Roll-forming lines, coil, tooling and the factory floor. In this article we walk through what we have learned on real projects, with numbers you can use.
How the process works
1. Import the model
Upload an IFC or DXF export. The software reads wall centrelines, openings and levels, then proposes a frame layout using your default profile rules.
2. Review and adjust
Walk the model in 3D, fix clashes and tweak stud spacing around services. Changes ripple through the cut list automatically.
3. Send to the machine
Each panel is exported as a CSV or machine file. The roll-former reads it, forms the coil and punches dimples, service holes and labels in one pass.
“The first time we ran a whole house straight from the model, the site crew finished the frame before the scaffolding was down.”
Exporting a cut list
Most machines accept a simple CSV. A minimal row looks like this:
panel,member,profile,gauge,length_mm,operations
W01,S01,C89,0.95,2700,"DIMPLE@0;SERVICE@900;DIMPLE@2700"
W01,S02,C89,0.95,2700,"DIMPLE@0;SERVICE@900;DIMPLE@2700"
W01,T01,U90,0.95,3600,"LABEL@0"Keep member names unique per panel so the assembly drawings stay readable.
Typical section sizes
The table below lists the profiles we see most often on two-storey residential work. Always confirm with your engineer — loads, spans and local codes vary.
| Element | Profile | Gauge (mm) | Max spacing | Notes |
|---|---|---|---|---|
| Load-bearing wall | C89 × 41 | 0.95 | 600 mm | Single storey above |
| Load-bearing wall | C89 × 41 | 1.15 | 400 mm | Two storeys above |
| Partition | C70 × 35 | 0.75 | 600 mm | Non-structural |
| Floor joist | C200 × 50 | 1.55 | 450 mm | Spans up to 4.2 m |
| Roof truss chord | C89 × 41 | 0.95 | 1200 mm | Webbed truss |
