Now days, rolling technology plays a great role in industrial and economical development in most countries and it is because in compare with other metal forming processes, rolling is used to manufacture more products. Regarding the construction application of channel, angle and I-Beam sections, shape rolling have a special position among other rolling processes. One of the main aspects of this process is designation of hot shape rolling steps named rolling calibration. Shape rolling calibration is usually done based on trial and error in industry, as a result, the most expenses of installation of a rolling production line is assigned to this part.This paper presents a three dimensional analysis for hot rolling of channel section beams by the finite element method using ABAQUS/Explicit. A complete production line containing 13 passes for forming the section including break-down, intermediate and finishing sequences are modeled, and the exit section of each pass is imported as the entering material for the next pass. The geometry and dimensions of the exit cross section of each stand, separation force, roll torque and the power consumptions in each pass are calculated. The output geometry and work power predicted by the numerical solution were verified by the practical information of Zobahan-Esfahan Company. In the next step, a group of 3-D finite element simulations using ABAQUS/Explicit are performed to study the parameters affecting the spread of working material in shape rolling processes. The results are verified by other analytical researches and available experimental findings. Then, a sample caliber design process to achieve a certain cross section is made. The minimum possible number of passes according to the parameters affecting the spread is the main strategy for a new pass design. Then the production line for this new caliber is simulated using ABAQUS/Explicit, and the geometry and dimensions of the exit cross section, the separation force, roll torques and the power consumption in each stage are calculated. A comparison for the new design and a practical caliber used in industry for the same cross section is made. At the end a new caliber design is presented to reduce the forming steps in channel section rolling according to standards from 13 passes to 11 passes and then with the use of finite element simulations different rolling parameters; such as, roll separation forces, roll torques, power consumption, stress and strain contours, and geometry of work piece cross section in each stage are calculated. The new caliber design is compared with industrial design to show the advantages and disadvantages of new design. Key words Roll pass caliber design, Shape rolling, Finite element method, Spread