Hat Channels, Hat Channel Manufacturer

By: Johnson Roll Forming  09-12-2011
Keywords: roll forming, Roll Formed, Formed Metal

Hat Channel Description

Johnson Bros. has been Roll Forming Hat Channels in all metals since 1948. Aptly named to reflect it?s hat like appearance, the Hat Channel is composed of two horizontal outward flanges (the brim) and two vertical? dimensions, (the sides of the hat) giving it the appearance similar to the side view of a top hat. From a 3 dimensional perspective, the top of a Hat Channel reveals a flat, horizontal surface - the hat?s ?top.?

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. These outward flanges can also be called Wings or Fins.

Sometimes referred to as ?Hats?, a Hat Channel can be manufactured with lower tooling costs than most roll formed parts due to the simpler forming required. Many Hat Channel sizes can be made with our existing tooling, as demonstrated by the size illustrations below.

Hat Channel Dimensions

Thickness and Height

Johnson Bros. Hat Channels can be made in thicknesses varying from .005” - .150”. (An Aluminum Hat Channel allows for even greater thicknesses.)  Hats can be Roll Formed up to of 19" wide in .060" thickness and 14" wide with up to a .150" thickness. When the material is thin enough to be roll formed, Hat Channels can be as narrow as .250" wide.

Heights of Johnson Bros. Hat Channels can be Roll Formed to be as high as 5.25" O.D., and as low as 3/16"; and even less with thinner metals. 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. As such, all areas of the Hats will be enclosed by the Roll Dies used to form them. ?Blind or Air Forming is called for to achieve the required shape of other, more complex profiles.

Hat Channel Materials and Production

Customers request Roll Forming for ?a variety of Hat Channel types, including:

  • Aluminum Hat Channels
  • Copper Hat Channels
  • Galvanized Hat Channels
  • Pre-Anodized Hat Channels
  • Perforated and Embossed Hat Channels
  • Pre-Painted Hat Channels
  • Pre-Plated Hat Channels
  • Pre-Polished Hat Channels
  • Stainless Hat Channels
  • Steel Hat Channels

Other Metals can be used to Roll Form a Hat Channel, such as Bronze, Clad, High Strength, Woven Wire and Wire Mesh, Alloys, Electro Galvanized, Hot Dip Galvanized, and more.

At Johnson Brothers, Hat Channels are produced with Inline Fabrications such as:

  • Cutouts
  • Cutting to Length
  • Double Sided Tape Applications
  • Embossing
  • End Fabrications
  • Holes
  • Insertions
  • Miters
  • Notches
  • Perforating
  • Ring Bending
  • Shear Forms
  • Slots
  • Tabs
  • and more?

Hat Channel Ordering Specifications

Johnson Bros. is a reliable, high quality and timely manufacturer of Hat Channels and other Roll Formed parts with very reasonable pricing. ?We do require at least 2,000 feet or more per order, though exceptions can be made for lower volumes when prototypes are required and with the anticipating of forthcoming higher volumes. Volume requirements may also be adjusted with ?additional Roll Formed Parts to accompany the low volume Hat Channels. If quantities are very low, we suggest contacting a local sheet metal shop that can press brake form the Hat Channels. Unfortunately, we are not able to send any parts out of stock - we produce to order! ?Johnson Bros. can provide ?Just In Time? releases from Blanket Orders with low or high volume release quantities.

Keywords: Formed Metal, Roll Formed, Roll Formed Metal, roll forming,

Other products and services from Johnson Roll Forming


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

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. 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.


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

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