Cold Bending PDF

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Presented by Dr. Cris Moen, Assistant Professor

Charles E. Via, Jr. Department of
Civil and Environmental Engineering
Virginia Tech
www.moen.cee.vt.edu
TRB AFH70 Committee Meeting

Fabrication and Inspection of Metal Structures
January 24, 2011
OUTLINE
•  Introduction
─  personal background, interest in cold bending fabrication
•  Examples-cold bending (curving) steel for bridge applications
─  girders
─  orthotropic decks
─  folded plate systems
•  Cold bending (curving) techniques and mechanics
─  girders, beams, plates
─  advantages, challenges, solutions
•  Research needs
─  connect the dots between the art of cold bending, material
science and mechanics
─  address the presence of cold bending residual stresses
─  quantify fatigue resistance
─  develop tools and methods that help fabricators, engineers
PERSONAL INTRODUCTION
Professional experience
J. Muller International, 1997-2002
Parsons Transportation Group, 2002-2005
Academic preparation
BSCE, University of Virginia, 1995
MSCE, University of Virginia, 1997
PhD, Johns Hopkins University, 2008
Nonlinear FE modeling to collapse,

i.e. simulated tests
Include plastic strains

and residual stresses
from cold bending in FE
analysis
COLD BENDING STEEL
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Cold bending changes steel material properties
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Chajes, A., Britvec, S.J., and Winter, G. (1963). "Effects of cold-straining on structural steel
sheets." Journal of the Structural Division, ASCE, 89(ST2), 1-32.
Cold bending produces residual stresses.
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Quach, W.M., Teng, J.G., and Chung, K.F. (2006 ). "Finite element predictions of residual
stresses in press-braked thin-walled steel sections." Engineering Structures, 28, 1609-1619.
Key, P., and Hancock, G.J. (1993). "A Theoretical Investigation of the Column Behaviour
of Cold-Formed Square Hollow Sections." Thin-Walled Structures, 16, 31-64.
We have simplified methods for approximating cold
bending residual stress and plastic strain distributions.
Moen, C.D., Igusa, T., and Schafer, B.W. (2008).

"Prediction of Residual Stresses and Strains in Cold-
Formed Steel Members." Thin-Walled Structures, 46(11),
1274-1289.
!
OUTLINE
•  Introduction
─  girders
COLD BENDING AND BRIDGES
Bill McEleney, NSBA

Horizontal curves!
Bill McEleney, NSBA

Horizontal curves!
Gergess, N.A., and Sen, R. (2008). !Cold Curving Steel Bridge Girders.! Transportation
Research Board: Journal of the Transportation Research Board, 2081, 165䇲175.
Bend in segments to avoid web stiffeners

Orthotropic bridge decks!
McQuaid, D.L., and Medlock, R.D. (2005). "Constructability Issues in Orthotropic Steel Bridge Deck Bridges."
2005 World Steel Bridge Symposium, American Institute of Steel Construction, Orlando, FL.
Press braking steel plate!

Atorod Azizinamini, Ph.D., P.E.
Highway Bridge Services, L.L.C
402-770-6210
Folded plate bridge systems!

Folded plate bridge systems!

Cold-formed light poles!

OUTLINE
•  Introduction
─  girders
BENDING METHODS (BEAMS, GIRDERS)
Easy way,
Hard way,
camber
Repair and
straightening
Alwood, T.A. (2006). “What Engineers Should Know About Bending Steel”. Modern Steel
Construction, American Institute of Steel Construction, May 2006.
ROLLING (COLD BENDING)
Kottler Metal Products
Winters䇲Downey, E. (2006). “A Conversation with a Bender!. Modern Steel Construction, July 2008, American
Institute of Steel Construction, Chicago, IL.
ROLLING (COLD BENDING)
Compared U.S. and European

minimum bending radii limits
for HSS sections
Kennedy, J.B., Seddeik, M., and Brady, F. (1986). "Deformations in cold-bent HSS members."
Engineering Journal, AISC, Third Quarter, 117-123.
Brady, F.J. (1978). "Determination of minimum radii for cold bending of square and rectangular hollow
structural sections." Programme 11B Final Report, Comité International pour le Développment et l'Etude de
la Construction Tubulaire (CIDECT), Hamilton, Ontario.
INCREMENTAL BENDING
Bendco
Gag pressing is typically used for camber operations.

BENDING METHODS (PLATES)
Roll-forming Press braking

COLD BENDING ADVANTAGES
and cold bending!
%Thatcher, W.M. (1967). "Horizontally Curved Steel Girders - Fabrication and Design." AISC National
Engineering Conference, American Institute of Steel Construction, San Francisco, CA.
Cut everything straight, then bend to final shape.

COLD BENDING ADVANTAGES
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Shanley, F.R. (1957). Strength of

8 9 Materials, McGraw-Hill Book Company,
New York, NY.
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Increased yield stress, capacity? Engineers need to be careful about
this one!. Cold bending residual stresses can counteract increased
yield stress.
OUTLINE
•  Introduction
─  girders
COLD BENDING CHALLENGES
Flexural stiffness is reduced by the presence of

cold bending residual stresses.
Beam cambered for unpropped construction
Lange, J., and Grages, H. (2009). "Influence of the Bauschinger Effect on the Deflection Behaviour of Cambered Steel
and Steel Concrete Composite Beams." Structural Engineering International, International Association of Bridge and
Structural Engineers, Zurich, Switzerland.
COLD-BENDING CHALLENGES
Residual stresses can be much different for
straight and roller bent wide flange steel beams
straight roller bent
Spoorenberg, R.C., Snijder, H.H., and Hoenderkamp, J.C.D. (2010). "Experimental investigation of
residual stresses in roller bent wide flange steel sections." Journal of Constructional Steel Research,
66(6), 737-747.
Cross-section deformation, fracture
Bjorhovde, R. (2006). "Cold Bending of Wide-Flange Shapes for Construction."

Engineering Journal, AISC, 4th Quarter, 271-286.
Cross-section deformation, fracture
Brady, F.J. (1978). "Determination of minimum radii for cold bending of square and rectangular hollow
structural sections." Programme 11B Final Report, Comité International pour le Développment et l'Etude de
la Construction Tubulaire (CIDECT), Hamilton, Ontario.
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Ross, C. (2002). “The Art of Bending”. Modern Steel Construction, American Institute of Steel Construction,
October 2002.
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Ricker, D.T. (1989). !Cambering Steel Beams.!
Engineering Journal, AISC, 4th Quarter, 136䇲142.
Cold-bending can cause material fracture leading to

scrap.
AISC (2002). “Meet the experts-bending steel”.

Modern Steel Construction, American Institute of
Steel Construction, June 2002.
Winters䇲Downey, E. (2006). “A Conversation with
a Bender!. Modern Steel Construction, July 2008,
American Institute of Steel Construction, Chicago,
IL. Fatigue resistance?
Fracture toughness?
Geometric limits on bending?
ENGINEERING SOLUTIONS
Mechanics-based cold bending prediction methods
Gergess, N.A., and Sen, R. (2006). !Refined analysis for cold bending steel plate girders.! Journal of
Constructional Steel Research, 61, 1353䇲1372.
Gergess, N.A., and Sen, R. (2007). !Full䇲Scale Cold Bending Demonstration Test.! Journal of
Constructional Steel Research, 63(10), 1295䇲1304.
Gergess, N.A., and Sen, R. (2008a). !Cambering structural steel I䇲griders using cold bending.!
Journal of Constructional Steel Research, 64, 407䇲417.
Gergess, N.A., and Sen, R. (2008b). !Cold Curving Steel Bridge Girders.! Transportation Research
Board: Journal of the Transportation Research Board, 2081, 165䇲175.
Bjorhovde, R. (2006). "Cold Bending of Wide-Flange Shapes for Construction." Engineering Journal,
AISC, 4th Quarter, 271-286.
Moen, C.D., Igusa, T., and Schafer, B.W. (2008). "Prediction of Residual Stresses and Strains in Cold-
Formed Steel Members." Thin-Walled Structures, 46(11), 1274-1289.
Cold bending simulations and experiments

Brockenbrough, R.L. (2006). !Development of Fabrication Guidelines for Cold Bending of Steel Plates.!
Engineering Journal, AISC, First Quarter, 49䇲56.
Quach, W.M., Teng, J.G., and Chung, K.F. (2006 ). "Finite element predictions of residual stresses in
press-braked thin-walled steel sections." Engineering Structures, 28, 1609-1619.
Spoorenberg, R.C., Snijder, H.H., and Hoenderkamp, J.C.D. (2010). "Experimental investigation of
residual stresses in roller bent wide flange steel sections." Journal of Constructional Steel Research,
66(6), 737-747.
ENGINEERING SOLUTIONS
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Mechanics-based rules and approximations

RESEARCH NEEDS
science and structural mechanics
─  use simply applied math/physics/mechanics to increase
fabrication speed, accuracy, efficiency
─  address the influence of cold bending residual stresses on
structural behavior – deflections, strength,"
─  quantify fatigue resistance of cold-bent members
Thank you for your attention!
This presentation can be downloaded at
www.moen.cee.vt.edu
OUTLINE
AISC Engineering FAQ, 2006
OUTLINE
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OUTLINE
Winters䇲Downey, E. (2006). “Curved steel – a reference for architects and engineers”.

American Institute of Steel Construction.

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!"#$%&'($)(*%+,&-)!,.)"(%/%0.,.'1"+1.2'1,-.

Presented by Dr. Cris Moen, Assistant Professor

TRB AFH70 Committee Meeting

Nonlinear FE modeling to collapse,

Include plastic strains

Cold bending changes steel material properties

9; 9; 9;

9: 9: 9:

1678 1678 1678

4"#$%&'-0+1*+, !"#$%&'$()*+,'-#&. /0$*12#"'$3)0$$0$

Moen, C.D., Igusa, T., and Schafer, B.W. (2008).

Bill McEleney, NSBA

Bill McEleney, NSBA

Bend in segments to avoid web stiffeners

Orthotropic bridge decks!

Press braking steel plate!

Folded plate bridge systems!

Folded plate bridge systems!

Cold-formed light poles!

Kottler Metal Products

Compared U.S. and European

Gag pressing is typically used for camber operations.

Roll-forming Press braking

Cut everything straight, then bend to final shape.

Shanley, F.R. (1957). Strength of

!"#$%"&&'()&"*$%+('%,&-. /&"*$%+(01&2"-%13( :,*%-0"&(*$#,**,*(;#2<

Flexural stiffness is reduced by the presence of

Beam cambered for unpropped construction

straight roller bent

Cross-section deformation, fracture

Bjorhovde, R. (2006). "Cold Bending of Wide-Flange Shapes for Construction."

Cross-section deformation, fracture

Cold-bending can cause material fracture leading to

AISC (2002). “Meet the experts-bending steel”.

Cold bending simulations and experiments

M 1 ! plastic (y) .& *+)/ /0$*12#"'("#$%&'$3)#*+

Mechanics-based rules and approximations

This presentation can be downloaded at

Winters䇲Downey, E. (2006). “Curved steel – a reference for architects and engineers”.

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M 1 ! plastic (y) .& +)/ /0$12#"'("#$%&'$3)#*+