Roll Forming Process: Hidden Insights for Better Engineering Design

Earn 1 PDH / 1 LU|HSW

Light gauge steel construction systems are increasingly popular in residential and commercial buildings due to factors like labor shortages, construction costs, and supply chain issues. These systems use cold-formed steel trusses, panels, and connections. Engineers specify member sizes based on the project’s load, but sometimes the designs are structurally adequate yet difficult to procure or construct. With new roll-forming sections entering the market, engineers must carefully select the right profiles, considering stiffeners and ribs in the manufacturer’s design.

Connection design is another crucial aspect. Modern roll-formers can perform operations like pre-punching, dimpling, coping, flattening, cutting, and notching to ease assembly, either as standalone features or integrated into software systems that ensure structural integrity. Despite these advancements, engineers often specify common sections like lipped channels and hat sections without detailed tolerances or manufacturer-specific information, leading to potential issues. This presentation discusses the best practices including practical insights into roll-forming operations and their impact on strength prediction, as well as key issues like eccentric truss and end-bearing connections.

Dr Hari Magarabooshanam
Scottsdale Construction System

Hari is the Technical Sales Manager at Scottsdale Construction System, with over 10 years of experience in structural engineering. He holds a Ph.D. in Structural Engineering, specializing in cold-formed steel, and assists new and existing customers with onboarding and support within the Scottsdale environment. Hari provides project-specific guidance for the efficient use of cold-formed steel frames, ensuring compliance with various national codes of practice using the Scottsdale methodology.

He is passionate about integrating technology into structural engineering to automate calculations and workflows, helping clients optimize their projects using Scottsdale software suite. Hari advocates for sustainable construction practices by highlighting the environmental benefits of cold-formed steel, such as recyclability and a lower carbon footprint, assisting clients in meeting their sustainability goals.

Hari also plays a key role in pre-sale conversations, demonstrating the cost-saving advantages of Scottsdale’s technology and building strong client relationships. He stays current with industry trends by participating in conferences and workshops, and he is dedicated to sharing his knowledge to advance the field of cold-formed steel.

Mahsa Mahdavian
Scottsdale Construction System

Mahsa is the Technical Marketing Director at Scottsdale Construction System, bringing over a decade of expertise in cold-formed steel products. During her master's studies, she specialized in cold-formed steel shear walls, conducting more than 70 full-scale shear wall tests and developing supporting finite element models. She also researched cold-formed steel clip angles, publishing her findings in AISI Research Reports.

Mahsa began her career in the steel deck products sector as a research engineer focused on new product and market development. In this role, she developed product engineering software and later transitioned into a technical representative engineering role, where she worked closely with engineers to provide innovative solutions to complex challenges. Her contributions to the Steel Deck Institute and the American Iron and Steel Institute have been instrumental in advancing the industry.

Today, Mahsa is focused on promoting the benefits of cold-formed steel and advocating for building durable, efficient structures. Her core principles are: Let the new generation lead, Build with steel, and Make engineering easy. Together, we can achieve stronger, more sustainable structures with cold-formed steel material.

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