Structural steel products are created within a structural mill. The process begins with a beam blank that is reheated and then fed through a series of rollers. These rollers progressively shape the metal into its final form. Adjusting the spacings between the rollers allows for the production of different sections with the same nominal dimensions.

Once shaped, the steel's final form emerges as a continuous length, which is then segmented by a hot saw into manageable pieces. These segments are subsequently cooled and passed through another set of rollers that straighten the steel, rectifying any deviations or flaws that might have been introduced during the shaping process.

For heavier structural sections, an alternative method involves welding flange and web plates together instead of relying solely on rolling. This method allows for the production of larger and more robust sections needed for substantial construction demands.

Structural steel shapes are standardized and identified by specific nomenclature which includes a letter representing the shape followed by size, thickness, or weight details. Common structural shapes include beams, columns, channels, and T shapes, each characterized by specific dimensions such as nominal depth and weight. Additionally, other forms like angles, hollow sections, bars, and plates are designated by their shape, size, and thickness.

Structural steel can also be modified post-production through cold-working methods such as rolling, bending, or stretching at room temperature to alter the shape of the members. Thin steel sheets are often used to create lightweight C-sections, while thicker sheets can be cold-formed into various hollow shapes like square, rectangular, round, or elliptical forms, which are then welded along their longitudinal seams to produce robust hollow sections.