Fabrication Machinery Solutions

We offer a full range of flexible, creative, easy-to-use high tech iron workers. Cold work Iron bar, saving time, space, and money to mold into desired shapes. Carell Ornamental Equipment Represents the Best Most Versatile Machines Available! We manufacture and stock; tools for bending, tube rolls, pipe rolls, special tooling and custom tooling. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! ​ SUPPORTER/MEMBER Carell Corporation Ornamental Metal Working Equipment Represents the Best, Most Versatile Machines Available. These machines are Built to Exacting Standards for Industrial use and Long-Term Dependability. Knowledgeable Carell Machine Specialists are also just a Phone Call away and Ready to Help You! BACK TO TOP ORNAMENTAL BENDERS CARELL In-Stock Specials Click Image or Scroll Down for descriptions, standard equipment, options & technical specifications Request-A-Quote E-MATIC E-MATIC CE/CN Ideal for Tight Bends and Special Applications CARELL In-Stock Specials Request-A-Quote The Carell E-MATIC by Memoli; incorporates a rotary bending head, a wide stable base and digital programmable controls into a uniquely versatile package. Heavy Duty, Rugged unit is compact and easy to use. Tooling changes are rapid and simple. Application of the different attachments are shown below or use of easily produced special tooling offers unlimited versatility Video: Carell E-Matic Universal Bender SPECIFICATIONS: E-MATIC UNIVERSAL BENDER Main Drive: Speed: Weight: Memory: Controls: Voltage: Dimensions: 4.50 HP 7 rpm 500 lbs 45 steps 24 VAC 220V – 3PH – 60Hz 34” x 25” x 39” h Optional "SUPER SCROLL" 20" Diameter x 5/8" Bar PF Option – Bar Brake/Folding Tooling Bend up to 1” Round Rod, 4” x 5/16” Flat Bar D Option – Bar Twisting Tooling Twist up to 7/8” Sq. 1-1/2” x 3/8” Flats CT Option – Tube Bending Tooling Bend up to 1-1/2” OD x .079 wall CS/3 Option – Scroll Tooling w/ 3 Formers Bend up to ½” Sq. or Round – 1-1/4” x ½” Flats CF Option – Curve/Radius Tooling Bend up to 1” Round Rod, 2” x 9/16” Flat Bar BACK GALILEO G50 Heavy Duty - Up to 2" Pipe Capacity CARELL In-Stock Specials Request-A-Quote The G50HV Series are Heavy Duty, 3 Roll Universal Bending Machines with SOLID STEEL WELDED FRAMES, LED Readouts, high strength shafts and ALL 3 ROLLS DRIVEN through heavy duty drive trains for high torque delivery and energy efficiency. Video: G50 Universal Bender-Ornamental Options 3 Rolls Driven: Heavy Duty Drive Train Scroll Tool: 1-1/2 x 3/16 Scrolled on Flat Bar Twist Tooling:up to 7/8” Sq. and 1-1/2” x 3/8” Flat Bar Bar Brake Spiral Tool G50-HV Specification Chart BACK G50 ORNAMENTAL

Fabrication Nation Radio and Podcast covering the latest in the fabrication industry and playing a Gumbo of The World's Finest Rock to help you get thru your work day! Welcome to Fabrication Nation Playing a Gumbo of The World's Finest Rock We’ve got the music to keep your crew fired up and powering through the day. This is the soundtrack that fuels your grind and shapes America. From timeless classics to rowdy country rock and everything else that gets you moving. Whether you’re on the job or just need a boost, we’ve got something to keep everyone pumped and pushing through the workday! This is your Station! Our gift to you, The American Worker. The backbone of our great country. Fabrication Nation Radio—turn it up and let’s crush the day! Live 8:00am - 5:00pm Monday - Friday Request Line: 251-459-1038 Fabrication Nation - Interviews Fabricaton Nation, where American ingenuity takes center stage! This isn’t just another radio station; it’s your backstage pass to the heart and soul of the fabrication and manufacturing industries. Join us as we sit down with the visionaries and hard-hat heroes who are not only driving innovation but are also championing the spirit of American craftsmanship. From the blue-collar backbone of our great nation to the cutting-edge technologies shaping our future, we'll dive into what makes these industry leaders tick, why they’re passionate about their work, and their bold predictions for where we're headed next. It’s a celebration of the American Dream, the unsung heroes who keep our factories humming, and the promise of a future built on the principles of "Made in America." So grab your steel-toed boots and a cup of coffee, and let’s make America’s manufacturing great again, one episode at a time! Tell Us Your Story! First name* Last name Phone Email* Write a message Submit

Making the leap into exponential growth in fabrication production, knowing how to apply & select the right automation production systems is key. We manufacture and stock tools for plate roll bending, angle rolls, tube & pipe benders, custom & special tooling, section benders and more. We also carry the following brand names - Acrotech, Air Liquid, Cansa Makina, BPR Curvatrici, CBC, Comac, Hyllus, Icaro, Isitan, Lucas, Macri, Memoli, Ofmer, OMCCA, Omera, Parmigiani, Pedrick, Sahinler, and Simasv. We manufacture and stock tools for plate roll bending, angle rolls, tube & pipe benders, custom & special tooling, section benders and more. We also carry the following brand names - Acrotech, Air Liquid, Cansa Makina, BPR Curvatrici, CBC, Comac, Hyllus, Icaro, Isitan, Lucas, Macri, Memoli, Ofmer, OMCCA, Omera, Parmigiani, Pedrick, Sahinler, and Simasv. Automation Production Systems Evolving Into Automation Production Systems For small businesses making the manufacturing leap into exponential growth in fabrication production, understanding how to apply and select the right automation production systems is key. Capital investment is one of the biggest investment decisions a small business can make for large-step growth, so it’s essential to choose right the first time. The wrong equipment can seriously impact profit margins as well as limit the scale of service a fabricator can offer its clientele. Carell Corporation provides a large portfolio of automation production systems for growing companies, handling equipment needs for manufacturing for everyone from startups and small business to medium and large-size plant companies. With a high-performance selection available in multiple fabrication categories, Carell insures its customers are guided to the right equipment and tooling systems they need at every stage of their growth track. And, the automation system series that are available provide for all types of situations, including small footprint needs as well. Getting into the Accuracy of CNC Controls When it’s time to start moving in high accuracy fabrication, particularly of metal end product goods, CNC controls are essential. They can be guided manually or with automation programs (more popular), coupling with high production fabrication runs and demands. And because the accuracy potential is so high on the production side, companies can open up their possibilities for additional markets and sales as a result, especially into niche markets where specs are down to the millimeters or smaller for order fulfillment. The high quality CNC system Carell Corporation can make available also come with extensive guidance, training and capital equipment support through Carell for long investment life and profit margin turnaround in maintained production levels. With all these wins, its surprising more fabricators haven’t instituted CNC controls as fast as possible, especially with Carell Corporation’s available support.

The CARELL 308HV is a 3 driven rolls, double initial pinch universal bending machine with independent hydraulic adjustment of both lateral bending rolls and powered rotation of all three bending rolls. 308HV DOUBLE PINCH ANGLE ROLL Precision Engineered for Dependability Backed by the Best Guarantee in the Industry! CARELL In-Stock Specials Request-A-Quote Series PDF Brochure 308HV Specification Chart Capacities* Flats Hard: 5-1/2 x 3/4 Ø60 Flats Easy: 8" x 2" Ø42 Pipe Schedule 40: 5" Ø470 Angle Leg-In: 4" x 1/2" Ø48 *with standard equipment Angle 4 -1/2 " • Pipe 5" • Flats 8" CARELL's 308HV double initial pinch universal roll bending machines are available with 6 way m ulti-axis adjustable lateral guides, variable speed powered rotation of all three bending rolls and i ndependent hydraulic adjustment of the lower rolls for double pre-bending. This versatile unit is ideal for rolling standard/special sections plus tube & pipe in a variety of material types. The 308HV Series Universal Roll Set is designed for bending standard profiles , flat bar (on flat and on edge), square bar, tees, channel as well as round bar, square & rectangular tube sections, angles leg-in, leg-out and can be setup to operate in horizontal or vertical position adding further value to your production. Standard Features Dual LED Digital Displays monitor bending roll positions. Rigid, one piece solid steel weldment frame , normalized and precision machined, ample sized access panels and ventilation for internal hydraulic unit. 3 Shafts Driven w/ 3 Direct Coupled Hydraulic Motors and Planetary Speed Reducers for 100% efficient torque delivery. Larger, high strength steel shafts , heat treated and ground, journaled in dual self aligning spherical roller bearings for optimum performance. Hydraulic power unit integral to the machine frame. Multi axis, 6 way, fully adjustable lateral guides. Variable Speed rotation via electronic proportional valves. Universal bending rolls with modular components, hardened and wear resistant. Operates in both h orizontal & vertical orientations. Options Rolls for tubes pipes, and special profiles Tooling for production of half tubes Overhead Supports for coil production Compression and Tension tooling for C, & I hard way NC and CNC Controls with various automation levels for repetitive jobs and production of variable radius bends and parts with multiple bends LED digital displays for movements on lateral material guides

Carell Corporation makes it easy for clients and fabricators to secure the right horizontal presses for the jobs that need to be met. We manufacture and stock tools for plate roll bending, angle rolls, tube & pipe benders, custom & special tooling, section benders and more. We also carry the following brand names - Acrotech, Air Liquid, Cansa Makina, BPR Curvatrici, CBC, Comac, Hyllus, Icaro, Isitan, Lucas, Macri, Memoli, Ofmer, OMCCA, Omera, Parmigiani, Pedrick, Sahinler, and Simasv. Horizontal Presses A Wide Selection of Horizontal Presses Carell Corporation makes it easy for clients and fabricators to secure the right horizontal presses for the jobs that need to be met. With a selection of presses that range from small footprint to extra wide capabilities, the Carell T-series horizontal presses make it easy for fabricators to handle custom jobs without difficulty. All of the T-series presses incorporated forced lubrication with multiple tooling choices as well as accessories for added functionality. Straightening, bending, curling, rotary pipe modification, die cutting, shearing, twisting and form pressing are all doable. With all these added tooling options, a fabricator can easily create a wide range of metal hardware products with very little effort and cost aside from materials and system press maintenance. In fact, one could argue that Carell’s horizontal press equipment may almost be only limited by an owner’s imagination of what can be manufactured. We manufacture and stock tools for plate roll bending, angle rolls, tube & pipe benders, custom & special tooling, section benders and more. We also carry the following brand names - Acrotech, Air Liquid, Cansa Makina, BPR Curvatrici, CBC, Comac, Hyllus, Icaro, Isitan, Lucas, Macri, Memoli, Ofmer, OMCCA, Omera, Parmigiani, Pedrick, Sahinler, and Simasv.

The CARELL 304HV is a 3 driven rolls, double initial pinch universal bending machine with independent hydraulic adjustment of both lateral bending rolls and powered rotation of all three bending rolls. CARELL In-Stock Specials Request-A-Quote Series PDF Brochure 304HV Specification Chart 304HV DOUBLE PINCH ANGLE ROLL Precision Engineered for Dependability Backed by the Best Guarantee in the Industry! Angle 2-1/2" • Pipe 2" • Flats 4" Capacities* Flats Hard: 2-3/4 x 1/2" Ø28 Flats Easy: 4" x 1" Ø26 Pipe Schedule 40: 2" Ø24 Angle Leg-In: 2" x 5/16" Ø30 *with standard equipment CARELL's 304HV double initial pinch universal bending machines are available with independent hydraulic adjustment of both lateral bending rolls and powered rotation of all three bending rolls. This versatile unit is ideal for rolling standard/special sections as well as tube and pipe in mild-structural-stainless steels, aluminum, brass, copper and other materials. Machines are furnished with a set of standard universal rolls. Standard Features Dual L ED Digital Displays monitor bending roll positions Double Pinch G eometry permits pre-bending of leading & trailing ends of the profile without removal from the machine Telescoping modular multi-component roll set specifically designed to bend standard sections including angle leg-in/out and square/rectangular tube, as well as other shapes in a variety of material types Tri-Directional Lateral Guides with cam rollers for correcting inherent twist when rolling angle leg-in Operates in both horizontal and vertical orientations Options Rolls for tubes pipes, and special profiles Tooling for production of half tubes Overhead Supports for coil production Compression and Tension tooling for C, & I hard way NC and CNC Controls with various automation levels for repetitive jobs and production of variable radius bends and parts with multiple bends Powered Movements on lateral material guides on models 302HV through 307HV LED digital displays for movements on lateral material guides

STANDARD AND CUSTOM TOOLING Carell manufactures tooling in-house in our CNC Machine Shop for rapid turn-around and enhanced quality control for Angle Rolls,Tube & Pipe Rolls, Special Profiles, Supports, Cap Rail, Half Pipe, Coils, Traction & "V" Groove Tooling. STANDARD AND CUSTOM TOOLING Carell manufactures tooling in-house in our CNC Machine Shop for rapid turn-around and enhanced quality control" TUBE & PIPE ROLLS Most Common Tube OD & Pipe Sizes In Stock. Hardened, Solid Tool Steel. Any Size Can be Made. Specify Smooth or Knurled. Also available in Polymer Material for Delicate Finishes. CUSTOM TOOLING FOR SPECIAL PROFILES We can produce special tooling for a variety of machine makes, types and models. Forward drawings of your profiles and machine information for a quote TOOLING AND SUPPORTS FOR HALF PIPES & COILS 3000 Series Machines can be equipped with tooling for producing half tubes from strip & supports for coiling. Overhead supports (man. or hydraulic) may have coil diameter & pitch adjustment or be interlocked to NC/CNC controls. TRACTION TOOLING BEAMS BENT HARD WAY Larger capacity 3000 Series Angle Rolls can be fitted with traction tooling and rolls for effective rolling of beams as well as channels bent in the X-X axis or 'Hard Way" SECTION DIES FOR PLATE ROLLS For Plate Bending Machines with extended shafts, roll sets for profiles and tube or pipe can produced. Call to discuss capacities and pricing. "V" GROOVE ROLLS Roll Bar Stock and Square Tube on a 45° angle to Create a Unique Look. Available for all Models in both Smooth and Knurled. Made of Solid, Hardened, Tool Steel here at Carell Corp. CUSTOM ROLLS We manufacture Tooling In-House To Roll a Wide Range of Custom And Special Profile Shapes in a Variety of Material Types. CAP RAIL SOLUTION A For Aluminum & Brass Cap Profiles. Three Fully Contoured Polymer Rolls. Six Steel Shoulder Plates May be Required. Call for Capacities CAP RAIL SOLUTION B The Most Economical Cap Solution. 3 Semi-Contoured, Hardened Steel Inserts to Match the Cap. Most Commonly Used With Standard Tooling. Furnished Smooth. CAP RAIL SOLUTION C Best Suited For Production Jobs. 3 Fully Contoured, Hardened Steel Rolls Built To Match Your Cap Sample. Furnished Smooth. REPLACEMENT COMPONENTS Lost a piece or need a smooth surface component for working with soft or delicate material? We stock Smooth and Knurled standard roll components for all machines. CUSTOM TOOLING Send Drawings and/or Samples For Pricing on Custom Rolls And Accessories. Carell also can create custom tooling for other metal bending machines such as; PARMIGIANI, COMAC, FAMAR, ICARO, MEMOLI, CBC, SIMASV and more… Carell Corporation can handle your tooling/rolling needs for aluminum extrusions, satin/polished/pre-painted finished sections, steel/brass/aluminum decorative hand rails, oversized 'U' and 'C' shapes, overwide flats, half tube production from flats, hard way beam and channel rolling to name just a few.

The CARELL 306HV is a 3 driven rolls, double initial pinch universal bending machine with independent hydraulic adjustment of both lateral bending rolls and powered rotation of all three bending rolls. Series PDF Brochure 306HV Specification Chart CARELL In-Stock Specials Request-A-Quote Shown in Horizontal & Vertical Orientation Capacities* Flats Hard: 4" x 5/8" Ø42 Flats Easy: 6" x 1" Ø30 Pipe Schedule 40: 3" Ø42 Angle Leg-In: 3" x 3/8" Ø40 *with standard equipment 306HV DOUBLE PINCH ANGLE ROLL Precision Engineered for Dependability Backed by the Best Guarantee in the Industry! Angle 3 -1/2 " • Pipe 3" • Flats 6" CARELL's 306HV double initial pinch universal roll bending machines are available with 6 way m ulti-axis adjustable lateral guides, variable speed powered rotation of all three bending rolls and i ndependent hydraulic adjustment of the lower rolls for double pre-bending. This versatile unit is ideal for rolling standard/special sections plus tube & pipe in a variety of material types. The 306HV Series Universal Roll Set is designed for bending standard profiles , flat bar (on flat and on edge), square bar, tees, channel as well as round bar, square & rectangular tube sections, angles leg-in, leg-out and can be setup to operate in horizontal or vertical position adding further value to your production. Standard Features Dual LED Digital Displays monitor bending roll positions. Rugged, rigid, one piece solid steel weldment frame , normalized and precision machined, ample sized access panels and ventilation for internal hydraulic unit. 3 Shafts Driven w/ 3 Direct Coupled Hydraulic Motors and Planetary Speed Reducers for 100% efficient torque delivery. Larger, high strength steel shafts , heat treated and ground, journaled in dual self aligning spherical roller bearings for optimum performance. Hydraulic power unit integral to the machine frame. Multi axis, 6 way, fully adjustable lateral guides. Variable Speed rotation via electronic proportional valves. Universal bending rolls with modular components , hardened and wear resistant. Operates in both horizontal and vertical orientations Options Rolls for tubes pipes, and special profiles Tooling for production of half tubes Overhead Supports for coil production Compression and Tension tooling for C, & I hard way NC and CNC Controls with various automation levels for repetitive jobs and production of variable radius bends and parts with multiple bends Powered Movements on lateral material guides on models 302HV through 307HV LED digital displays for movements on lateral material guides

Welcome to Our Testimonials Page Here are just a few of our thousands of satisfied customers If you would like to be featured, contact us for more information. We manufacture and stock; tools for bending, tube rolls, pipe rolls, special tooling and custom tooling. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! ​ Welcome to Our Testimonials Page Here are just a few of our thousands of satisfied customers If you would like to be featured, contact us for more information Request-A-Quote Red Pepper Forge Inc - Carell MT500 & Eagle Model CP40-H We have been the proud owners of a CP40-H and MT500 for many years. Your company has given us great service and your products are high quality and long lasting with few maintenance issues. Thank you Jim Bomba, President, Red Pepper Forge, Inc. Howden - Carell 4RH 6/3 & Eagle Model CP40-H Howden North America first purchased our Carell CNC plate roll back in 2000 for our South Carolina facility. The machine was subsequently related to our plant in Mexico City. Throughout these sixteen years, we have found the Carell Plate Roll to be of outstanding quality, very reliable. Carell has always been very responsive and have provided excellent support both while machine was in SC, then in Mexico. I would certainly recommend Carell and Eagle. David G. Smith, Operations Director Howden North America, Managing Director Howden Mexico Laser Fabrication and Machine Co. Inc. Carell 303HV Angle Roll + 4RH CNC 8/7 Plate Roll + E-Matic CE/CN Bender, Eagle BA50 Section Roll My company has purchased several pieces of equipment from Carell Corporation. They have always provided excellent customer service. Their pricing is competitive and equipment arrives quickly. The equipment efficiently performs the tasks it was purchased to do. I will use Carell Corporation in the future. Alyson Orth, Laser Fabrication and Machine Co. Inc. Impact Storefront Designs - Carell ETM60 & Eagle CP30 Impact Storefront Designs is a team of building envelope specialists primarily focused on the fabrication and installation of glass. curtain wall, and storefront products. However, when we decided to tackle custom railing fabrication we turned to Eagle Bending Machines & Carell Corporation. Our team is now able to produce custom bent railings and metal work with superior craftsmanship. Our Eagle CP30 Roll Bender and Carell ETM-60 Rotary Pipe Bender has helped continue our tradition of top quality metal work as seen in our latest accomplishment at the Uncommon Charter School in Newark, NJ. These machines give us excellent results regardless of the magnitude of the project. ISD’s vision is one of simplicity; to fully control the fabrication, delivery, and installation of pre-assembled storefront products and our Eagle & Carell Bending Machines have also allowed us to add to the vast catalog of specialty products that we offer our customers. Mike Fileti,Operations Manager, IMPACT Storefront Designs Purolator Facet Inc. - Carell 3 & 4 Roll Plate Rolls of various sizes February, 2016 We at Purolator were interested in 4 roll plate rolls for long and small diameter perforated filter tubes with short unbent flats and perfect cylindrical dimensions, ready for our seam welding machines. These machines were auto-cycle and the operator does not need to touch the sheet. I was recommended to contact Carell by another engineer at Purolator that had made several prior purchases of other Carell rolls. We spoke to Mr. David Donnell who assisted us with the valuation and final equipment recommendation. We received 3 competitive proposals and chose Carell. We were completely satisfied with these 2 new Carell rolls. The machines worked as promised, which for me means a successful project. When contacting Carell, they are always responsive. They have Great customer service! The whole experience was nothing less than Excellent, and I would certainly recommend Carell Corporation to others. Doug Moser, Sr. Metals Design & Manufacturing Engineer , Purolator Facet, Inc. Sears Welding & Fabrication Sears Welding & Fabrication - Carell 307 Angle Roll + 8' x 3/8" Plate Roll I have depended on Eagle Bending & Carell for roll benders, custom tooling and technical support for quite a while. They are great to work with and quick to respond with quality equipment and the information I need." Pat Sears, Sears Welding & Fabrication Sonoco Steel Reels - Carell 308HV & 305HV Angle Rolls When you need the strength and durability of a steel reel, Sonoco has the product for you. When Sonoco began looking to purchase equipment to roll flat bar, I beam and channel, we looked to Carell Corporation because of their service and reputation for reliability. We spoke with Mr. Bill Richards at Carell. He was very knowledgeable about our application and helped guide us through the process of making the right equipment choice for our needs. In fact, we've been so pleased with the experience that we recently purchased additional equipment from them. If you're looking for reliable equipment backed by great technical support and service, look no further than Carell Corporation. Doug Ainsworth, Sonoco Steel Reel

Plate rolling is one of the most complex metal fabrication processes. Changing just one variable directly affects numerous others. Today many plate rolls have CNCs with data tables that draw from decades of rolling experience, which has made the process much more predictable. Request-A-Quote BACK BACK BACK BACK BACK BACK BACK Published Articles: "Plate Rolling Rolls On" By: Francesco Massa Advanced controls make a highly variable process more predictable. Click here for PDF Comprehensive Guide to Plate Rolling Machines "A Rundown On Rolling Machines" By: David Donnell, President, Carell Corporation The type of bending application determines the style of machine and bending capacity needed to do the job. Click here for PDF See Below for Quick References by Subject - More About Roll Forming - BACK TO TOP Plate Roll Bending Selection Guide Plate rolling is one of the most complex metal fabrication processes… Changing just one variable directly affects numerous others. Today many plate rolls have CNCs with data tables that draw from decades of rolling experience, which has made the process much more predictable. With predictability also comes automation. Some plate roll operations now have automated the loading, rolling, and unloading, producing precisely rolled workpieces time after time. QUICK LINKS Quick Links by subject: Plate Roll Manufacturers Machine Capacity Pre-Bending vs. Rolling Ratings Pre-Bending Ratings Rolling Ratings Automation Three Roll Initial Pinch Double Pinch Automatic NC or CNC Controls Variable Geometry Plate Rolls True Pyramid Machines Two Roll Machines Vertical Format Plate Rolls Optional Equipment & Accessories Cone Rolling Devices Lateral & Overhead Supports Extended Roll Shafts Roll Movement Up/Down Roll Balancing Plate roll manufacturers Plate roll manufacturers commonly rate machines according to baseline material yields between 36 to 38,000 psi. When choosing a roll you must refer to your mill delivery certificates, to your proposed supplier or to the Internet to specifically verify the average yields of the plate you need to roll. In our current manufacturing environment, the term “A36 Steel” has little correlation to the actual yield since the A36 generalization encompasses many specific sub-denominations. Some of these may have yields strengths of 70,000psi or more. The old common term “Mild Steel” will generally represent steels with yields of 45,000 to 55,000 psi. Machine capacity must be commensurate to your material yield. Most roll manufacturers can provide tables or graphs that allow you to match machine capacity to the material yield. Pre-Bending vs. Rolling Ratings will often be presented in numerous formats and tied to a minimum shell diameter at a given thickness for each Plate Roll model. The Pre-Bending operation is performed at the leading and trailing edge of the sheet (in most cases, the eventual seam). Sheets cannot physically be bent completely to the leading edge and will thus leave what is referred to as an ‘Unbent Flat’. As a rule of thumb, the minimum you should expect for an unbent flat length is 1.5 times the material thickness. This may approach 2.5 to 3.5 times the material thickness for thicker plate. It is this pre-bending operation which attempts to reduce the unbent flat to the minimum possible length which requires the most power from the machine. This operation is also very critical as care must taken to ensure that the sheet does not disengage from between the rolls. Because of this “safety factor” claims of unbent flats equal to 1.1 times the material thickness should be thoroughly investigated as it is rare that this can be achieved. Pre-bending ratings with the shortest possible unbent flats are necessarily lower than the overall rolling capacity rating for any given machine. You must be mindful when reviewing machine ratings since the maximum total rolling capacity is generally expressed with the intrinsic requirement of multiple rolling passes, longer un-bent flats and larger minimum shell diameters, even if not entirely clear from reading a simple roll specification. Un-bent flat lengths for any given sheet are a function of thickness, width, cylinder diameter, machine geometry, material yield, top roll size, operator proficiency and other factors. Rolling ratings anticipate that the plate is in motion, translating through the machine. This is called “dynamic” as opposed to the “static” pre-bending operation when the sheet is held between the rollers and one or more rolls move upward to “curl” the leading edge. Dynamic rolling mode will always allow a greater thickness to be rolled than can be bent during static pre-bending. Automation in the workplace is becoming more common as pressure increases to reduce labor costs. Most all CNC and NC controlled machines are 4 roll types. Automated controls are recommended for high volume or significantly repetitive cylinder or shell production or to roll complex shapes that are not easily reproduced by using manual machine controls. Multiple bends, variable radius bends, ovals and the like are some examples. Over automation on a roll when the production volume is not significant can be a costly mistake. Three Roll Initial Pinch or Single Initial Pinch Plate Rolls are generally for lighter capacity applications and may be electro-mechanical or hydraulic. They work by "pinching" the flat sheet between two counter-opposed rolls while the third offset roll or ‘bending roll’ moves upward to contact and then bend the sheet. When rotation of the rollers is activated, the sheet exits at a given radius. With the sheet cut to the developed length and the bending roll properly positioned; the part is rolled into a cylindrical form, where it can then be welded at the seam to produce a cylinder. The upper roll is in a fixed position; the lower pinch roll can move up/down to pinch the material. The third roll (the forming roll) is also adjustable. To remove a rolled cylinder, it must be extracted from off of the top roll. Machines are generally equipped with some type of release mechanism on the top roll to allow extraction of the cylinder. Typical methods are either a forward tilting or releasing top roll or a removable end yoke. In most applications, these machines require removal and re-insertion of the sheet in order to pre-bend both ends. They are cost effective but in contrast may be more labor intensive in a production setting. There were many large mechanical initial pinch machines built during the 1930’s, 40’s & 50’s and can be found on the used market. All have cast frames as modern alloys and welding techniques had yet to be invented. Double Pinch Plate Rolls are available from light to extremely heavy capacities and may have three or four rolls. The terminology can be confusing as these units may sometimes be referred to as ‘double pinch pyramid plate rolls’ or ‘double initial pinch plate rolls’. Both three and four roll styles have fixed position top rolls and two offset rollers or ‘lateral rolls’, one on each side. The 4 Roll styles have an additional roller directly underneath the top roll, which constantly pinches the plate during rolling. Double Pinch Rolls can pre-bend both ends of the plate without removal as is required with single pinch rolls. Three Roll machines generally require pre-bending the leading end, running the sheet through the machine to pre-bend the trailing end then switching roll rotation direction to roll the cylinder body. Four Roll Plate Rolls have a slight advantage in cycle time since t hey permit pre-bending of the leading edge, rolling the cylinder body and finishing off of the trailing edge all while rolling in the same direction. High volume products can be produced faster when using a four roll machine. Smaller machines can be mechanical but most modern machines are hydraulic and include drop end yokes for easy extraction of the work-piece. Automatic NC or CNC Controls and Four Roll Plate Rolls: Automatic cycle systems are generally used only on four roll plate rolls because there is minimal chance for slippage since the sheet is constantly pinched between the top roll and the 4th roll or “pinching roll”. Automatic controls use an encoder to track movement of the plate through the machine. If the plate slips, the bending roll movements will be out of sync with the material’s translation through the machine. Variable Geometry Three Roll Plate Rolls are not new but are gaining in popularity around the world. They are built for medium, heavy to extremely thick plate applications. The top roll moves up/down and the lower two rolls each move horizontally. This lower roll movement allows increasing the offset distance from the top roll and commensurately increasing mechanical advantage in bending. A machine of this type works well over a wide range of material thickness. By adjusting the geometry they can be used similar to single pinch, double pinch and pyramid style machines and require minimal sheet movement during the pre-bend operations. In the past these machines were commonly found in shipyards but now are being placed in general job shop and manufacturing applications. True Pyramid Machines are not generally manufactured by modern roll builders. They may be found on the used market and are more common in developing countries. They have 3 rolls, both lower rolls fixed in position with the top roll moving up/down. In general they leave very long un-bent flats and have only one or two rolls motorized in rotation. Some special application machines are still produced on a custom build basis and are mostly found in shipyards. They will have the lower two rolls spaced closely together and be of small diameter with midpoint support trunnion rollers. Two Roll Machines are designed for thin or light gauge material rolled to reasonably small diameters. They use a large diameter urethane coated pinch roller which moves up with extreme pressure against a small diameter steel top roller. A mandrel or drum, very close in OD to the desired ID of the part is fitted over the top roll. Two roll sheet rolls are extremely fast and will roll round cylinders or shells even if the blank has large cutouts, voids or holes. Since they require a mandrel for each different part diameter and material thickness they are not as versatile as some other machines. For dedicated high speed production of light gauge cylinders they can be an optimal solution. Vertical Format Plate Rolls can be of nearly any geometry, double pinch, single pinch or pyramid. Vertical rolls are most often used for rolling large diameters and can be advantageous when used in the field for storage tank production. Carell offers automated Vertical Tank Production Systems which are fed from coil stock and can include vertical sheet cutoff and automatic vertical seam welding among other options. These Systems can be used in-house or in the field and increase production output while reducing labor input Optional Equipment and Accessories are offered for most Plate Rolling Machines. The most important items to consider are hardened roll surfaces and cone rolling devices. With today’s harder materials and laser/plasma cutting techniques it is imperative to have a hardened outer surface on the rollers. Look for hardness ratings in the range of 52 to 55 Rockwell C Scale and also for the indication that the hardening process used is “induction hardening”. Hardness in the 52 to 55 RCS range will have a reasonable hardness penetration depth to provide long lasting protection against roll surface wear. Hardness exceeding 58 RCS will have a shallow penetration and a more brittle outer surface which can result in cracking or crazing. Cone rolling devices permit the operator to roll a conical shape and are standard on some machines. Some machine brands require a machine to be pre-disposed at the time of purchase if cones will be rolled in the future. This important point should not be overlooked. Lateral as well as Central Overhead Supports are optional on nearly all Double Pinch Plate Rolling Machines. Some rolls may require pre-disposition for the eventual addition of hydraulic powered supports. Overhead supports prevent lighter materials from collapsing when rolled to large diameters and must be sized according to plate thickness and shell diameter. An overhead support is not a crane and it is designed to sustain nominally only 40 to 60% of the total shell or cylinder weight. A side support can also assist in this function to prevent light materials from re-curving toward the floor if the radius is very large. Some plate rolls are designed with Extended Roll Shafts that protrude through the machine frame at the yoke end. Section or Pipe Dies can be fitted on these ‘stub’ or extended shafts. Some machines are designed with collars inside the machine frame that can be used for profile rolling but when rolling a complete 360 degree hoop it will be impossible to remove from the machine. It is also not possible to coil with inboard collars. It is not practical to anticipate rolling angle iron on a plate roll. Angle will always twist when being rolled. Plate rolls do not have outboard adjustable lateral profile guides to prevent this inherent twist. You should consider using a section rolling machine or double pinch angle roll instead for these applications. In general, section dies on plate rolls are good for bending flat bar the hard way, rods or small pipe. Roll Translation or Roll Movement Up/Down is accomplished either by using inclined linear guides or via swing arms. Direct rectilinear guides direct the thrust of the roll directly toward the top roll and have the fewest moving parts. Rectilinear guides are found on small as well as extremely high capacity rolls. Swing arm designs are not common on large machines and have more moving parts, pins, and bushings. Roll Balancing can be achieved in a variety of methods. Maintaining the bending roll or rolls parallel to the top roll is necessary in order to produce a good true cylinder. Volumetric type and electronic type balancing are the most trouble free for general job shop use. They have up to 80% fewer moving parts than swing arm balancing systems and thus significantly lower maintenance costs in the long run General Note: Roll Bending Machines are very dangerous if used carelessly. It is the responsibility of the owner to ensure the installation and proper use of point of operation safety guards or devices. Machine capacity Pre-Bending vs. Rolling Ratings Pre-bending ratings AUTOMATION Rolling ratings Three Roll Initial Pinch Double Pinch Automatic NC or CNC Controls Variable Geometry Three Roll Plate Rolls True Pyramid Machines Two Roll Machines Vertical Format Plate Rolls Optional Equipment and Accessories Cone rolling devices Lateral and Overhead Supports Extended Roll Shafts Roll Translation Roll Balancing

We recognize the need to bend and curve many different materials in production. Carell's Specialty Machines are designed and manufactured on specific customer needs while combining the best technical solution for the demands in manufacturing. We manufacture and stock; tools for bending, tube rolls, pipe rolls, special tooling and custom tooling. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! ​ CUSTOM BENDING MACHINES CARELL In-Stock Specials Request-A-Quote CORRUGATED PLATE ROLLS BACK TO TOP Anchor 1 CUSTOM FABRICATION SOLUTIONS C arell’s many years of experience and search for dynamic solutions beyond standard equipment to meet the specific needs of our customers, has led to the development of special machines. Resulting in better design, for better production rates, quality & performance while staying in budget. Call Us Today and Let one of our Application Professionals help make the right choice!

CARELL Rebar Benders produce quality bends swiftly and efficiently to the desired degree with electric limit stops. Our Units feature TEFC electric motors, continuous oil bath reducers, safety guards, E-Stop switches, foot pedal operation and a tooling set. We also carry the following brand names Parmigiani, Comac, Memoli, Omcca, Simasv, Isitan, Icaro, Offmer & More! REBAR BENDERS & SHEARS True Mobility • Rugged Frames & Low Maintenanc e The Best Solution For Your Rebar Fabricating Requirements! CARELL In-Stock Specials Request-A-Quote Rebar Benders & Cutters from Heavy Production to Economical uni ts. We offer Combination Benders with Shears, Benders, Portable Bar Shears, Stirrup Benders, Spiral Applications, Optional Tables & Tooling for your production. BENDER & SHEAR COMBOS REBAR BENDERS PORTABLE YARD SHEARS STIRRUP BENDERS Scroll Down to Click Images & Links for descriptions of standard equipment, options & technical specifications BACK TO TOP TP-SERIES COMBO REBAR BENDERS W/SHEARS Cutting and Bending in One Machine! CARELL In-Stock Specials Request-A-Quote BACK TO TOP Each TP-Series Rebar Bender & Shearing station produces quality bends swiftly and efficiently to your desired degree with electric limit stops . TP Series Benders have a mechanical bar shear on board with an adjustable backstop , safety guard and E-Stop . Standard with 6 BEND programmable repeat memory digital controls STANDARD FEATURES: • Automatic Hands Free Operation: Bending sequence can be controlled by foot pedal switch & E-Stop Pins . • Heavy Duty Work Head: Solid steel top rotary plate mounted in a heavy-duty welded steel base frame. • Forward & Reverse Controls: Standard controls allow clockwise/counterclockwise operation. • Bends up to 360 Degrees in one pass operation. • Quick Change Tooling: Simple spindle design allows for tooling changes in seconds! • Shears: Built on a heavy cast frame the speed reducer assembly includes interchangeable multi-sided blades, a safety shield and E-Stop. Shear cycles with bend rotation. • Portable: Equipped with 4 large casters for ease of mobility. • Electrical System: Switchgear consist of a Main fuse group, low voltage controls, motor overload protection, reversing low voltage relays and main power switch with indicator lamp. • 24VAC Low Voltage Controls • Safety Protection: Equipped with shield, emergency stop palm switch & limit cut-out • Tooling: Includes one set of counter pins, main arbor pin, squaring/checking block, tool tray and instruction manual. All tooling is heat treated for durability. COMBO BENDER/SHEAR REBAR BENDER P-SERIES REBAR BENDERS Versatile High-P erformance Rebar Bending "Made to Build" CARELL In-Stock Specials Request-A-Quote BACK TO TOP Spiral Tooling Large Radius Arm Angle Control Long Saddles Our P-Series Rebar Benders use a rotating head with a forming arbor and lateral pins around which the bar is bent. Quality bends are produced swiftly and efficiently to the desired degree with electric limit stops . Rotation powered via TEFC electric motor and a continuous oil bath speed-reduction unit . Safety guards and stop switches are standard. STANDARD FEATURES: • Automatic hands free opera tion: Be nding sequence can be operated by foot pedal switch with E-Stop Pins . • Heavy Duty Work Head: Solid steel top rotary plate mounted in a heavy-duty welded steel base . • Forward & Reverse Controls: S tandard controls allow clockwise/counterclockwise operation. • Bends up to 360 Degrees in one pass operation. • Quick Change Tooling: Simple spindle design allows for tooling changes in seconds ! • Portable: Equipped with 4 large casters for ease of mobility. • Electric al System: Switchgear consist of a Main fuse group, low voltage controls, motor overload protection, reversing low voltage relays and main power switch with indicator lamp. • 24VAC Low Voltage Controls • Safety Protection: Equipped with safety shield and emergency stop palm switch. • Tooling: Includes one set of counter pins, main arbor pin, squaring/checking block, tool tray and i nstruction manual. All tooling is heat treated for durability. C-SERIES REBAR YARD SHEARS Your Choice of 6 Models " Designed For Job Site Use" CARELL In-Stock Specials Request-A-Quote BACK TO TOP Our C- Series Rebar Shears are designed for job site use and abuse as primary criteria. Every machine is equipped with three speed reduction sections for maximum cutting power with minimal energy usage. Units use TEFC electric motors, are equipped with foot pedal and manual controls for maximum versatility. Each comes with wheels, safety covers and guards. STANDARD FEATURES: • Powered Operation: Units powered by TEFC electric motors for swift cutting/shearing • Extra Heavy Frame: Frame and reduction unit are in heavy steel plate & castings • Controls: Shear actuation is via foot pedal and/or manual lever for • Quick Change Blades: Each blade has 8 cutting sides and are easily changed • Single Speed operation with continuous oil bath heavy-duty reduction unit • Portable Unit with Wheels: Every unit equipped with 2 large wheels for Mobility! • Electrical System: Equipped with a magnetic motor shutoff for motor overload protection. • Safety Protection: Top shield covers shear area including limit switch, anti-repeat lock & overload protection. YARD SHEARS ST-SERIES REBAR STIRRUP BENDERS Easy to Transport, Compact Design with Removable Legs CARELL In-Stock Specials Request-A-Quote BACK TO TOP Our ST-16 Stirrup Bender is designed to rapidly bend stirrups and ties to the desired degree using electric limit stops. Safety guard and Emergency stops are standard STANDARD FEATURES: • Heavy Duty Work Head: Solid steel top rotary plate mounted in a heavy-duty welded steel base . • Removable L egs for easy transport . • Bends up to 270 Degrees in one pass operation, includes rotation inversion switch • Quick Change Tooling: Simple spindle design allows for tooling changes in seconds! • Electrical System: Main fuses, low voltage controls 24 VAC, motor overloads and reversing contactors, main switch & E-Stop. • Safety Protection: Equipped with emergency stop palm switch and limit cut-out • Standard: Instruction manual, one set of counter pins, main arbor pin, arbor sleeves, remote foot pedal, length stop and squaring arm/checking block. STIRRUP BENDER PS-SERIES REBAR STIRRUP BENDERS Digital Control with Program Memory For Up To 20 Bend Angles CARELL In-Stock Specials Request-A-Quote BACK TO TOP PS-Series includes digital bend angle control and full base cabinet. It is designed for automatic pre-set bending of each step in the program. STANDARD FEATURES: • Heavy Duty Work Head: Solid steel top rotary plate mounted in a heavy-duty welded steel base . • Portable Unit: Every unit equipped with 4 large casters for ease of mobility. • Bends up to 270 Degrees in one pass operation, includes rotation inversion switch • Quick Change Tooling: Simple spindle design allows for tooling changes in seconds! • Electrical System: Main fuses, low voltage controls 24 VAC, motor overloads and reversing contactors, main switch & E-Stop. • Safety Protection: Equipped with emergency stop palm switch and limit cut-out • Standard: Instruction manual, one set of counter pins, main arbor pin, arbor sleeves, remote foot pedal, length stop and squaring arm/checking block. PS16 Stirrup Bender