Hot Rolled Steel Roll Forming Material Guide: Coil Sizes, Thickness, Properties & Applications

Hot Rolled Steel Roll Forming Material

1. Overview of Hot Rolled Steel in Roll Forming

Hot rolled steel (HR steel) is a widely used material in roll forming, particularly for heavy-duty and structural applications where surface finish is less critical but strength, thickness, and cost efficiency are important. It is produced by rolling steel at high temperatures (typically above 900°C), which allows it to be shaped easily and in larger thicknesses.

In roll forming, hot rolled steel is commonly used for thicker gauge profiles such as structural channels, heavy-duty purlins, rails, and industrial components. Compared to cold rolled steel, it has a rougher surface and looser tolerances, but it is significantly more cost-effective.

Hot rolled steel is often further processed into pickled and oiled (P&O) steel to improve surface quality and remove mill scale, making it more suitable for roll forming applications.

2. Material Composition & Structure

Hot rolled steel is similar in composition to mild steel:

• Iron (Fe): ~98–99%
• Carbon (C): 0.05–0.30%
• Manganese (Mn): 0.3–1.5%
• Trace elements: Silicon, sulfur, phosphorus

Structure:

• Coarse grain structure due to high-temperature processing
• Surface scale (iron oxide layer) present
• Less uniform than cold rolled steel
• Available as black steel or pickled (cleaned)

3. Available Coil Specifications

Thickness Range

• 1.5mm – 16mm (roll forming typically 1.5mm – 6.0mm)

Coil Width

• 600mm – 2000mm

Coil Weight

• 5 tons – 30 tons

Coil ID / OD

• ID: 508mm / 610mm
• OD: up to 2000mm

Tolerance

• Thickness tolerance: ±0.05mm – ±0.10mm
• Less precise than cold rolled steel

4. Mechanical Properties

Typical properties:

• Yield Strength: 200 – 400 MPa
• Tensile Strength: 350 – 600 MPa
• Elongation: 20% – 35%
• Hardness: 120 – 200 HB

Hot rolled steel offers good strength with high ductility, especially for thicker materials.

5. Coating Types (If Applicable)

Hot rolled steel is typically supplied uncoated but can be processed into:

• Pickled and oiled (P&O) steel
• Galvanized steel (after processing)
• Painted or coated steel

P&O is the most common upgrade for roll forming.

6. Surface Finishes

• Mill scale finish (dark, rough surface)
• Pickled surface (clean, scale removed)
• Oiled surface (corrosion protection)

7. Common Roll Forming Applications

Hot rolled steel is used for heavy-duty profiles:

• Structural channels and beams
• Heavy gauge purlins
• Guardrails and highway barriers
• Steel frames
• Storage racks and industrial supports
• Agricultural equipment components
• Trailer and chassis parts

8. Advantages of Hot Rolled Steel

• Lower cost than cold rolled steel
• Available in thicker gauges
• Easier to produce in large volumes
• Good ductility for forming
• Suitable for heavy-duty applications

9. Disadvantages / Limitations

• Rough surface finish
• Mill scale can damage rollers
• Lower dimensional accuracy
• Requires cleaning (pickling) for precision work
• Not suitable for visible or decorative applications

10. Roll Forming Machine Considerations

Roll Tooling

• Heavy-duty rollers required
• Wear-resistant materials recommended

Speed

• 10–40 m/min depending on thickness

Lubrication

• Often required to reduce friction and wear

Cutting

• Hydraulic shear for heavy gauge
• Flying cut-off for continuous production

Common Issues

• Scale damaging rollers
• Increased tool wear
• Springback in thicker materials

11. Common Problems in Production

• Surface scale causing roller damage
• Inconsistent thickness affecting profile accuracy
• Coil camber leading to alignment issues
• Edge cracking in thicker sections
• Excessive wear on tooling

12. Pricing Guide

Typical global pricing:

• Low: $500–$700 per ton
• Medium: $700–$900 per ton
• High: $900–$1100+ per ton

Factors affecting price:

• Thickness
• Grade
• Processing (P&O vs raw)
• Origin and market conditions

13. Comparison with Other Materials

Hot Rolled vs Cold Rolled Steel

• Hot rolled = cheaper, thicker
• Cold rolled = smoother, more precise

Hot Rolled vs Mild Steel

• Very similar, but hot rolled refers to processing method

Hot Rolled vs Galvanized Steel

• Hot rolled = no corrosion protection
• Galvanized = coated for durability

14. Best Industries Using Hot Rolled Steel

• Structural steel fabrication
• Construction and infrastructure
• Transportation and trailers
• Agriculture and heavy equipment
• Industrial manufacturing

15. How to Choose Hot Rolled Steel

Choose Hot Rolled Steel When:

• Thick material is required
• Cost needs to be minimized
• Surface finish is not critical
• Heavy-duty strength is needed

Avoid When:

• High precision is required
• Surface finish matters
• Coating is required before forming

16. FAQ Section

What is hot rolled steel used for in roll forming?

It is used for structural and heavy-duty profiles.

What thickness is typical for hot rolled steel?

Usually 1.5mm to 6.0mm for roll forming.

Does hot rolled steel have a rough surface?

Yes, due to mill scale from high-temperature processing.

Is it cheaper than cold rolled steel?

Yes, it is generally more cost-effective.

Can it be coated?

Yes, it can be pickled, galvanized, or painted after processing.

17. Machine Matcher Section

We supply roll forming machines for all material types including hot rolled steel.

• Custom-built machines to your profile
• New machines built to specification
• Global delivery available
• UK and USA technical support

Contact:
Machine Matcher
Sales & Technical Team

Quick Specs

Thickness
1.5–6.0mm

Yield Strength
200–400 MPa

Coil Width
600–2000mm

Coil ID
508 / 610mm