Flexural strength of cold-formed steel unstiffened and edge-stiffened hexagonal perforated channel sections

Cold-formed steel (CFS) channel beams are increasingly used as primary structural elements in modern construction due to their lightweight and high-strength characteristics. To accommodate building services, these members often feature perforations—typically circular and unstiffened—produced by punching. Recent studies indicate that adding edge stiffeners, particularly around circular web openings, can improve flexural strength. Extending this idea, attention has shifted to hexagonal web perforations; however, limited research exists on the bending performance of hexagonal cold-formed steel channel beams (HCFSBs). This study presents a detailed nonlinear finite element (FE) analysis to evaluate and compare the flexural behaviour of HCFSBs with unstiffened (HUH) and edge-stiffened (HEH) hexagonal openings. The FE models were validated against experimental results and expanded to include a comprehensive parametric study with 810 simulations. Results show that HEH beams achieve, on average, a 10% increase in moment capacity compared to HUH beams. However, when evaluated using current Direct Strength Method (DSM) provisions, moment capacities were underestimated by up to 47%, particularly in cases governed by lateral–torsional or distortional buckling. A reliability analysis confirmed that the proposed design equations yield accurate and dependable strength predictions.