This project demonstrates to develop and evaluate a new cold-formed HPE profile consisting of a C-profile with two web notches and one flange notch. Using an automated welding equipment, the profile is welded to two U-profiles with single notches in the web to produce a composite section with increased structural efficiency. This innovative design ensures the HPE profile is fully effective and puts the cold-formed profile on level with traditional IPE sections in terms of load-bearing capabilities, efficiency, and durability. Through material and shape optimization, the recommended profile greatly reduces weight while maintaining structural performance. Furthermore, by combining a notched cold-formed C-profile with two welded U-profiles, this work presents a novel welded composite HPE profile that deviates from previously published built-up and hybrid cold-formed sections. This arrangement permits manufacture through continuous roll-forming and automated welding while optimizing local stiffness and material distribution. To clearly establish the originality and useful benefits of the proposed HPE section, a comparative synthesis of important geometric and performance parameters against representative built-up and hot-rolled profiles has been added (see Table 1). According to the study, as compared to equivalent IPE sections, the suggested HPE profiles were able to reduce weight by up to 35% while keeping load-bearing capacity same or even slightly greater (by up to 8%). These numerical results highlight the developed cold-formed profiles’ structural and economic benefits. These advancements address the financial challenges caused by rising steel costs and encourage sustainable building practices by lowering resource consumption. This study offers a comprehensive evaluation of the recommended profile’s structural behavior, effectiveness, and price, positioning it as a competitive choice for modern steel construction.
