales copy and arranges shipping, or keeps it in a numerical file by date, until the your ship date. Once the parts are shipped, your P.O. with all the work order copies is given to the Work Order entry assistant for invoicing. Once invoiced it is given to an assistant to double check the invoice and enter the information in your account's memory held by our computer network. Once this is done your P.O. and Work Order copies are checked by our cost accountant. The P.O., Work Order Copies, and costings are given to the Vice President for evaluation and then are placed in the work order portion of your customer file, in our file room, and held there indefinitely.

Safety information:

Safety is top priority at Johnson Bros. Roll Forming, a family-owned company based outside of Chicago. Our company maintains annual employee safety training, with all required safety programs, by inside and outside training personnel. Many programs contain even more than is required. Our safety record is outstanding with many safety awards given to the company in recent years. Guarding of equipment, Controls, and press set-up with operating instructions, are key and are constantly evaluated and upgraded when necessary. A safety manual containing our efforts is available to all our employees which contains required, and more than the required, in our written programs.

Roll Forming Equipment List:

Over 20 Roll Forming machines with accompanying Presses, Shear & End Welders, Coil Reels, Straighteners, Guides, Fixtures, etc. Roll Forming machine's used are: 6 Tishkens, 2 Dahlstroms, 1 Yoder, 1 Contours, 2 Michigan Roll Form, 6 Lockformers, and 5 Johnson Bros. Models, made in-house. Shaft sizes are from 2.50" through 1.00". The Roll Formers have from 28 Stations through 8 Stations each. Many of the Roll Forming machines have been retrofitted with modern D.C. and A.C. Drive systems for a wide speed range, energy efficiency and accuracy, along with extra torque. Roller straighteners and entry guides are attached to each Roll Forming machine. Occasionally, solid block straighteners are required. Johnson Bros. Roll Forming has 35, Inline, Cut-to-Length, Post Fabricating and Prenotch Presses including mostly Pneumatic Presses, Some Hydraulic and Mechanical Presses. These presses are produced by Yoder, Airam, Pneu-Power, Tishken, Dahlstrom and several other manufacturers. Most Presses have Die Accelerators or Die Boosts, with computer controllers signaled by stock measuring encoders for close tolerances. Our Die Accelerators have up to 12 different functions or gag punching operations that are available on the same machine and can operate al of the Prenotch, Post Fabricating and Cut-to-Length presses used in one forming line. Some positive stops, proximity switches and electric eyes are also used when required. Press tonnages range from 100 Ton through 5 Ton. Strokes range from 4.00" through .50". 9, mostly hydraulic presses designed for safety, are also used in the secondary fabricating dept for piece work. 9 automated portable Shear/End Welders and some spot welders are each used on several machines at a time. Each coil end welder is shared by one, two or three roll forming machines that are next to it. 20 coil reels are used with 6,000# through 2,000# capacities. All but one reel are Littel models. Most are double ended with a few that are single ended. Our tool room contains: 3 Bridgeport vertical mills, 4 horizontal grinders-2 Mitsui, 1 K.O. Lee and one Elb, one I.D./O.D. grinder, 3 lathes, a 50 ton arbor press, Hardening Furnace, vertical and horizontal and saws, bench grinders, belt sanders and much auxiliary equipment. A 30" optical comparator and hardness testers are shared by the tool room and inspection dept. 2 Lathes are used for making and repairing roll dies and equipment parts.

Donated Tooling & Shared Ownership:

Complete and Partial Die Sets may be donated, or paid for by Johnson Bros., on higher volumes, or when needed to hold to a policy of existing tooling capability for specific products, or for new product lines that may be needed by many customers. When this is the case, there are no proprietary usage rights, for a customer, on this tooling. Johnson Bros. may also Share Ownership of tooling to defray customer costs on the Complete or Partial tooling. This also does not give any proprietary usage rights to the customer who pays for a share of this tooling ownership. If more than one customer agrees to pay the full cost of complete tooling sets, they will all share proprietary usage and rental rights.

Existing Tooling(Roll Dies, Cutoff and Inline Post Fabricating Dies, Prenotch Dies, Secondary Fabricating Dies, Weld Fixtures):

Johnson Bros. Roll Forming maintains a very large amount of in-house, existing, tooling, useable for all customers. In addition, a large amount of proprietary dies is stored on the premises, only useable by customers who paid for them. Occasionally, when confidentiality is allowed to be overlooked by a customer who uses proprietary tooling, dies can be rented out by a customer who will then get that rental fee. After a two year obsolete die use period, or if a customer buys the same part elsewhere as the complete tool set he/she paid for produces, does not remove his tooling, is unwilling to pay tooling surcharges, does not offer to pay storage fees, then the proprietary tooling becomes the complete property of Johnson Bros. with all rights of usage and/or disposal as Johnson Bros. sees fit. Modifications, Shared tooling expense with Johnson Bros, and partial tooling is not removable and is only for a customer's proprietary use, if there is a special agreement, and the two year obsolete die period has not elapsed or the purchasing of the those parts elsewhere does not occur. Detailed tooling descriptions on invoices, are given when tooling is paid for. Johnson Bros. maintains all tooling customers pay for, in working condition, at no charge, unless dies are removed which incurs a surcharge.

New Tooling (Roll Dies, Cutoff and Inline Post Fabricating Dies, Prenotch Dies, Secondary Fabricating Dies, Weld Fixtures):

Johnson Bros. Roll Forming utilizes both, in-house new tooling design and production, as well as outside sources. Complete Die Sets paid for by a customer gives proprietary usage to the customer, or customers (if more than one), only for use by that customer or those customers. Once Tooling is produced, and is not used for two years, it is considered in an obsolete status as stated under existing tooling section above. Complete Die Sets, paid for by a customer, will not be allowed to be used, for any other customer, unless the customer that pays for them approves in writing. Tooling customers pay for will be maintained in a well working condition and held by Johnson Bros., as long as the tooling does not become obsolete or the customer goes elsewhere to obtain the same parts made off the tooling they paid for while dies are still held by Johnson Bros. Partial Tooling, Die Modifications, Shared Ownership with Johnson Bros., or tooling Donated by Johnson Bros. does not give proprietary usage rights to a customer without a written mutual agreement that is subject to review and revision by Johnson Bros. at any time. On Cutoff Dies, when quoted and or invoiced for cutters only, modifications, or Inserts. This refers to Yoke Inserts that fit in Johnson Bros. Standard Die Bases and in the standard Johnson Bros. Blades or Yokes that hold those blade inserts. Proprietary usage and tooling rights only applies to those blade inserts, not the complete cutoff die. This is done to save the customer expense when we must charge for new tooling. Straighteners are not usually charged for unless shown separately on quote or invoice. When shown, it refers to a straightener block or straightener rolls, not the complete straightener fixture that holds them. Secondary fabricating dies are quoted as using standard Johnson Bros. die bases that are not part of the quote or invoice unless indicated that way on the invoice. This is also done to save on die costs incurred by customers. Customers may opt to remove tooling for in-house use at some later date and prefer to purchase entire cutoff dies, roll dies sets and Prenotch dies, instead of paying for partial dies, Inserts, Modifications or sharing ownership. If this is the case, it's important to let us know in writing, at the time we quote. Tooling is not removable for 2 years after it's production unless there is a prior separate mutual agreement, or it involves a complete roll form line with dies and equipment that Johnson Bros. may offer for sale. Confidentiality of Prints will be maintained as long as tooling is not obsolete, or storage is paid for. Special Confidentiality arrangements can be made by a separate, mutually agreed on, confidentiality agreement.

Clinching is an alternative to Spot Welding or Riveting

Contact us for more information on Johnson Brothers rolling forming Chicago based company. We are a Chicago clamps manufacturer and Chicago drawer slides manufacturer, bringing you the best quality products. We are ready to work for you!


Proudly Servicing American, Canadian & International Companies on all custom roll forming needs!
5744 McDermott Drive - Berkeley, Illinois 60163-1102 (Chicago Suburb)
Telephone: +00(1)(708) 449-7050 - 24 Hour Fax: (708) 449-0042

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