Square and rectangular hollow sections are generally produced either by hot-rolling or cold-forming. Cross-sections of nominally similar geometries, but from the two different production routes may vary significantly in terms of their general material properties, geometric imperfections, residual stresses, corner geometry and material response and general structural behaviour and load-carrying capacity. In this paper, an experimental programme comprising tensile coupon tests on flat and corner material, measurements of geometric imperfections and residual stresses, stub column tests and simple and continuous beam tests is described. The results of the tests have been combined with other available test data on square and rectangular hollow sections and analysed. Enhancements in yield and ultimate strengths, beyond those quoted in the respective mill certificates, were observed in the corner regions of the cold-formed sections—these are caused by cold-working of the material during production, and predictive models have been proposed. Initial geometric imperfections were generally low in both the hot-rolled and cold-formed sections, with larger imperfections emerging towards the ends of the cold-formed members—these were attributed largely to the release of through thickness residual stresses, which were themselves quantified. The results of the stub column and simple bending tests were used to assess the current slenderness limits given in Eurocode 3, including the possible dependency on production route, whilst the results of the continuous beam tests were evaluated with reference to the assumptions typically made in plastic analysis and design. Current slenderness limits, assessed on the basis of bending tests, appear appropriate, though the Class 3 slenderness limit, assessed on the basis of compression tests, seems optimistic. Of the features investigated, strain hardening characteristics of the material were identified as being primarily responsible for the differences in structural behaviour between hot-rolled and cold-formed sections.