Tool wear manifests in change of roughness of roll surfaces and governs the surface quality of both coated and uncoated products. Decrease of friction and wear in the roll–strip interface will stabilize the performance of the cold roll forming (CRF) mill and ensure uniform process output. The scope of this paper includes an experimental study of adhesive wear of hardened tool steel blocks sliding against a mild steel wheel and field observation of tool wear in the CRF of zinc coated mild steel. Wear mechanisms are identified for the materials interacting during the CRF process. The results include an empirical value of tool wear coefficient for D2 steel sliding against unlubricated uncoated hot rolled AISI C1020 mild steel.