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This paper aims to present the design optimisation using genetic algorithm (GA) to achieve the highest strength to weight (S/W) ratio, for cold-formed steel residential roof truss.

The GA developed in this research simultaneously optimises roof pitch, truss configurations, joint coordinates and applied loading of typical dual-pitched symmetrical residential roof truss. The residential roof truss was considered with incremental uniform distributed loading, in both gravitational and uplift directions. The structural analyses of trusses were executed in this GA using finite element toolbox. The ultimate strength and serviceability of trusses were checked through the design formulation implemented in GA, according to the Australian standard, AS/NZS 4600 Cold-formed Steel Structures.

An optimum double-Fink roof truss which possess highest S/W ratio using GA was determined, with optimum roof pitch of 15°. The optimised roof truss is suitable for industrial application with its higher S/W ratio and cost-effectiveness. The combined methodology of multi-level optimisation and simultaneous optimisation developed in this research could determine optimum roof truss with consistent S/W ratio, although with huge GA search space.

The sizing of roof truss member is not optimised in this paper. Only single type of cold-formed steel section is used throughout the whole optimisation. The design of truss connection is not considered in this paper. The corresponding connection costs are not included in the proposed optimisation.

The optimum roof truss presented in this paper is suitable for industrial application with higher S/W ratio and lower cost, in either gravitational or uplift loading configurations.

This research demonstrates the approaches in combining multi-level optimisation and simultaneous optimisation to handle large number of variables and hence executed an efficient design optimisation. The GA designed in this research determines the optimum residential roof truss with highest S/W ratio, instead of lightest truss weight in previous studies.