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1 s2.0 S0143974X1000026X Main
1 s2.0 S0143974X1000026X Main
article
info
Article history:
Received 21 October 2009
Accepted 21 January 2010
Keywords:
Steel storage racks
Drive-in racks
Drive-through racks
Bolted moment connection
Cyclic tests
Cold-formed steel
Connection looseness
abstract
The stability of steel storage racks, which are often unbraced, may depend solely on the pallet beam
to upright connector and on the stiffness of the base plate to floor connection. This paper presents
experimental results from cyclic tests performed on portal beam to upright bolted moment connections
intended for cold-formed steel drive-in and drive-through storage racks. In storage racks, portal beams
are typically connected to uprights by tab connectors, which are costly to manufacture and experience
initial looseness. By simply bolting the portal beams to the uprights, bolted moment connections may
represent a cost-effective alternative to tab connectors. A literature review shows that bolted moment
connections between cold-formed steel members are economical and feasible. However, experimental
results show a significant amount of looseness in the connection after an initial high momentrotational
stiffness. Being slender structures, storage racks are sensitive to the second-order P effect, and
international racking specifications require the initial looseness of the tab connectors to be considered
when analysing the stability of the rack in the down-aisle direction (sway motion). The non-linear cyclic
behaviour of bolted moment connections is presented and explained herein. Based on finite element
results, it is shown that, for drive-in and drive-through racks, the looseness in bolted moment connections
can be ignored in ultimate limit states design. Finally, the paper concludes with proposing two methods,
with different degree of complexity, for the design of drive-in and drive-through racks with bolted portal
beam to upright bolted moment connections.
2010 Elsevier Ltd. All rights reserved.
1. Introduction
Rarely seen by the general public, steel storage racks are
extensively used in industry for storing goods on pallets. They
are freestanding structures mainly made from cold-formed steel
profiles and are able to carry heavy loads while being designed
to be as light as possible. Different racks are available on the
market and they are described in [1]. Selective racks are the most
common type of rack, in which each racking structure is separated
from another by aisles, allowing each pallet to be always accessible.
Fig. 1 shows a typical selective rack.
Drive-in and drive-through racks are less common types of rack,
where pallets are stored on beam rails one after the other. When
storing the same good or in a limited and expensive storage area
(e.g. industrial freezers), drive-in and drive-through racks are often
an attractive alternative to selective racks. In the two systems, the
forklift truck drives into the rack to place or remove pallets; it can
only access the rack on one side in drive-in racks but it can access
on both sides in drive-through racks (see Fig. 2). By allowing the
forklift truck to enter the rack, drive-in racks can only be braced at
the back (spine bracing) and at the top (plan bracing), while drivethrough racks can only be braced at the top.
The stability of steel storage racks is sensitive to the stiffness
of the base plate to floor connection, the pallet beam to upright
connector stiffness (for selective racks) [2] and the portal beam
to upright connector (for drive-in and drive-through racks). The
main international racking design specifications such as those of
the Rack Manufacturers Institute (RMI) [3], Australian Standard
AS 4084 [4] and European Standard EN 15512 [5] only deal with
selective racks and require testing for determining the stiffness
and strength of the pallet beam to upright connectors, and propose
alternative test set-ups referred to as cantilever tests and portal
frame tests. EN 15512 [5] has recently been published and it
supersedes the FEM (Fdration Europenne de la Manutention)
Specification [6]. While the FEM [6] Specification proposed either
the cantilever test or the portal frame test, only the cantilever test
has been retained in EN 15512 [5]. The cantilever test can also be
used to determine the initial connector looseness.
A literature review of the behaviour of pallet beam to upright
connectors shows that the portal frame test is an accurate way to
determine the stiffness of the pallet beam/portal beam to upright
connector when analysing the stability of the rack in the downaisle direction (sway motion). This paper reviews the method for
determining the pallet beam/portal beam to upright connection
characteristic from the main racking design specifications.
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B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
Fig. 1. Typical selective storage rack with base plate and pallet to column connector
shown.
B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
757
determined under the sway motion of the frame, results from the
portal frame tests are generally used for sway analysis while results
from the cantilever tests are usually used for the design of beams
and connectors [11].
Harris [10] compared the two experimental set-ups and found
that the connector stiffness values obtained from the cantilever
test are typically half the connector stiffness values obtained
from the portal frame test. Harris explained the difference by the
closingopening effect of the connector in the portal frame test.
Indeed, when the portal beam is loaded with its service pallet
load, the left and right connectors are closing up, as shown in
Fig. 6(a), and when the portal frame is subsequently subjected to a
horizontal load the left connector in Fig. 6(b) keeps closing up while
the right connector starts opening. Typically, cyclic cantilever tests
show that, when reversing the load, the stiffness does not follow a
linear path and the unloading stiffness is significantly higher than
the loading stiffness [12,13], resulting in two different stiffness
values for the right and left connectors when performing a portal
frame test and explaining the difference between the stiffness
values obtained from the cantilever and portal frame tests.
2.2. Bolted moment connections between cold-formed steel members
Investigations to determine the momentrotational behaviour
of bolted moment connections between cold-formed steel members have been reported using gusset plates between members [1417], and with members bolted directly together [18,19].
These investigations were motivated by the growing trend of using
cold-formed steel members in buildings in the 1990s and the lack
of design rules for this type of connection [14].
Studies in [1416] showed that bolted moment connections
between cold-formed steel members are feasible and economical
with an ultimate capacity of the connection up to 85% of the
capacity of the connected members. The stiffness of bolted
moment connections can also be used to reduce the effective
length in member design [18].
A typical experimental momentrotation curve of a bolted
moment connection is given in [20] and is reproduced in Fig. 7.
High initial connection stiffness followed by a slippage of the
Fig. 6. Portal frame test deformation: (a) application of pallet load and (b) application of lateral load.
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B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
Table 1
Section properties.
Member
Name
Gross area
(mm2 )
Thick
(mm)
Yield stress
(MPa)
Ultimate
strength (MPa)
Imajoraxis
(mm4 )
Iminoraxis
(mm4 )
(mm4 )
Warping
(mm6 )
Upright
Portal beam
RF12519
SB15019
727.9
559.1
1.9
1.9
459a
450b
513a
1.328 106
1.746 106
6.852 105
1.683 105
780.6
672.8
2.510 109
1.011 109
a
b
(2)
In Eq. (2), t is the ply thickness, d is the bolt diameter and Fu is the
ultimate tensile strength.
A procedure for calculating the seismic design moments and
forces in cold-formed members is also developed in [24], taking
into account bolt slippage and yielding of the bolt holes due to
bolts in bearing. While considering bolt slippage in the design, the
previous study is intended for seismic design, not for the ultimate
or serviceability limit state.
3. Experimental analysis
3.1. Choice of test set-up
Fig. 8. Pallet beam to upright bolted moment connection tested.
(1)
B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
759
Fig. 9. Portal frame experimental test set-up: (a) schematic of the set-up and (b) photo of actual set-up.
Fig. 10. Portal frame deformation broken into two parts: (a) portal sway and (b) connection stiffness.
Hh3
3EIc
Hh2 L
6EIb
Hh2
kRMI ,As
(3)
1
2
Hh2
h
3EIc
L
6EIb
(4)
When no vertical load is applied to the portal beam, the FEM [6]
gives the moment MFEM in the connector when a lateral force F is
applied to a test set-up with two portal frames as
MFEM =
Fh
4
1
d
L
(5)
where h is the vertical distance from the bottom hinge to the top
of the portal beam, d is the width of the face of the upright and
L is the distance between the centrelines of uprights. The FEM [6]
expresses the rotation FEM of the beam end connector as
FEM =
F
h2
12EIc
hL
24EIb
(6)
760
B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
Table 2
Values used in Eq. (9).
h (mm)
h1 (mm)
L (mm)
kc (kN mm)
kb (kN mm)
690
625
1475
2.899 108
4.639 105
3.608 108
2.471 105
and
kb =
EIb
L
(11)
(8)
k=
2
Fh2
(3h2h1 )(hh1 )
12kc
i
+ C
1
6kc
(3hh1 )
h
(9)
1
6kb
where h1 is the vertical distance from the top of the hinge to the
centre of the portal beam and C is the lateral displacement at the
portal beam centreline. kc and kb are the upright stiffness and the
portal beam stiffness, respectively, given as
kc =
EIc
h1
(10)
B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
761
3.4.2. Observations
It is observed from Figs. 1214 that the momentrotation
curves are not symmetrical about the origin, which is a result of
small initial out-of-plumb of the frame.
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B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
Table 3
Connection stiffness.
Phase 1
Phase 2
Phase 3
k1 (kN mm/rad)
k2 (kN mm/rad)
M2 (kN mm)
k3 (kN mm/rad)
M3 (kN mm)
96 326
3289
286
59 345
2091
H (end phase 2) =
2 mm
100 mm
= 0.02 rad.
(12)
Fig. 17. Phase 3 behaviour for first and second loading cycles: (a) portal frame no. 3 result and (b) grooves cut in upright.
B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
763
Fig. 18. Test performed on portal frame no. 3 (a) experimental result (b) local yielding of upright bolt hole.
(13)
Fig. 20. Design storage racks with stiffness k3 and with connection looseness
considered in the out-of-plumb.
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B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
Table 4
Section properties for the finite element rack.
Member
Imajoraxis (mm4 )
Iminoraxis (mm4 )
J (mm4 )
Warping (mm6 )
Upright
Portal beam
Rail beam
Frame bracing
441.5
559.1
640.8
283.7
6.603 105
1.746 106
1.450 106
2.662 105
2.778 105
1.683 105
6.067 105
9.928 104
331.1
672.8
771.1
212.8
1.264 109
1.011 109
4.638 108
1.337 108
Fig. 21. Design storage racks with multi-linear momentrotation curve including
the connection looseness: no additional out-of-plumb.
3000
2500
2500
2000
1500
1000
(14)
3500
3000
Pallet load (kg)
3500
1
0 1 +
+ 1
2000
1500
1000
500
500
0
0
50
100
150
200
250
300
1000
2000
3000
4000
5000
6000
Fig. 22. Drive-in rack FE results for different portal beam to upright stiffness models: (a) top front displacement and (b) moment in the critical upright at floor elevation.
B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
2500
2500
2000
2000
765
1500
1000
500
1500
1000
500
0
0
50
100
150
200
250
300
350
400
450
500
1000
2000
3000
4000
5000
6000
7000
8000
Fig. 23. Drive-through rack FE results for different portal beam to upright stiffness models: (a) top front displacement and (b) moment in the critical upright at floor
elevation.
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B.P. Gilbert, K.J.R. Rasmussen / Journal of Constructional Steel Research 66 (2010) 755766
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