C-Channels, Box Channel, Steel C Channel, Aluminum, and Stainless Channels

By: Johnson Roll Forming  09-12-2011
Keywords: Wire Cloth, Black Oxide, Copper Alloys

Metal C-Channels & Box Channels

Since 1948, Johnson Brothers has manufactured Metal channels including C Channels & Box Channels. We also specialize in Open Seam Tubing including Square Tubing, Square Steel Tubing, Rectangular Tubing, and Rectangular Steel Tubing.

Channel and Box Channel: Types of Metals

  • Steel (ie. Steel C-Channels, Steel Box Channel)
  • Stainless (ie. Stainless C-Channel, Stainless Box Channel)
  • Aluminum (ie. Aluminum C- Channel, Aluminum Box Channel)
  • Brass
  • Bronze
  • Copper
  • Alloys
  • Galvanized
  • Martinsite
  • Titanium
  • High Strength
  • Domex
  • Cor-Ten
  • Perforated
  • Embossed
  • Wire Cloth
  • Laminated
  • Clad
  • and more.

Channel Finishes can be plain or pre-finished such as:

  • Pre-Painted
  • Pre-Plated
  • Pre-Anodized
  • Pre-Galvanized (Hot Dip: G30, G-60, G-90
  • G-120
  • Bonderized
  • Chem-Treat
  • Electro
  • Chromate
  • Galvanneal
  • Galvan
  • Aluminized
  • Terne Plated
  • Black Oxide
  • Vinyl Laminated
  • Pre-Polished
  • Strippable PVC Covered
  • Pre-Laquered
  • Pre-Printed
  • and more.

Johnson Bros offers many types of C Channels and Box Channels, including:

  • Aluminum C Channel & Box Channel
  • Formed C Channel
  • Steel C Channel & Steel Box Channel
  • Metal C Channel
  • Electrical C Channel

C Channel & Box Channel - Thickness & Length

C Channel & Box Channel thicknesses vary from .003" thick up to .150" thick. On 1/4 & 1/2 hard aluminum, Aluminum C Channel & Aluminum Box Channel thicknesses can reach up to .250" thick. Many different decorative pre-coated metals are generally not recommended when more than .030" thickness is required unless larger than normal corner radii can be used. Some coatings can be used, however, up to .125" thick such as a pre-finished Hot Dip Galvanized coating. Box Channel & C-Channel Lengths may be from 3" thru 40 feet long with close tolerances. Many different lengths can be put on one purchase order.

C Channels & Box Channels - Differences

C Channels are different than Box-Channels in the manner in which they appear in print, on Drawings, Sketches, and other images. C-Channels are shown with the opening or gap on the side of the image whereas on a Box Channel and Open Seam-Square or Rectangular Tubing, the opening or gap is on the top or bottom side as seen in the image. All of these 3 products are different names for the same part. Our Standard Sizes Chart on this page gives a summary of sizes with existing tooling that is available. The size chart gives dimensions, as they would be on a print with the opening or gap on the top or bottom, not on the side. With the part's image in this configuration, the sides are considered the legs and the width is considered the web. The flanges on both sides of the opening are considered the returns. Johnson bros has the capacity to manufacture the sides or legs up to 5" tall and the width can be as wide as 18" depending on the size of the legs and returns. There is a maximum raw material flat coil width of 19" that can be used. Inward flanges can also be added to the returns to turn the Box Channel into a Strut Channel or what is also called Framing.

C Channel & Box Channel - Manufacturing Process

The Johnson Brothers C Channel & Box Channel manufacturing process is state of the art.

  • Notches
  • Holes
  • Slots
  • Cutouts
  • Tabs
  • Perforating
  • Shear Forms
  • Ring Bending
  • Miters
  • End Fabrications
  • Depressions
  • Embossing
  • Key slots
  • Double-Sided Adhesive Tape Application
  • Material Insertion
  • Identification
  • and more.

Johnson Brothers offers many different C-Channel & Box Channel Die Operations.

C Channels & Box Channels have many popular uses.

C Channels, Box Channels, Open Seam: Square and Rectangular Tubing are used in almost all industries for any possible application such as in this brief summary of other known terms:

  • Holders
  • Covers
  • Framing & Frames
  • Inserts
  • Decoration
  • Trim
  • Cladding
  • Brackets
  • Tracks
  • Slides
  • Posts
  • Standards
  • Supports
  • Reinforcements
  • Stiffeners
  • Railings
  • Rails
  • Rims
  • Subgirts
  • Girts. (Many other styles of Roll Formed Profiles have these same descriptions, however.)

High Speed Roll Forming is available from Johnson Bros.

Superior Length Tolerances allow more rapid production, however our modernized length control system permits normal production speeds at close tolerances as well. Tolerances on legs and web of +/- .032 are common with +/- .005 and in some instances less are possible. Highly Accurate Roll Straighteners and Die Boosts permit for very straight parts without kinks from the cutoff operation.

C-Channel & Box Channel - Minimum Orders

Minimum orders are generally 2,000 feet total and up as parts are produced to order and not kept as a stock list to choose from on a shelf. Exceptions can be made for sample requirements, Blanket Order Releases or for other unique circumstances.

Keywords: Black Oxide, Bronze Copper Alloys, Copper Alloys, Hot Dip Galvanized, Open Seam Tubing, Wire Cloth,

Other products and services from Johnson Roll Forming


Hat Channels, Hat Channel Manufacturer

Hat Channels can also be described as a Roll Formed Metal U-Channel with a bottom horizontal web and 2 vertical legs with outward flanges. Close tolerances of Roll Formed Hat Channel dimensions are easier to reach as there is no Blind or Air Forming required to Roll Form them. Aptly named to reflect it?s hat like appearance, the Hat Channel is composed of two horizontal outward flanges and two vertical.


Metal Mouldings (Moldings), Aluminum Moulding (Molding), Profiles, Special Shapes & Sections

Our cutoff operation includes End Fabricating as well as accurate Cutting-to-Length along with other fabricating that in the past were always considered as part of the Prepunch operation. Our roll forming machines are modernized and kept in top condition with our preventative maintenance program and many have DC and High Speed drive systems.


Z-Channel & Other Channels - Johnson Brothers Metal Forming Co

Purlins are typically Prefinished with Galvanized or another rust inhibiting coating and can be made in all metals, including Aluminum and Stainless Steel. For Zees with a small Web between the Legs, new dies may also be needed, although these dies are not as expensive as dies for Zees with longer Webs. When there are returns at the top of each leg tooling will usually need to be produced unless its for a size we already have dies made for.


U-Channel, J-Channel & Metal Channel :: Johnson Brothers :: Metal Forming Co

Some additional tooling costs may be required for: Special Corner Radii, Amco Bronze needed for highly polished stainless steel that is not allowed to be coated with a protective strippable PVC Covering, Legs bent more or less than 90 degrees, and other more sophisticated forming requirements.