Maximizing Versatility in High-Mix Job Shops

How Hammer Haag Automates Heavy Plate and Section Bending

Plate Rolling Plays into Structural Steel Shop’s Big Business

Story overview

At Hammer Haag Steel, we deliver end-to-end structural steel solutions under one roof. From tube laser cutting and plate rolling to structural fabrication, CNC machining, and on-site blast and paint, our team handles every stage of the process with precision and accountability. Whatever the scope of your project, we have the capabilities to bring it to life.

Website

https://hammerhaag.com/

Location

United States

Industry

Jobshop & Metal Structures

Related products

MCB , MCP

The Challenge

For heavy-duty job shops and custom fabricators, rolling thick-walled steel cylinders and heavy plate segments is an operation filled with variables. When working with high-yield materials, the immense bending forces required naturally cause the machine frame and the rolls to deflect under load. If this structural deflection is not accurately compensated for, the plate ends suffer from an extended flat section, and the main body of the cylinder exhibits a barrel or camber effect.

Traditionally, operators have had to rely on a manual trial-and-error process—constantly pausing the machine to perform "sweep checks" with physical cardboard or wood templates, and resetting the rolls based on guesswork. This recursive checking routine slows down cycle times, creates severe production bottlenecks, and risks wasting expensive material when parts do not fit downstream welding lines flawlessly. For shops running multi-shift operations, these manual steps limit versatility, increase labor costs, and restrict the shop's overall capacity to take on large-scale projects confidently.

The Solution

Synchronized 4-Roll and Double-Pinch Technologies

To address these versatility and productivity requirements, US-based fabricator Hammer Haag updated its shop floor by integrating two distinct Davi technologies into a unified fabrication center:

The Davi MCB (Four-Roll Plate Roll): Engineered for high-volume repeatability and automated ease of use. The bottom roll firmly clamps the heavy plate, providing perfect control over its position throughout the entire pre-bending and forming cycle.
The Davi MCP (Three-Roll Double-Pinch Angle Roll): Designed to handle large sections, beams, and pipes. The MCP features three independent hydraulic motors driving each individual roll, managed by the exclusive Davi Torque Management System (DTMS) to automatically synchronize contact speeds and prevent profile slippage.

Both machines are equipped with advanced, Industry 4.0-ready iRoll control systems. This interface allows the shop to store an unlimited number of custom programs and generate automated rolling sequences based on material yield strength and thickness

The Results

Drastic Time Reduction

Operators recall saved bending programs instantly, letting the CNC automate plate positioning, feeding, and squaring. This entirely eliminates the time-consuming trial-and-error process of template checking

Shortest Flat Ends and Flawless Fit-Up

Motorized rolls maximize torque transmission directly to the material, allowing the operator to pinch the sheet precisely at the tangent point. This delivers the shortest possible flat end, eliminating test scrap and ensuring a perfect fit for downstream welding lanes.

Tooling Versatility

The MCP's standard universal rolls enable the team to quickly switch production between flats, squares, rounds, angles, channels, and beams without requiring expensive, time-consuming tooling changes.

Empowering Younger Operators

The intuitive, smartphone-like touch interface allows newer tradespeople to successfully run complex rolling cycles by following on-screen digital guides, bridging the skilled labor shortage.

The Industrial Credibility: Over 50 Years of Engineering Stability

Davi’s high-mix fabrication technology is backed by more than 50 years of continuous R&D and dedicated vertical industry expertise. Every heavy-duty machine is designed and manufactured under strict quality standards (ISO 9001, ISO 14001, ISO 45001) in Cesena, Italy, utilizing premium, commercially sourceable components to guarantee maximum uptime. To ensure long-term manufacturing continuity, our customer service structure provides dedicated engineering support, 24/5 remote assistance via secure network access, and rapid spare parts shipping from a stock inventory exceeding 11,000 line items.

With higher quality top-of-the-line equipment, we gain the exibility to handle a wider range of work. Yes, we can roll thinner gauge material if needed, but our goal is to accommodate the big stuff

Tim Maneval

Vice president of operations, Hammer Haag Steel

Operational updates