Manufacturing Process

Our Manufacturing Production Process

1. Our Aluminum

 The mill engineers each slab and coil of metal to meet our standards. Each coil is given a code number that designates when and how it was made.

Used aluminum, including beverage cans and other items, is collected for recycling and taken to an aluminum mill where it is cleaned, melted down, and formed into giant slabs of metal. It is then rolled into aluminum coils to meet our specific thickness and width requirements.

2. Our Coatings

The aluminum coils then travel to a coil coater, where our advanced Kynar 500 or Hylar 5000 coating system is applied. The bare metal is placed on a continuous coating line where it is cleaned and specially treated to accept paint before the multi-coat system is applied and baked on. At the end of each paint run, the color and quality of the coating are tested to ensure they meet our quality standards.

3. Our Quality Assurance

Once the coated aluminum arrives at our manufacturing facility, we test it again for quality, color, and strength. No coil is released to our manufacturing floor until it has passed redundant quality checks by one of our Quality Assurance Engineers. 

We know that the conditions on a roof can be brutal. The metal used on it must meet our exact and industry-leading standards. ASTM procedures, the Metal Construction Association (MCA), the National Coil Coating Association, and our engineering team have determined the standards we have set. We are 1 of only 4 companies producing products that meet the Certified Metal Roofing Panel program administered by MCA.

4. Our Manufacturing Process

Once a coil of aluminum has been released from production, it is sent through one of our large-bed, high-tonnage stamping presses. Each press contains a series of dies that give the metal its defining shape and character. 

As the shingle panel progresses through each die (from 5 to 8, depending on the product), the shingle’s look is created with increasing degrees of complexity. 

The tooling and processes we use are among the most complex in the metal forming industry. Our operators control the 350 to 1500-ton presses with care to ensure the authentic look and feel of our roofing system. 

Each shingle panel is immediately inspected for the quality of the locking system as well as for color, appearance, and integrity. Once they pass inspection, the panels are carefully packaged to ensure safe transit so they can be installed on a roof for a lifetime of beauty and protection!

5. Our Post-Manufacturing Process

All of our machine scrap is meticulously collected, bundled, and sold back to an aluminum mill so it can be remade into new coils of metal, which are then painted, tested, and manufactured into aluminum roofing, continuing the recycling loop.

We love having visitors and showing off our team of roofing experts. So don’t hesitate to get in touch with us if you’d like to schedule a tour of our manufacturing facilities in Piqua, OH.