Roll Forming Steel Door Frame for the Storm Doors Industry

At Johnson Bros. Roll Forming Co., we help our customers through the fabrication of high quality metal formed products.

From mass produced construction framing to high strength steel channel, our capabilities let us produce many specialized products to high standards.

We were recently contracted by a customer in the Storm Door industry seeking a production partner for security door mullions. Being a multi-generational company with a vast knowledge of older as well as more advanced fabricating procedures, we were able to use the customer’s original design. We adjusted the tooling and made the necessary modifications needed to help improve the roll forming process. This allowed us to produce a superior product, while holding down any additional costs for the customer.

The Security Storm Door Mullion was manufactured on site using our proprietary roll forming process. The parts were produced from galvanized and annealed cold rolled steel, run to customer custom lengths x 0.033″ thick and pre-pierced where necessary. Our tooling bent each mullion to its final shape using our specially developed bend tooling, which satisfied a bend tolerance of ± 0.005″ and an angular tolerance of ± 0.3°. To finish the part, we employed our special lubricating and packaging process to maximize dryness of parts for customer’s painting process.

We manufacture various order quantities of these parts per year, meeting our customer’s specific expectations and our standards for excellence. We welcome the challenge to design and construct high quality custom metal shapes at a cost effective rate. For more information about this Door Frame Mullion project, please see the table below or contact us directly.

Project Specifications

Project Name & Description

Security Storm Door Mullion

  • Used to secure sections that will hold up in any weather condition
Capabilities Applied / Processes
Roll Forming
Lock Seam
Overall Part Dimensions

Length: 1-7/8”
Width: 13/16”

Tightest Tolerances

Bend Tolerance: ±0.005”
Bend Angles: ±0.3°

Material Used

Cold Rolled Steel

  • Thickness: 030-.034”
Material Finish


Industry for Use

Storm Doors


10,000 ft Annual to Millions

Standards Met

Customer Specification