Roof Tile Machines

tile panel machine,
metal roof tile panels,
roll forming  process, 
stationary tile press,
flying tile press, sheet metal

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- Tile Panel Machine produces Scandinavian type Metal Roof Tile Panels which run down from ridge to the eave. - Full width, 10 tn pre-coated steel or aluminum coils are used (48"-50" or 1200mm-1250mm) mainly in 24 to 26 gauge, or 0.45-0.55 mm. - Choose from standard panel design or make your own.
 

Conventional, Scandinavian Metal Roof Tile Panel Line. 
Metal Roof Tile Production Lines:

Metal roof tile panel

Metal roof tile panel was developed in Scandinavia twenty years ago. The Scandinavian roof tile panel is produced in North America from 48´ mother coil width (elsewhere 1220-1250 mm is the most common). Scandinavians are enjoying the quality of metal roofing and European, or Spanish, looks of conventional tile. In the early 1990´s metal roof achieved a stunning 60 percent market share in residential roofing. 

FUSA offers a complete integrated line as a single source for your metal tile panel business. FUSA´s hardware partner is the world leader in tile panel forming lines. Over 40 custom-designed lines have been supplied all over the world. The leading tile panel producers in North America are using these machines. 

Extensive experience in integrated sheet metal production lines where the metal tile panel lines are only one specialty application. Thus, FUSA is able to offer all kinds of sheet production lines for your needs.  

Roll forming

is done with a highquality, gentle forming process.  
 

- offers stationary tile press in the standard line configuration

- a flying tile press available which will increase the output of the line by 30 percent.

- Automatic panel stacking systems are available and capable of various kinds of stacking patterns, including the pyramid stacking. 

- roof ridge cap presses for different cap designs.

In addition to these standard designs engineered roof tile panels for 15 years, and thus, has accumulated lots of tool design experience. We welcome customer panel design suggestions. 

Conventional, Scandinavian Metal Roof Tile Panel Line.

Metal roof tile panel was developed in Scandinavia twenty years ago. The Scandinavian roof tile panel is produced in North America from 48´ mother coil width (elsewhere 1220-1250 mm is the most common). Scandinavians are enjoying the quality of the metal roof and European, or Spanish, looks of conventional tile. In the early 1990´s, the metal roof achieved a stunning 60 percent market share in residential roofing. 
 

HISTORY OF METAL ROOF

Around the 14h century, the first roofs in Europe were covered with metal sheets. There is, therefore, a record of the history of metal roofing, although it is impossible to say what the lifetime of an individual metal roof will be.  Metal roofs that were built as early as the 18th century are still in good condition!  Modern metal roofs are made mainly of precoated galvanized steel or aluminum sheets; copper is used in some special applications.

Major developments in metal roofing really started in the middle of the1970's when the new Tile Effect designs--imitating traditional clay and cement tiles--were presented.  At the same time the new color-coated materials made it possible to achieve the looks of original tile.

The new idea was adopted especially in Scandinavia.  The roll forming industry there immediately found out the great business opportunities the new product made possible in the roofing market where clay and concrete tiles, asphalt composite shingles, and fiber cement  panels dominated.

In only ten years, precoated steel has achieved the market leader position in Scandinavia in residential housing.  At the moment, up to 50% of new roofs are made of color-coated metal, especially in Tile Effect shapes.  In the reroofing business, the figures are even higher--up to 75%.
 

BENEFITS OF METAL ROOF

The benefits achieved by using metal in roofing are clear.   The material is light-weight--only 1/10 of the weight of cement tile--meaning that the truss construction can be much lighter, and the cost of the total supporting structure will be approximately 10% less than when using the heavier tiles.  Depending on actual metal panel tile designs, it may have exceptional structural capabilities, which can be incorporated in the supporting structure to accumulate additional savings.

The Tile Effect sheets are most often delivered in full vertical lengths--panels running from the ridge down to eaves--making the actual installation time minimal.

Metal does not break, shrink or burn, proving it a long-lasting and safe roofing material.

A variety of different designs are available for Tile Effect in a large number of colors and coating materials.  Industry is also using embossed and multicolored materials to differentiate products from one another.  Also, the metal tile panels may be post-coated; also an aggregate stone coating is gaining interest.

Metal is an environmentally friendly and recyclable material, factors that continue to grow in significance in today's ecologically conscious world.
 

TILE EFFECT METAL PANEL

Tile Effect has spread from Scandinavia to all over the world.  At the moment, the panels are being produced in growing numbers in Europe, the Middle East, the Far East, and in North America.  Although the market share in North America is still rather low, the interest in the product, as well as the capacity to produce it, has grown significantly during the last two years.  New lines and new exciting panel designs have been introduced here.

Since the technology has mainly been developed in Scandinavia, the most advanced designs and solutions are Scandinavian.

In general, the manufacturing process of Tile Effect sheets is very straight forward.  The 48" wide mother coil--typically 26 gauge steel or aluminum--is formed into the desired shape using a conservative roll forming process. The tile step is then stamped in a specially-designed hydraulic press.  Finally, the sheet is cut to the desired length and stacked.

There are obvious possibilities to enhance the total output of the line.  Foremost, the production of the tile panel is dependent on the cycle time of the press.   A stationary tile press is the most common choice, and the material is stopped while the tile step is formed.  A flying press option is also available, where the material flow is continuous.  The take-off may be also expedited and automated with a stacker.
The critical item, and the most demanding part in the manufacturing process, is the tile step press, especially the tool technology, because it ultimately determines the quality of the tile panel.  Although the latest machining technology is used, the professional touch of a craftsman is essential.  The market would not accept any deformation of the panel, not to mention any process-damage on the coating.
The operation of the line is very simple because everything is controlled by a single PLC.  The operator sets the lengths and amounts of the panels to be formed for the order.  The PLC control system takes over from there.  The panel may also be produced in various step lengths, the most common being 16".   By turning a scale at the control board, one may produce quite different-looking panels by altering the step length and not pay a dollar more for this operational  flexibility.  For marketers and specifiers of the tile panel, it is important to understand this special capability.

All the tile lines are custom designed, most of them to produce a single tile design.  As any roll forming machine, the line may be rafted and tooled to produce other trapezoidal panels as well.  Some of the tile panel's basic profile designs are suitable also to be produced without steps.  This would add a nice-looking trapezoidal panel to the panel manufacturer's offering.

FUTURE DEVELOPMENT

Presently, Tile Effect panels are available in an unlimited number of designs, based on traditional Tile and Shake designs.  Most of the designs are vertical, overlapping at the vertical seam, and fixed throughout the panel.  Although the Scandinavian vertical panel system has a proven reliability record of over 20 years, the industry has also searched for some new alternatives.

FUSA Tech, of Reston, Virginia, has worked for two years to meet with the new challenges, and has developed a new type of Tile Effect panel with concealed fixing.  The panel is produced typically using a 24" wide coil generating an 18" cover width.  Concealed fix panels are smaller than conventional Scandinavian vertical panels and are produced in 8' long modular sheets.  The panel has a tongue and groove engagement with adjoining panels.  The installation of these smaller panels is easy, self-guiding, and fast.  Panels have pre-punched oval holes at the fixing flange, greatly facilitating the fixing.  These oval holes allow for thermal expansion of the panel.  A smaller sized panel is easy to handle on a roof, yet it is big enough to warrant fast installation.  Since the panel is narrow, the installer does not need to step on it,  again making the installation faster and safer.
From the manufacturer's point of view, this new panel is very attractive because it is shipped in standard lengths. This is unlike conventional tile panels, which are manufactured according to customer's orders and in full vertical lengths of the roof.  The modularity of the concealed fixed panel also makes the manufacturing process efficient and lowers the cost of the product.  In addition, the distribution of a modular panel may use conventional channels, making it possible to cover new markets and secure faster market penetration.

The concealed fix approach requires a narrow panel in order to withstand the wind uplift forces.  A production line for a narrower panel is shorter, meaning also less invested dollars.  Because the new panel is modular, the line can be used for three-shift production.  As a result, the feasibility numbers of this new machine are very favorable.  The new concealed fix tile panel was introduced at the NRCA show in Orlando this February and the feedback from the industry was very congenial.  Manufacturing of the panel will be commissioned in the United States in the early fall of this year.

Industry has developed new coatings suitable for tile panels.  In Scandinavia, the trend is more flexible and thicker coating types; also, a satin finish is more desirable than a high gloss surface.  A new polyurethane-based coating has been developed and is now on the market.  It is competitively priced compared to commonly used PVF2 coatings.  In the United States and the Pacific area, new multi-colored coating options are available,  and will make the product even more attractive to both the producers and the users.

Represented by: FUSA Tech, Reston, VA  20190, ph (703) 481-9308, fx (703) 481-9309
 

FUSA Tech, Inc.