Unit of Measure



N/A Roll Formed C-Channels, Box Channels, Sub-Girt, Open Seam Square and Rectangular Tubing. Standard tooling available for many sizes. Roll Formed in all metals: Plain or Prefinished, Prenotched & Cut To Length Inline. Max thickness of .120" down to .005" thick. Developed material widths from 15" max down to .375". Finished accurate lengths from 3" through 40 feet long. Available in Steel, Stainless, Galvanized, Aluminum, Copper, Brass, Bronze, High Strength, Cor-Ten, Clad, Perforated, Embossed, Woven Wire Cloth, Martinsite, Titanium, Nickel, Special Alloys and more. Prefinished include: Galvanized(G30, G60, G90, G120, 2-oz, Bonderized, Chromate, Electro), PrePainted, PrePlated, PreAnodized, PreLaminated Vinyl, PrePolished, Galvanealled, Aluminized, Galvan, Strippable-Pvc, and more. Inline fabrications include: Holes, Slots, Notches, Perforating, Embossings, Shear Forms, Cut-to-Length, Swept length radii, Ring Bending, Tabs, Cutouts, Depressions, Miters, and more. Min. order-2,000 feet.


N/A Thickness & Length

C Channel & Box Channel thicknesses vary from .003" thick up to .150" thick. On 1/4 & 1/2 hard aluminum, Aluminum C Channels & 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. Lengths may be from 3" thru 40 feet long with close tolerances. Many different lengths can be put on one purchase order.



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.

Manufacturing Process


Additional Inline fabrication during Roll Forming is regularly part of the manufacturing process for C Channels, Box Channels, & Open Seam Square and Rectangular Tubing; such as:

  • 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.

In several circumstances our modernized inline post fabricating can comprise many die operations in what used to be only a flying Cutoff Die operation. Our inline post fabrication dies can now handle all hole punching and other required notching that used to be done during the pre-punch operation. This decreases the number of necessary dies and permits closer tolerances on the locations of the notching without the distortion that would take place if fabricated with a pre-punch press and then bent into the C Channel, Box Channel or Open Seam Tubing. Sophisticated inline Flying Die Accelerators and Die Boosts utilizing close tolerance length measurement systems in the Post-Punching and Pre-Punching Presses are the vital for close tolerance, higher speed, inline fabricating. The Die Accelerator permits up to 12 different functions carried out in the same die and can operate both Pre-Punching & Post-Punching/Cutoff presses at the same time.

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
  • Purlins
  • Subgirts
  • Girts. (Many other styles of Roll Formed Profiles have these same descriptions, however.)

High Speed Roll Forming


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.

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.