MSC January 2013

MSC
MODERN STEEL CONSTRUCTION

January 2013
IN THIS ISSUE
AESS
Steel Castings
Welding
'RQ·WJHWSX]]OHGDERXW\RXUEROWLQJ
UHTXLUHPHQWVZH·YHJRWWKHDQVZHUV
A325 & A490 HEAVY HEX
STRUCTURAL BOLTS
F1852 & F2280
SL
TENSION CONTROL BOLTS
ANCHOR BOLTS, ASSEMBLIES, AND MANY

OTHER STRUCTURAL FASTENERS
Phone: 800-237-7059
Fax: 314-389-7510
1887 Email:
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Web:
www.stlouisscrewbolt.com
Structural Bolting Crossword Puzzle

2 4
1 5
1
2
3
3
4
5
ACROSS DOWN
1. A quantity of uniquely identified bolts of the same size and length 1. A non-profit, volunteer organization, comprised of over
produced consecutively from a single mill heat processed at one time 70 leading experts in the fields of structural steel
2. An assembly of one or more joints that is used to transmit forces connection design, engineering, fabrication, erection and
between two or more members bolting
3. To cause to move around in order to achieve a result 2. A bolted assembly with or without collateral materials
4. The total thickness of the plies of a joint through which the bolt that is used to join two structural elements
passes, exclusive of washers or direct-tension indicators 3. A unit of measure primarily used to measure loads
5. The continuous protection of fastener components in closed 4. As defined by the RCSC this party is responsible to
containers in a protected shelter is protected __________ provide, prepare and assemble the fastener components
and connected parts
5. The act or process of stretching something tight
Down 1. RCSC 2. joint 3. kips 4. contractor 5. tension

Across 1. lot 2. connection 3. turn 4. grip 5. storage
January 2013
features columns
steelwise
28 Theater on the Roof
BY CAWSIE JIJINA, P.E., AND ALVARO 17 Economical Weld Design
BY ERIK NELSON, S.E., P.E.,
CASTAÑO, P.E.
AND ETHAN TIRRELL
There was nowhere to go but up for New
Using fillet welds instead of CJP
York’s Lincoln Center, which added a new
groove welds.
performance space on top of its original
theater building. product expert series
34 Making Up for Lost Time 22 Cast Away!
BY JASON SQUITIERE, P.E., AND BY CARLOS DE OLIVEIRA, P.ENG., AND
JANIS VACCA, P.E. MICHAEL GRAY, PH.D.
34 An adaptive reuse project in Philadelphia
adjusts to the current economy with
Common questions on steel castings for
structural applications.
prefabricated sensibility.
economics
40 A Bridge in Building’s Clothing
24 The World of My Backyard
BY TIMOTHY COSTELLO, P.E., AND MARK BY JOHN CROSS, P.E.
RAULLI, P.E. A region-by-region look at construction
A community college conceives a creative activity across the U.S.
crossing to connect its campus.
people to know
46 Ticket to Ride
66 Going Global
BY STEVEN C. STEFFENS
For Christian Colombo, coming home to
The newest Chicago “L” station sports its own
work for the family business offered bigger
look thanks to hundreds of curved hollow
opportunities than he expected.
structural sections.
50 Outside In
BY JAMES E. THEIMER, AIA, LEED AP
BD+C
The great outdoors come into the classroom—
and sometimes the classroom goes outside—
at the Redding School for the Arts.
in every issue
56 Widening the Gap departments
BY LANCE BORDEN 6 EDITOR’S NOTE
A bridge replacement and expansion project
eases water and road traffic and accommodates
9 STEEL INTERCHANGE
future growth in the Hampton Roads region 12 STEEL QUIZ
of Virginia.
60 NEWS & EVENTS
resources
64 MARKETPLACE
65 EMPLOYMENT
46
ON THE COVER: The Lincoln Center Theater, p. 28. (photo: © Francis Dzikowski/Esto)
MODERN STEEL CONSTRUCTION (Volume 53, Number 1. ISSN (print) 0026-8445: ISSN (online) 1945-0737. Published monthly by the American Institute of Steel
Construction (AISC), One E. Wacker Dr., Suite 700, Chicago, IL 60601. Subscriptions: Within the U.S.—single issues $6.00; 1 year, $44. Outside the U.S. (Canada
and Mexico)—single issues $9.00; 1 year $88. Periodicals postage paid at Chicago, IL and at additional mailing offices. Postmaster: Please send address changes to
MODERN STEEL CONSTRUCTION, One East Wacker Dr., Suite 700, Chicago, IL 60601.
AISC does not approve, disapprove, or guarantee the validity or accuracy of any data, claim, or opinion appearing under a byline or obtained or quoted from
an acknowledged source. Opinions are those of the writers and AISC is not responsible for any statement made or opinions expressed in MODERN STEEL
CONSTRUCTION. All rights reserved. Materials may not be reproduced without written permission, except for noncommercial educational purposes where fewer than
25 photocopies are being reproduced. The AISC and MSC logos are registered trademarks of AISC.
4 MODERN STEEL CONSTRUCTION JANUARY 2013

editor’s note
Editorial Offices
1 E. Wacker Dr., Suite 700
Chicago, IL 60601
312.670.2400 tel
312.896.9022 fax
Editorial Contacts
EDITOR & PUBLISHER
Scott L. Melnick
312.670.8314
melnick@modernsteel.com
SENIOR EDITOR
Geoff Weisenberger
AT MY SON’S HOCKEY GAME LAST WEEKEND, we happened to be sitting near 312.670.8316
one of his coaches from last year. After a particularly impressive shift, he turned to us and weisenberger@modernsteel.com
exclaimed: “Wow! Jason’s really improved since last year.” ASSISTANT EDITOR
Tasha Weiss
312.670.5439
As a parent, that’s what we really want to ➤ Working with Difficult People weiss@modernsteel.com
hear. We don’t have grand illusions of a future ➤ Welding Questions Answered: Duane DIRECTOR OF PUBLISHING
pro career. But we appreciate how much effort Miller Responds to Solution Center Areti Carter
312.670.5427
he puts in and the resultant improvement. Inquiries areti@modernsteel.com
It’s that same continuous improvement ➤ Laser Scanning and Steel Construction GRAPHIC DESIGNER
that we strive for with NASCC: The Steel ➤ Future Fabrication for Bridges—And Kristin Egan
312.670.8313
Conference. Unfortunately, while the 2012 All Structures! egan@modernsteel.com
conference was a good event, it was rare to There’s also the always-fascinating T.R. AISC Officers
hear anyone say, “Wow! That was the best Higgins Lecture, this year featuring SOM’s CHAIRMAN
conference yet!” I think this year’s conference Bill Baker, who’ll be discussing structural William B. Bourne, III
will be different. innovation. VICE CHAIRMAN

Jeffrey E. Dave, P.E.
Scheduled for April 17–19 in St. Louis, Even the pre-conference events are TREASURER
everything from the technical program to exciting. In addition to three short courses, Richard Phillips
the networking events will be a step above we’re offering two fabulous free tours: SECRETARY & GENERAL
what we’ve done in the past. The engineering Attendees have their choice of visiting a steel COUNSEL
David B. Ratterman
program continues its tradition of excellence fabricator (Hammert’s Iron Works/Stupp PRESIDENT
while the fabrication sessions have been Bros.) and a bolt manufacturer (St. Louis Roger E. Ferch, P.E.
substantially upgraded. Screw & Bolt) or visiting a galvanizer (AZZ VICE PRESIDENT AND CHIEF
In addition, there’s a separate conference Galvanizing). STRUCTURAL ENGINEER
Charles J. Carter, S.E., P.E., Ph.D.
focusing on technology in steel construction And finally, I’d be remiss if I didn’t VICE PRESIDENT
plus a new track focusing on bridges. And, mention the growing exhibit hall, which Jacques Cattan
as always, SSRC offers its Annual Stability will feature more than 200 companies VICE PRESIDENT
Conference. There are more than 100 sessions showcasing products ranging from the latest John P. Cross, P.E.
VICE PRESIDENT
to choose from, so it’s almost impossible for structural design software to the most modern Scott L. Melnick
me to list a favorite—but there are definitely equipment for steel fabrication.
Advertising Contact
some that I find particularly intriguing: You can view the entire program and Account Manager
➤ Lessons I Wish I had known Starting register for the show at www.aisc.org/nascc. Louis Gurthet
231.228.2274 tel
Out! Two fabricators, two engineers I look forward to seeing you in St. Louis 231.228.7759 fax
and an erector share the lessons they’ve and hearing from you that 2013 was “the best gurthet@modernsteel.com
learned from their long career. Steel Conference yet!” For advertising information, con-
tact Louis Gurthet or visit
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Economical Steel Buildings Address Changes and
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HeavyMetalGuy asks:
What should I consider when
using HSS for seismic bracing?
You should check out this video — helped me

a lot: HSS Flexes Its Muscles
JohnT asks:
:HQHHGWRÓOHSS with concrete.
What do I need to know?
Good question. View this forum thread:

+RZWRÓO+66"
Beth546 asks:
I need to get up to speed on
curved HSS. Any information
out there?
Atlas has a good thread about it. Go here:

Straight talk on curved HSS
Get answers
with
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When every connection counts, connect with Atlas Tube.

Join today — atlasconnection.com
If you’ve ever asked yourself “Why?” about something related to
structural steel design or construction, Modern Steel Construction’s
monthly Steel Interchange column is for you! Send your
steel
questions or comments to solutions@aisc.org. interchange
Tolerances on Punched Holes This second approach uses the concept of virtual work, with
Regarding the tolerance for punched holes, RCSC a unit virtual load in the same position as F. In the real force
Specification Table 3.1 footnote b simply states that holes system the force in each brace is:
are acceptable if properly matched dies are used. Is there F
Pr =
a numerical tolerance on punched holes? 2cos θ
In the virtual force system the force in each brace is:
There is not a numerical tolerance for punched holes. The 1
pv =
flare size will vary based upon the thickness that is punched 2cos θ
because a properly matched die is dependent on that thickness For two braces (which adds the factor of 2 in the numerator),
to control the punch energy required to make the hole. The the deflection is:
provision is based upon proper matching for that reason, and 2Pr pvL
the matched die size defines the size that is permitted. Δx =
AE
Heath Mitchell, S.E., P.E.
F 1 L
=2
Braced Frame Stiffness 2cos θ 2cos θ AE
I’ve seen various sources showing that the lateral stiffness F L
of a braced frame is a function of cos2θ, where θ is the =
2cos2 θ AE
slope of the brace, but I have not been able to find the
derivation of this formula. How is the lateral stiffness of The stiffness is:
an X-braced bay derived? F
Kx =
Δx
It’s been said that if you give two engineers the same problem AE
to solve, you will end up with at least two different answers. In =2 cos2 θ
L
this case, giving the problem to two engineers in AISC’s Steel Brad Davis, S.E., Ph.D.
Solutions Center ended up with same answer, but two different
paths were taken to get there. In both derivations that follow, Alternative Materials
the θ, A, E and L are assumed constant for both braces, and the Section A3 of the AISC Specification lists the materials
braces are assumed to be the only source of deformation. The approved for use. Why are materials limited to those
first derivation is based on the deformed geometry. listed in this section? Can other materials be used?
Deflected Shape
You may find the Commentary to Section A3 of the AISC
F→
Specification to be useful; it is printed in the 14th Edition
AISC Steel Construction Manual and can be found starting on
Δx P page 16.1-247 (note also that the 2010 Specification is a free
θ
download at: www.aisc.org/2010spec).
θ θ F
L δ 2 The AISC Specification references only those materials that
are most commonly useful to structural engineers working
with buildings and building-like frames. These are the most
commonly produced structural materials, and they are known
to have a history of satisfactory performance.
δ δ The AISC Specification does not prohibit other
cos θ = → Δx =
Δx cos θ materials from being used when they are considered and
qualified by the engineer of record and acceptable to the
F/2
cos θ = → F = 2P cos θ building official. However, they are not listed because
P they were not contemplated by the AISC Committee
on Specifications during development of the AISC
F 2P
Kx = = cos θ Specification. When considering alternative materials,
Δx δ engineers and building officials may find the article that
appeared in the August 2011 “Material Substitutions”
PL AE SteelWise helpful since it outlines some of the more
δ= → Kx = 2 cos2 θ
AE L common considerations.
Martin Anderson
Heath Mitchell, S.E., P.E.
JANUARY 2013 MODERN STEEL CONSTRUCTION 9

steel interchange
Definition of K-Area Blast Cleaning and Slip-Critical Connections
Is the k-area the same as the k-dimension published for In terms of SSPC designation, what level of blast cleaning is
W-shapes in Table 1-1 of the AISC Steel Construction required to meet the requirements for “Class A” or “Class
Manual? B” faying surfaces in the RCSC Specification? AISC Steel
Construction Manual Table 2-8 lists several levels of blast
No. The k-dimension and the k-area denote different parts cleaning ranging from “brush blasting” to “near white.”
of the cross-section. The “k-area” is located adjacent to the
“k-dimension.” There are two separate considerations related to your
A discussion of this topic can be found in the Commentary question: uncoated surfaces and coated surfaces. Let’s start
to AISC Specification Section J10.8, including sketches (figures with coated surfaces as they are the easier of the two to
C-J10.6 and C-J10.7) that depict the difference between the address. The required level of blast cleaning for a qualified
k-dimension and the k-area. As shown in these figures, the coating (Class A or Class B) will depend on what was used
k-dimension represents the distance from the outside face in the coating manufacturer’s qualification testing. In other
of the flange to the intersection of the web-to-flange fillet words, the coating manufacturer should specify the required
with the beam web. The k-area is the region of the web that level of blast cleaning for their coating.
extends approximately 1½ in. beyond this intersection. Blast cleaning is not required for uncoated Class A surfaces,
Keith Landwehr so that is another easy one.
Finally, let’s look at uncoated Class B surfaces. Neither
Slots in HSS the AISC Specification nor the RCSC Specification make a
Is there guidance on how far beyond the edge of a gusset direct reference to a required SSPC surface preparation
a HSS can be slotted? for uncoated Class B surfaces. The intent is to remove
loose mill scale and any other foreign matter and produce a
I am not aware of any published guidance specific to slots in roughened faying surface. From Table 12.2 in the Guide to
HSS. However, one approach is to determine how far apart Design Criteria for Bolted and Riveted Joints (a free download
stitch welds would need to be to make two channels (each ½ at www.boltcouncil.org) that grit blasting to white metal
of the HSS) act as a built-up section. You will likely find that produced a slip coefficient of 0.73 +/- 0.05. This is much higher
the slot can be quite large without adversely affecting the than what’s reported in Table 5.1 of the Guide for grit blasted
compression strength of the section. surfaces (0.51 +-0.09) or sand blasted surfaces (0.52 +/- 0.09).
Larry S. Muir, P.E. So, SSPC SP10 (near white) would definitely get you the 0.5
slip coefficient, but you can satisfy the intent with a much lower
Effective Length of X-Bracing level. In fact, any of the SSPC blast cleaning preparations listed
When X-bracing is connected at the center, what should in AISC Manual Table 2-8 will be acceptable. As a bottom line,
be considered the unbraced length of the brace? Some SSPC-SP6 provides the minimum level of blast cleaning of
engineers suggest using the full end-to-end length in those listed in the table. This goes hand-in-glove with our FAQ
determining the effective length, while others suggest 10.3.4, which addresses blast cleaning in general.
using half the length. Heath Mitchell, S.E., P.E.
In R=3 designs and those that are not expected to undergo The complete collection of Steel Interchange questions and answers is available online.
large, cyclic inelastic deformations, the unbraced length Find questions and answers related to just about any topic by using our full-text search
capability. Visit Steel Interchange online at www.modernsteel.com.
is typically considered to be the distance from the corner
connection to the intersection of the “X,” or L/2 of the brace.
Heath Mitchell is director of technical assistance and Martin Anderson is Steel Solutions
Two AISC Engineering Journal articles—“Effective Length
Center Information Specialist at AISC. Brad Davis, Keith Landwehr and Larry Muir are
Factor for the Design of X-Bracing Systems” (Q1 1986) consultants to AISC.
and “Practical Application of Energy Methods to Structural
Stability Problems” (Q4 1997)—discuss this topic. Steel Interchange is a forum to exchange useful and practical professional ideas and
Note that this practice may not be advisable when information on all phases of steel building and bridge construction. Opinions and
suggestions are welcome on any subject covered in this magazine.
considering bracing in a seismic force resisting system that
The opinions expressed in Steel Interchange do not necessarily represent an official
is expected to undergo large, cyclic, inelastic deformations, position of the American Institute of Steel Construction and have not been reviewed. It is
such as those expected to occur in a special concentrically recognized that the design of structures is within the scope and expertise of a competent
braced frame (SCBF). In this case, using the full length of the licensed structural engineer, architect or other licensed professional for the application of
principles to a particular structure.
member is recommended.
If you have a question or problem that your fellow readers might help you solve, please
Heath Mitchell, S.E., P.E. forward it to us. At the same time, feel free to respond to any of the questions that you
have read here. Contact Steel Interchange via AISC’s Steel Solutions Center:
One East Wacker Dr., Suite 700

Chicago, IL 60601
UFM"4,"*4$tGBY
solutions@aisc.org

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steel The answers to this month’s Steel Quiz (there are only six questions this time) can be
found in the AISC Specification, Steel Manual and Design Guides as well as on the AISC
quiz and Modern Steel Construction websites at www.aisc.org and www.modernsteel.com.
1 When designing reinforcing at a web opening in a wide-flange shape using AISC Design Guide 2, what is the
appropriate weld length to use in the calculation of the weld capacity for the weld between the reinforcement and the
beam web within the length of the opening, ao, for each case illustrated below?
Case 3
ao a) ao
Case 1 b) 2x ao ao
a) ao Ar c) 3x ao
b) 2x ao d) 4x ao Case 4
c) 3x ao ao
ao a) ao
d) 4x ao ao
Case 2 ao b) 2x ao
a) ao Ar c) 3x ao
Ar
b) 2x ao d) 4x ao
c) 3x ao
d) 4x ao
Ar
2 In the figures from Question 1, what does “Ar” represent? 5 True/False: Bolts to be used in a snug-tightened joint are
not required to be tested in a tension calibrating device.
3 True/False: AISC Design Guide 2 assumes that the
reinforcement and the steel beam have the same yield 6 What is the maximum number of F436 washers permitted
strength. for use with A325 bolts in a snug-tightened joint?
a) 2 b) 3 c) 4 d) No Limit
4 True/False: The performance of single-plate connections
with short-slotted holes and standard holes is the same. TURN TO PAGE 14 FOR ANSWERS
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steel quiz ANSWERS
1 ao ao
ao ao ao ao
Case 1 Case 2 Case 3 Case 4
a) ao Ar b) 2x ao Ar b) 2x ao d) 4x ao
Ar Ar
2 Ar is the cross-sectional area of reinforcement above or that snug-tight joints are not included. Section 8.1, Snug
below the opening. Tightened Joints, contains no language for the use of a
tension calibrator. However, Section 8.2, Pretensioned
3 True. Reinforcement with a higher yield strength than and Slip-Critical Joints clearly states: “Pre-installation
that of the beam could be used, but the interaction testing shall be performed for each fastener assembly lot
of beams and stiffeners of differing yield strengths is prior to the use of that assembly lot in the work.”
beyond the scope of the design guide.
6 d) The RCSC Bolt Specification (a free download from
4 False. Much of the rotational demand on single-plate www.boltcouncil.org) does not limit the number of
shear connections results from the accommodation of washers that can be used. The use of multiple washers
simple beam end rotation. In testing, connections with is mentioned in the Commentary to Section 2.3, which
short-slotted holes typically have greater strengths than states: “If necessary, the next increment of bolt length
those using standard holes, presumably because the can be specified with ASTM F436 washers in sufficient
short slots reduce the rotational demand on the bolts. number to both exclude the threads from the shear
5 True. The Research Council on Structural Connections plane and ensure that the assembly can be installed
(RCSC) Specification Section 7.1 states: “A tension with adequate threads included in the grip for proper
calibrator shall be used when bolts are to be installed installation.” This applies equally to slip-critical and
in pretensioned joints and slip-critical joints…” Note bearing joints.
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3rd ORTHOTROPIC
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Hayward/San Mateo OCEA 1968
CONFERENCE http://www.asce.org/opal/past_ocea.cfm#1968
Registration Open - Sacramento, California 2013 Sponsors
Three-Day Conference with 3 optional Workshops and optional Tours

Northern California, USA, June 24, 25, 26, 27, 28, 29, & 30, 2013
The American Society of Civil Engineers, The US Department of Transportation
Federal Highway Administration, The Metropolitan Transportation Commission
and the sponsoring organizations invite you to attend and participate in the
third Orthotropic Bridge Conference. The objectives of this Conference are MTC Metropolitan
Transportation Commission
to present the latest developments in the design, construction, maintenance http://www.mtc.ca.gov
and repairs of orthotropic decks on bridges worldwide, and visit California

orthotropic bridges in operation. Many of the leading engineers and researchers
who contributed to the spectacular advances of orthotropic decks will present
their views at this conference. The conference hotel will be the Sheraton
Grand Sacramento Hotel. (Please go to www.orthotropic-bridge.org for the
hotel code and additional pricing information.)
Schedule:
Attendees may register for all events, or events may be selectively attended,
including a one-day registration for any day of the 3-day conference. See
www.orthotropic-bridge.org for more details and papers - subject to changes.
Co-Chairs: Ajay Sehgal, PE
Mon 24: One-day workshop “International Orthotropic Deck Bridges.” Alfred R. Mangus, PE
Separate registration - $300 for all attendees. 2I¿FH6WDII 9LYLDQ0HYRUDK
Tue 25: One-day workshop “USA FHWA Orthotropic Deck Bridges and Committee Chairs:
Technical co-chairs: Charles Seim, PE
Manual.” Separate registration required, but no admission fee.
Lian Duan, PhD, PE
Lunch will be provided. Secretary: Ray Zelinski, PE
Wed 26 - Finance: Richard Weitzenberg, PE
Past Chair: Natalie E. Calderone, PE
Fri 28: Orthotropic Bridge Conference.
Research Chair: Robert W. Luscombe, PE
Wed - Thur: 8:00 AM to 5:00 PM (LISTENERS: $575, Speakers or Government 6FLHQWL¿F&KDLU 0+HQN.ROVWHLQ3K'3(
Employees: $450.) 6FLHQWL¿F9LFH&KDLU 6X+DR3K'
Branch President: Mario Carreón, PE
Thur 27 Night (6:00 PM to 11:00 PM) bus tour of the San Francisco / Oakland Webmaster: Shawn Wei, PE
Bay Bridge East Spans (SAS = Self-Anchoring Suspension)
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Orthotropic Spans plus Zampa Suspension. Dr. Metwally Abu-Hamd 0U(ULF/HYHVTXH
http://www.mtc.ca.gov/projects/bay_bridge/ Dr. Nurdan M. Apaydin Mr. Feng Liangping
Dr. Atorod Azizinamini Dr. Gao Liu
Friday: 8:00 AM to Noon — Morning session concludes the conference.
Dr. Mourad M. Bakhoum 'U.KDOHG0DKPRXG
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steelwise
ECONOMICAL WELD
Using fillet welds instead DESIGN
of CJP groove welds. BY ERIK NELSON, S.E., P.E., AND ETHAN TIRRELL
IT IS TYPICALLY less expensive to use two-sided fillet welds The following equations assume the weld is a two-sided
instead of complete joint penetration (CJP) groove welds. fillet weld with a weld strength level FEXX = 70 ksi:
A fillet weld, like a CJP groove weld, can be sized to develop ➤ ASD Weld Strength per inch,
the full strength of the connection plate in shear and/or ten- V = 2 × 0.60 FEXX × 0.707 w / Ω = 29.7 w
sion. When the engineer of record indicates a CJP groove weld ➤ ASD Plate Shear Rupture Strength per inch,
(e.g., on a flange plate in a moment connection), it is possible V = 0.60 (Fu) t/ Ω = 0.60 (Fu) t /2 = 0.3 Fu t
for the fabricator to successfully substitute a fillet weld in the ➤ ASD Plate Shear Yielding Strength per inch,
shop with approval from the EOR. In fact, the current AWS V = 0.60 (Fy) t/ Ω = 0.60 (Fy) t /1.5 = 0.4 Fy t
D1.1 allows filled weld substitution (or PJP with fillet rein- LRFD calculations are similar and in the same relationship
forcement) automatically unless the EOR specifically requires a to each other.
CJP groove weld (for more about this, see Tom Schlafly’s article If the CJP groove welds are made with matching-strength
“The New Groove Weld System,” 01/12). filler metal, the strength of a connection is governed or con-
trolled by the base metal and no checks on the weld strength
Fillet Welds in Shear are required. Thus, setting the fillet weld strength equal to the
AISC Specification Table J2.5 provides the formula to calcu- controlling plate strength, we find the following weld leg size
late the nominal strength of a fillet weld as 0.60FEXX, where required:
FEXX is the weld metal strength. This is multiplied by the effec- Min (0.3 Fu t, 0.4 Fy t) = 29.7 w
tive area (Aw), which is the product of the effective length and Therefore, the required weld leg size is the lesser of 0.3 Fu t /29.7
the effective throat (0.707 times the leg dimension, w). The and 0.4 Fy t /29.7.
design strength for LRFD is then obtained by multiplying by For ASTM A36 plate, the size of the two-sided fillet weld
φ, and for ASD the allowable strength is then determined by must be 0.49 times the thickness of the plate to match the
dividing by Ω. strength of the plate. So, using this for T-joints loaded in shear
(for example, web to flange welds in plate girders), we find that
the fillet welds required to develop the web thickness can be
sized as half the web plate thickness.
OR
CJP
W
W
➤
Figure 1: Weld in Shear Figure 2: Plate Girders
Erik Anders Nelson is the owner of Structures Workshop, Inc., in

Providence, R.I., and teaches at the Rhode Island School of Design
and the Massachusetts Institute of Technology. You can reach him at
ean@structuresworkshop.com or you can visit and comment on his
engineering blog at www.structuresworkshop.com/blog. Ethan
Tirrell is a structural engineer with Structures Workshop, Inc. He can
be reached at ept@structuresworkshop.com.

steelwise
These conditions are rarely loaded to a level that would Therefore, the required weld leg size is the lesser of 0.5 Fu t /44.5
necessitate the use of a CJP groove weld, but even so these and 0.6 Fy t /44.5.
welds are often specified by EORs, perhaps because it is a For ASTM A36 plate, the size of the two-sided fillet weld
simple matter to call out a CJP groove weld. The economy of must be 0.49 times the thickness of the plate to match the
doing so is another matter, however, and the substitution of strength of the plate.
fillet welds often is more economical. In such cases, the fabrica-
tor can propose the substitution of fillet welds for CJP groove
welds (see Table 1) as a more economical option.
CJP - TYP TYP
W
Fillet Welds in Tension
The phrase “fillet welds in tension” is technically incorrect
but is used to compare the orientation of the weld to that of
a CJP groove weld in tension. Fillet welds only work in shear, OR
and it is better to describe this condition as “welds perpendicu-
lar to the load.”
➤
Figure 4: Moment Connections
A fillet weld substitution can often be made for CJP groove

welds in tension, such as for bolted moment connections where
flange plates are welded to the column (W-shape or HSS col-
umns). Due to the significant time and preparation required for
TYP CJP groove welds, a fillet weld alternative would be preferred
➤
W Figure 3: Weld in Tension

by most fabricators.
Why are two-sided fillet welds not used more in moment
connections? Sometimes it is a matter of fit-up (especially in
Fillet welds loaded perpendicular to their longitudinal axis the field). If the joint is open, the weld size adjustments for fil-
have 50% greater strength than when loaded parallel. Until let welds may erase the potential economy. When fit-up is not a
recently, this extra strength, based upon load angle, was often problem, it is likely that engineers use typical moment connec-
conservatively ignored (e.g., as in the AISC ASD Manual, 9th tion details that have not changed since AISC began to recognize
Edition examples). More recently, AISC examples and actual the 50% strength increase for fillet welds in this orientation. A
practice have tended to take advantage of this directional strict reading of AISC specifications before 2010 will show that
strength increase. the increase actually was applicable only to in-plane loading
The strength of a linear weld group loaded in-plane through cases. However, this limitation was rarely applied because fillet
the center of gravity is the following: welds usually have an orientation that can be said to align with a
➤ Fw = 0.60 FEXX (1.0 + 0.50 sin1.5θ) plane of the joint. To eliminate the confusion, and after confir-
➤ Fw = 0.60 FEXX (1.5) for welds perpendicular to loading mation by testing, the 2010 AISC Specification no longer has the
where, θ = angle of loading measured from the weld “in plane” requirement, and a two-sided fillet weld is officially a
longitudinal axis (degrees) viable option for plated moment connections. It must also be
Therefore, we can rewrite the equations for tension on the recognized that it is simply easier for an engineer to indicate a
plate and a 50% increase in the weld strength. The following CJP weld that will develop the strength of the plate without hav-
equations assume the weld is a two-sided fillet weld with a weld ing to perform any calculations—again, construction economy
strength level FEXX = 70 ksi: aside. The tables presented here may help in this regard.
➤ ASD Weld per inch, However, there are limitations to the use of fillet welds
T = 1.5 × 2 × 0.60 FEXX 0.707 w / Ω = 44.5 w in moment connections. Since the position of welding must
➤ ASD Plate Tension Rupture Strength per inch, be considered, the fillet weld option may not be feasible for
T = (Fu) t/ Ω = (Fu) t /2 = 0.5 Fu t directly welded beam flange moment connections. The two-
➤ ASD Plate Tension Yielding Strength per inch, sided joint detail would require overhead welding, and this may
T = (Fy) t/ Ω = (Fy) t /1.67 = 0.6 Fy t not be practical or more economical. Also, it should be noted
LRFD calculations are similar and in the same relationship that fillet welds cannot be used in place of CJP groove welds for
to each other. high-seismic applications (building structures with R > 3, for
Setting the fillet weld strength equal to the plate strength example) without careful consideration of the requirements of
(or CJP groove weld strength), we find the following: the AISC Seismic Provisions.
Min (0.5 Fu t, 0.6 Fy t) = 44.5 w (Continued on p. 20.)

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steelwise
(Continued from p. 18.)
ASTM A992 or A572
ASTM A36 Steel
Grade 50 Steel
The Right Size Two-Sided Fillet Weld in Shear w=½t w = 11∕16 t
We have found that the easiest way (Weld Parallel with force) (or w = 0.49 t) (or w = 0.66 t)
to do these calculations is to have the fil- Two-Sided Fillet Weld in Tension w=½t w = 11∕16 t
let weld size expressed as a fraction of the (Weld perpendicular to force) (or w = 0.49 t) (or w = 0.68 t)
plate thickness (much like what is done Two-Sided Fillet Weld on
with the w = 5∕8 t provision for single-plate Single-Plate Shear Connections w = 5∕8 t w = 5∕8 t
shear connections in the AISC manual). (per AISC Manual)*
Table 1: Two-Sided Fillet Weld Size to
➤
replace a CJP Groove Weld
*We also added single-plate shear con-
nections to the list, and for these the AISC
Manual procedure recommends using 5∕8t for
both steels (this splits the difference between
ASTM A36 and 572 Grade 50 steel). Since
shear tabs are generally either 3∕8 in. thick or
½ in. thick, this weld size is appropriate and
simple to use (¼ in. welds for 3∕8 in. plates and
5∕16 in. welds for ½ in. plates). For a deriva-
tion of the 5∕8t requirement, see the article

“Design of Unstiffened Extended Single-
Plate Shear Connections” by Larry S. Muir
and Christopher M. Hewitt in the Q2 2009
issue of AISC’s Engineering Journal.
Table 1 summarizes the different configura-

tions and allows the user to easily determine
the required fillet weld size on each side
of the element instead of specifying a CJP
groove weld. Surprisingly, we found that
the required weld size is dependent only on
the plate strength and is not affected by the
weld orientation. This is due to the use of
the directional strength increase.
There can be significant cost savings
using a two-sided fillet weld in lieu of a
CJP groove weld. One cost benefit is that
fillet welds can reduce weld metal volume,
although shop CJP groove welds can be
configured such that the weld volume is
not significantly increased over fillets
(e.g., by using details with two-sided bevel
preparation). There is additional time
associated with CJP groove welds, such
as beveling of the joints and removing
the weld tabs and backing. The cost and
scheduling of inspections of CJP groove
welds also adds costs over simple fillets. As
a result, a CJP groove weld is typically the
most expensive type of weld and should be
reserved for situations in which it is the
only viable option (such as in butt joints).
We hope this table serves to provide the
design community and construction
industry with an easy way to determine
fillet weld sizes that replace CJP groove
welds when appropriate.
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A V O O R T M A N S T E E L G R O U P C O M PA N Y
product expert series
CAST AWAY! Common questions on steel
BY CARLOS DE OLIVEIRA, P.ENG., AND MI- castings for structural applications.
CHAEL GRAY, PH.D.
WILL YOU be using cast connections in your next project? fore reduce the cost of both erection and of special inspection—
Assuming the answer is “Yes!” or at least “I’m considering it,” the latter being a cost that is born by the owner rather than the
there are several questions that may arise. contractor. This “fringe” savings can be very significant but may
As designers and implementers of both standardized and not be apparent to the steel fabricator nor general contractor. As
customized steel castings in steel structures, Cast Connex is such, simply asking your steel fabricator if a cast connection is
commonly asked how to design and specify cast steel structural more economical will often yield an incomplete picture; castings
components. We’ve attempted to answer some common ques- can save an owner’s money more often than most appreciate.
tions about steel castings below. Consider also that there may be other performance benefits
When does the cost of casting a connection make eco- to the use of cast connections—such as aesthetics, improved con-
nomic sense? We often think of the cost of fabricated steel on nection strength and stiffness and improved fatigue life (both
a per-ton basis—where the cost of the connections is amortized high- and low-cycle fatigue)—which may be more difficult to
over the tonnage of the entire building frame. If you compare quantify but that are likely very important to your client.
the cost per-ton of cast steel to that of fabricated steel in this For those looking for more tangible guidelines, we often
way, of course cast steel appears to be far more expensive. But suggest that castings may be appropriate in any of the following
were you to take the cost of fabricating a connection over the circumstances, with the suitability of castings being increased
weight of the steel in the connection region alone, you’d prob- in scenarios where more than one of these conditions applies:
ably be astounded at the cost of connections on a per-pound ➤ Complex connections (i.e., with incoming members at
basis and at how much that cost can vary from simple to com- different angles)
plex connections. That’s not to say that castings always make ➤ Connections subject to very high loading, where large
economic sense, but one can imagine that there is a breakeven welds are required but would be difficult to apply and in-
when labor and material costs in the fabrication of complex spect, or where connections require significant stiffening
connections can surpass those associated with producing a cast ➤ Architecturally exposed joints, particularly for HSS con-
steel alternative. And when the costs associated with the de- nections
sign, detailing, tooling and qualification of a new cast geometry ➤ Fatigue-critical connections
can be amortized over many identical cast connections, you can ➤ Repetitive details
appreciate that there are many scenarios where cast steel con- How does one go about designing and analyzing an ar-
nections can be far more economical than manually fabricated bitrarily shaped steel component like a casting? First, we
connections. This is the reason for the success of our company’s have to admit that we’re exaggerating a bit when we often boast
standardized cast steel connections. that steel casting manufacturing offers complete geometric
For custom cast components where engineering, tooling and freedom. To produce economical and structurally sound steel
first article (e.g., sample component) qualification costs cannot be castings, one must shape cast connections simultaneously for
amortized over many connections, a total cost comparison must their end use and for the casting manufacturing process. In gen-
be carried out if one’s goal is to justify the use of cast compo- eral, castings should be shaped in consideration of the molding
nents on economics alone. For example, consider that a cleverly process and with feeding and solidification in mind. The aim is
designed cast connection may eliminate field welding and there- to promote directional solidification, which limits the necessity
Carlos de Oliveira, P.Eng., (carlos@castconnex.com) is the

president and principal structural engineer and Michael Gray,
Ph.D., (m.gray@castconnex.com) is the vice president of advanced
technologies at Cast Connex Corporation, an AISC Associate
member company specializing in the design and supply of both
standardized and customized cast steel structural components
for building and bridge construction. For more information, visit
www.castconnex.com.

Cast Connex and Bradken, Inc.
➤
A nearly 16-ton cast steel node for the Queen Richmond Centre
West in Toronto. The node has just been removed from the
heat treatment oven and is being forced-air cooled pursuant to
Cast Connex’s specifications.
➤ A cast steel node and wishbone pedestal in Terminal 5 of
Heathrow Airport.
➤
A cast steel node, featuring recessed reveals, in the tree-like
roof supports of Stuttgart Airport.
Jeff Mullins Architekten von Gerkan, Marg und Partner, Copyright Juergen Schmidt
for the addition of risers to feed liquid metal into the part as it tic demand placed upon, and the available ductility of, the cast
solidifies and cools. We’ve said it before: The design of steel material. It’s also important to note that although steel castings
castings is as much of an art as is the design and detailing of are generally isotropic, heavy-walled castings exhibit through-
fabricated structural steel connections. thickness variation in yield strength.
The design of castings requires the use of 3D solid model- What considerations must be made with respect to lead
ling software, and the structural analysis of castings often re- time when specifying customized cast connections? This is
quires numerical techniques. When it comes to finite element a tough question because the answer really depends on the com-
analysis (FEA) of steel castings, we are most commonly asked plexity and size of the part and how busy the selected foundry
what level of stress is reasonable for a structural casting. Our and pattern shop are. For an order of magnitude, those consider-
answer: It’s complicated. ing castings can assume anywhere from six to 10 weeks for the
First, the acceptable level of stress within a region of a cast production of tooling, eight to 12 weeks for casting and quali-
steel element should be correlated to the allowable size and lo- fying a first article and another eight to 12 weeks to begin to
cation of internal discontinuities within the part, as established receive production castings. Also, consider that your structural
through the non-destructive examination requirements stipulat- steel drawings are not casting shop drawings. Just like standard
ed in the casting specification. This is difficult for those without steel connections, cast connections must be detailed before cast-
experience in the destructive structural testing of steel castings, ing manufacturing can begin, so time must be allotted for detail-
as there has not been much work published on the structural ing and coordination. The extended lead time involved in the
performance of cast steel meeting, say, “Level III” ultrasonic test- use of custom castings often requires special consideration by the
ing. But that’s not the whole story. Consider that for compact design team and owner, which is why we are often involved in
steel sections subjected to flexure, the code allows stresses and projects requiring custom castings well before they go to tender.
strains to exceed elastic limits (we compute the flexural strength What should be covered in a casting specification? At a
of a compact steel section based on its plastic moment of inertia, minimum a casting specification should cover foundry quali-
Z, rather than its elastic section modulus, S). However, for ele- fications, quality control and assurance, material grade, non-
ments loaded in tension, a safe margin must be left between the destructive examination requirements for both the first article
average stress and the yield strength of the steel material. This and production components, surface quality requirements, di-
means that in proportioning economical steel castings, one must mensional tolerances and machining requirements (if any). Also,
consider the distribution of stresses in the casting under a variety be sure to include a line or two in your structural steel specifica-
of load combinations (not just the peak stress) as well as specify tion on the handling and integration of the cast steel elements
non-destructive acceptance requirements commensurate with into the structural steel framing. If incoming structural sections
the level of stress in each region of the casting. Furthermore, this are to be welded to the steel casting, also note that welding pro-
approach also often requires the use of non-linear finite element cedure specifications must be qualified, because although many
analysis to understand how the cast steel component will behave, cast steel grades are weldable, there are currently no cast steel
which in turn requires that casting designers consider the inelas- grades listed as prequalified base metals in AWS D1.1.

economics
THE WORLD OF A region-by-region look at
MY BACKYARD construction activity across the U.S.
BY JOHN CROSS, P.E.
OVER THE PAST SEVERAL YEARS in this

column, I’ve attempted to view national construction Percentage of Domestic Market
market conditions from a variety of perspectives—
economic drivers, project demographics, market
share, employment and annual trends—but the
construction market in the United States is not
West
homogeneous. Coast Mid-Atlantic
Significant variations exist in the market 8% 12%
conditions in different areas of the country in
terms of growth rates, predominant project types
and material preferences. One of the challenges Southeast
of discussing these regional variations is that the 14% Mid-South
12%
market conditions in every region could justify
separate articles for each one. So rather than present
the reasons behind the following regional conditions,
I will simply share conclusions based on the AISC
Business Barometer, reports from AISC regional
South Midwest
engineers, projections from a variety of construction
Central 14%
economists and general business trends.
16%
It should be noted that these regions are not
defined in the same way as the Quarterly AISC
Construction Statistics publication or the current
Plains Mountain
regional engineer assignments. The regions used 7%
9%
in this study were arbitrarily chosen in an attempt
to group together states with similar market
characteristics. (You are free to disagree with the
regional boundaries chosen, but they make more
sense than the new NCAA conference boundaries!) New England
Northwest
5%
3%
John Cross is an AISC

vice president. He can
be reached at cross@ As an example of the differences that exist between re-
aisc.org. gions, there is an approximately $100 variation between
the average per-sq.-ft cost of construction between the
high end (West Coast) and low end (South Central) proj-
ects. This variation is a result of many factors—average
number of stories, seismic requirements, dominant proj-
ect type, etc.—but still instructive in appreciating the dif-
ferences between regions.

Average Project Cost per Square Foot
West Coast: CA, NV, HI
Southeast: MS, AL, GA,FL
South Central: TX, OK, AR, LA
Plains: ND, SD, MN, NE, IA, KS, MO
Northwest: WA, OR, ID, MT, AK
New England: ME, NH, VT, MA, RI, CT
Mountain: WY, CO, NM, AZ, UT
Midwest: OH, IN, MI, WI, IL
Mid-South: VA, WV, KY, TN, NC, SC
Mid-Atlantic: NY, NJ, PA, DE, MD, DC
$0 $50 $100 $150 $200 $250
Project Type Distribution by Region
100
90
80
70
60
50
40
30
20
10
0
Mid- Mid- New South West
Midwest Mountain Northwest Plains Southeast
Atlantic South England Central Coast
% Other 19 20 21 27 21 20 23 28 26 24
% Multi-Family 23 7 5 10 10 22 8 10 11 15
% Government 1 4 3 3 2 2 2 2 2 4
% Healthcare 8 9 10 10 6 7 11 7 6 7
% Schools 13 16 14 14 23 17 19 18 17 12
% Manufacturing 4 11 12 2 7 3 6 5 10 2
% Office 9 8 6 7 8 9 9 10 4 9
% Retail 23 25 29 27 23 20 22 20 24 27

economics
160
140
120
Millions of Square Feet
100
80
60
40
20
0
Mid- Mid- New South West
Midwest Mountain Northwest Plains Southeast
Atlantic South England Central Coast
2012 Square Footage (in millions) 94.5 98.4 108.2 55.8 36.5 25.9 70.7 126.7 106.4 60.5
2013 Square Footage (in millions) 98.3 106.3 110.4 59.1 38.0 27.5 73.5 136.8 114.9 65.9
2013 Projected Growth 4% 8% 2% 6% 4% 6% 4% 8% 8% 9%
Steel Market Share 60% 62% 55% 40% 77% 49% 63% 47% 42% 40%
Predicted 2013 Starts (Square Footage)
The project mix in each region varies significantly. Multi- Market share for structural steel varies across the United
family residential projects greater than four stories in height States, from a high of 77% in New England to a low of 40% in
account for more than 20% of construction activity in the both the Mountain and West Coast regions. Even in these latter
Mid-Atlantic and Northwest regions but are less than 10% of regions structural steel remains the dominant framing system
activity in the central area of the country (Midwest, Plains and selection, as the remaining market share in these areas is split
Mid-South regions). Similarly, school construction is continu- between pre-engineered steel building, concrete, masonry and
ing at a high pace in New England (25%) while lagging on the wood systems.
West Coast (12%). What does all this mean? Conditions vary by region of
Just as current trends vary by regions, so does the outlook the country impacting the type and size of projects being
for activity in 2013. Based on current trends, including an constructed. Attention must be paid to these differences as
increase in rental rates and the level of vacancies in various overall construction trends are tracked and addressed. But
metro areas, it is projected that the greatest level of growth even as some regions show a greater propensity for growth
in 2013 will occur on the West Coast (9%) with the South in 2013 than other regions, the level of growth from the still
(Mid-South, Southeast and South Central regions) close be- depressed starting point of 2012 is minimal in all regions.
hind at 8%. At the same time the Midwest at 2% will show Even assuming a successful resolution of the fiscal cliff issue
the slowest growth. Overall U.S. non-residential building in the U.S., 2013 will not be a break-out year for construc-
and multi-story residential construction is anticipated to tion in any area of the country; it will end up feeling a great
grow 6% in 2013. deal like an extension of 2012.

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It’s Our Nature.®

Theater on
the Roof BY CAWSIE JIJINA, P.E., AND ALVARO CASTAÑO, P.E.
© Francis Dzikowski/Esto
There was nowhere to go but up for New York’s Lincoln Center,

which added a new performance space on top of its original theater building.
THE LINCOLN CENTER THEATER (LCT) in New York has Expanding downward into the ground had already been done
long been associated with big productions. in the past, all the way down to bedrock, to house the 290-seat
But it serves as a showcase for lesser-known artists as well, Mitzi E. Newhouse Theater, LCT’s second theater. Therefore,
as indicated by LCT3, a program of scaled-down productions the only option was to follow the trend in city development and
and emerging talent. expand upward, requiring the insertion of new elements through
In searching for a permanent home for LCT3’s growing audi- existing volumes and changing the nature of exterior elements.
ence, the theater realized the need to expand its capacity within the Preservation of the logic inherent in Saarinen’s design meant
Lincoln Center for the Performing Arts (LCPA) campus and add that any major visual alteration to the base building was unac-
a small, intimate theater to serve LCT3’s needs. However, historic ceptable. LCT wanted this proposed addition, which opened last
preservation of the 16-acre LCPA complex, just northwest of New May, to feel as though it had always been there. The design team
York City’s Columbus Circle, had locked in the building layout responded with a light, airy 23,000-sq.-ft two-story addition on
and, except for temporary events, space was not available for new top of the original building.
construction. Successful completion required carefully navigating and sat-
The LCT building, designed by architect Eero Saarinen, was isfying the requirements set by city agencies, the Lincoln Cen-
originally built to house the 1,080-seat Broadway-style Vivian ter Development Partnership, the New York Public Library,
Beaumont Theater. The building features a column-free space preservationists, artists and community boards. In addition to
spanning 175 ft, over which the New York Public Library for design, the critical issue of constructability on a beloved and
the Performing Arts is located; columns can only be found at architecturally recognized structure, and its added associated
the perimeter, and any expansion needed to respect this layout. costs, framed the design-construct dialogue.

Direct Landing
To limit the structure’s weight, a steel frame with light-
weight concrete on a composite metal deck was chosen. Since
a standard column layout was impossible due to the limited
capacity of the existing concrete girders, Severud Associates,
the project’s structural engineer of record, elected to land
directly on the exterior columns and bypass the entire exist-
ing internal structural framing system. That decision would
require LCT3 to become a bridge unto itself—a conceptual
Yorke Construction nod to the minimalism of the original Saarinen design.
Deep truss configurations were picked over arches and
The LCT3 addition, under construction.
➤
plate girders to minimize weight, optimize the architectural

The interior of the space, with exposed truss elements.
➤
layout and allow clear runs for the mass of conduits, light-
ing, data, ductwork and the systems associated with the-
ater design. Two 30-ft-deep wide-flange main longitudinal
trusses, weighing about 65 tons each, would become the main
load-carrying elements that would vault the 175-ft span of
the original building. Two additional cross trusses would be
75 ft long and each end would cantilever an additional 15 ft.
Together they would also become the lateral force resisting
system. A third long truss would tie it all together.
The exact location of the trusses played an important role

in balancing the reactions to the chosen columns below, since
it was imperative that the load being delivered to the columns
was exactly what the columns had in “reserve.” The reserve
itself was a number conjured up by the structural engineers,
who combed through the existing structural system, paring
down theoretical excess, reducing allowances and precisely
accounting every weight that was in position rather than allo-
cating weight by floor area. A series of non-destructive tests
determined the actual material strength of the various existing
structural elements, and the reserve increased.
Since the architectural motif was a light box hovering over
the existing building, 36-in.-deep wide-flange steel girders
were used to transfer the load from the trusses into the col-
umns below via isolating bearing pads. The idea was that if
there had to be isolators, then they were going to do double
duty and they were designed to allow the new structure to
slide over the tops of the old columns, thereby subjecting the
existing columns to vertical loads only. In addition, a careful
and thorough distribution of the various force combinations
Yorke Construction
➤➤
The wide-flange main longitudinal trusses, weighing about 65 tons

each, are the main load-carrying elements of the addition.
Yorke Construction
Cawsie Jijina (cjijina@severud.com) is a principal and Alvaro

Castaño (acastano@severud.com) is an associate, both with
Severud Associates Consulting Engineers, PC, in New York.

➤
The new structure provides increased
capacity for the growing LCT3 program.
eliminated the need for an overall seismic ret-

rofit of the entire building.
Headroom clearance requirements and
architectural walkways necessitated the
incorporation of Vierendeel panels into the
truss configuration. The three long trusses
could not be hidden, so the architects chose
to show them off as architecturally exposed
structural steel (AESS). Since aesthetics pre-
cluded gusset plates, the engineers answered
by designing and detailing fully welded truss
connections in all the visible zones.
Access to the new space is provided by an
elevator tower, which carefully pierces through
the existing structure from the foundation up
to the rooftop. Constructed of square hollow
structural steel (HSS) and channel glass, the
elevator tower was designed for strict toler-
ances of wind and seismic movement. Struc-
turally, it is completely independent from the
original building and the new rooftop theater,
a slender steel and glass tower unto itself.
Relieving Stress
Staging the installation of the curtain wall
façade presented several challenges. The glass
had to be attached to the trusses before the
concrete floors could be formed and the inte-
rior finishes added. But forming the floors and
adding the finishes would make the trusses
deflect, which would likely cause the glass to
stress and crack. To prevent the glass from
cracking when the floors were formed, the
team designed joints into the curtain wall to
accommodate those deflections. To prevent
cracking during installation of the finishes, the
team applied temporary weight to the trusses
prior to attaching the curtain walls; doing so
ensured that the glass was in the appropriate
position to handle those deflections. It was a
balancing act between the jointing in the glass,
the sequencing of the finishes and the weight
that could be added at any given moment in
time. Cambers were calculated so that in their
final loaded configuration, the trusses would
stay flat over their entire span.
Another challenge: The theater could not
be stick-built because the roof of the origi-
nal building was incapable of handling the
weight of the raw material. Instead, the struc-
tural framing, including the large trusses,
was prefabricated, assembled in the shop to
ensure the fit, deconstructed and shipped to
New York. It was divided into sections so that
a crane could lift each section and hold it in

Yorke Construction Severud Associates
One of the lifts performed by the Manitowoc 16000 crane. A 3D model showing the trusses of the new addition and the
➤
➤
elevator, which is structurally separate from the new and old
buildings.
place over the roof during construction. Crane reach and lift capac- dance with the building's design and became concerned over
ity decided the size of the spliced segments (the furthest reach was the associated differential settlement issues this would cause.
220 ft with 13.5 tons, while the heaviest was 50 tons at 105 ft). Test pits and core samples were required to expose the theater’s
foundations, which rest directly on bedrock, and the engineers’
Weight Issues fears were confirmed; the foundation was smaller than depicted
As construction began, additional challenges related to on Saarinen’s drawings. Worse, there was no discernible pattern
weight arose and the engineers became wary that the founda- to the deviation in the four column foundations. While the col-
tion of the original building had not been constructed in accor- umns worked, the foundations did not.
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The ostensibly obvious solution—
“Sir, can I interest you in enlarge the foundation—would have
one of our hard to required evacuating the building and dis-
placing a number of people from their
find domestics?” A-588, A-992, offices within LCT. It would also delay the
-36
A-572, A
project. This led the structural engineers to
ams conduct an even more sophisticated analy-
At AZCO, specialties of Jumbo Be sis of the new theater as well as the origi-
els
the house always include MC Chann nal building. The analysis confirmed that
s
unusual shapes, Thick Plate the foundations were not evenly loaded,
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inventory. Mill micro-cracking in the original building,
certification is available the engineers analyzed the structure yet
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LCT3 perfectly illustrates this.
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Think Steel of Lou Occhicone, P.E., Daniel Surrett, P.E.,

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Architect
www.aisc.org/safety H3 Hardy Collaboration Architecture,

New York
Structural Engineer
Severud Associates Consulting
Engineers, PC, New York
General Contractor
Yorke Construction, New York
Steel Team
Fabricator and Erector
Capco Steel, Inc., Providence,
R.I. (AISC Member/AISC Certified
There’s always a safe solution in steel. Fabricator and Erector)
Detailer
Arcan Detailing, Inc., Windsor,
Ontario, Canada (AISC Member)

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Making Up
for Lost Time BY JASON SQUITIERE, P.E., AND JANIS VACCA, P.E.
An adaptive reuse project in Philadelphia adjusts to the current economy

with prefabricated sensibility.
THE PROVERBIAL “SIGN OF THE TIMES” can come in many

forms—for example, a vacant building.
The existing building at 2040 Market Street in Philadelphia,
formerly the headquarters for the American Automobile
Association (AAA), sat vacant through the “Great Recession”
of 2008–2009, providing a constant reminder of the dismal
economy. Several developers reviewed the possibility of
adapting the building for new use, and eventually PMC
Property Group of Philadelphia decided to develop a vertical
and horizontal expansion of the existing five-story concrete-
framed building.
Structural engineering firm The Harman Group was cho-
sen to determine how many additional floors could be added
to the existing building. Using a system incorporating a load-
bearing steel wall panel called Integrity Max by Integrity Wall
Panel, along with the Ecospan composite joist floor system from
Nucor-Vulcraft, it designed a 120,000-sq.-ft vertical overbuild
that added eight residential floors to the existing building. The
building was also expanded horizontally, with 68,000 sq. ft. added
to the original footprint reaching the same top floor elevation
as the overbuild. This vertical and horizontal expansion turned a
120,000-sq.-ft vacant office building into more than 300,000 sq.
ft of vibrant residential rental units and ground-level retail space,
now known simply as 2040 Market.
The Ecospan floor system helped maximize the number of
floors that could be added, thanks to its shallow depth and light-
weight construction—a structure depth of 15 ½ in., a span to
depth ratio of 27 and a weight of 40 lbs. per sq. ft. The light-
weight construction of this system allowed for three more over-
build levels than a traditional steel-framed system would have
allowed. In addition, the floor joists have a special flush joist seat
that allows for uninterrupted bearing through the floor slab from
The Harman Group level to level, which is critical for load transfer.

© Brian R. Tolbert
The 2040 Market overbuild added eight floors to an existing five-

➤
floor building as well as expanded the building's footprint.

➤
The building, before the expansion.
➤
An in-wall transfer truss.
The Harman Group
The Integrity Max panel also helped minimize the weight

of the overbuild portion, while at the same time helped reduce
erection time. The 11-ft, 2½-in.-tall panel is constructed with
4-in. cold-formed tubes supplemented with 4-in. hollow struc-
tural sections (HSS) where required. The interior tubes can
carry significant loads without any horizontal bridging, creating
an open vertical space between studs for mechanical and other
systems.
Transfer Structure
The existing building is concrete waffle-slab construction
with columns spaced 27 ft apart. To minimize cost and depth for
the transfer structure between the concrete building and the new
steel-framed floors, Integrity Wall prefabricated an in-wall HSS
transfer truss designed to transfer the loads from above. With
this combined structure providing load support and serving as Jason Squitiere (jsquitiere@harmangroup.com) and Janis
an architectural wall, the transfer level structure was reduced Vacca (jvacca@harmangroup.com) are structural engineers at
to only 10 lbs. to 15 lbs. per square foot, 40% to 60% less than The Harman Group, King of Prussia, Pa.

The Ecospan Composite Floor System uses a unique
Can a structural floor system be easy to configuration of components with high strength-to-
weight ratios that allows for longer spans, shallow
install, cost-effective and green? Yes. floor depths, greater rigidity and enhanced perfor-
mance – without sacrificing aesthetics.
5. Concrete Slab
The Ecospan® Composite Floor System offers all these advantages (by others)
and more. A safe, innovative choice, Ecospan helps reduce building

costs while offering the benefits of sustainable building materials that
qualify for LEED® certification through the U.S. Green Building Council. 4. Concrete
Reinforcement
(by others)
Made with 99% recycled steel joists and 70% recycled steel decking, 2. Vulcraft/Verco
Ecospan provides open web structural components with a lighter weight 3. Shearflex®
Steel Deck
HD screw
composite design for elevated floor construction. 1. Vulcraft E-Series
Steel Joist
Ecospan is the natural choice for:

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➤
Bill Pascoli
Integrity/South Shore
An Integrity Shear panel, providing interior framing.
➤
➤
Integrity spandrel panels line the building’s façade at
each level.
the 25 lbs. per sq. ft offered by a conventional stick-built

structural steel transfer floor.
A traditional base plate with post-installed anchor rods
would not resist the high net uplift forces at the interface
with the overbuild. Tie-down connections to the existing
roof slab would also not provide the strength necessary,
so the connection had to bypass the roof slab. The solu-
tion was to install 1½-in.-diameter rods through holes
drilled in the existing roof slab and weld the rods to steel
plates with post-installed anchors on all faces of the exist-
The Harman Group
ing concrete column. This anchorage would eventually
be fireproofed, though when a representative of Varen-
horst Architects (the project’s architect) saw the installed
solution on-site he exclaimed, “I would be really proud to
have steel like that exposed in my apartment!”
Maximizing all space available, the team used prefab-
ricated Vierendeel trusses for the girders. Also fabricated
by Integrity Wall/South Shore Iron Works, the 50%
➤
A Vierendeel truss performing as a girder.

Integrity/South Shore
➤ An Integrity Max door opening. Drywall is fastened to the light-gauge

steel, which is attached to HSS4x4—which carries the load.
➤
A tie-down for the vertical expansion.
➤
The Harman Group Integrity Wall Panels, installed on the building's façade.
open structure provided the ability to pass utilities

through congested areas.
Vierendeel trusses with HSS top and bottom
chords and vertical tubes, built by Integrity, were
used for the exterior as well. Installed at each
floor below the glazing, they were erected con-
currently with the building and support Trespa
façade materials. The new addition uses a total of
256 tons of structural steel in all.
Today’s economics demand new ideas in construc-
tion, emphasizing prefabrication of as many elements as
possible. The overbuild of 2040 Market, which opened
this past September, used every imaginable way of pre-
fabricating the steel structure to enable a lightweight
overbuild structure that was constructed quickly and
economically. If the original building was a sign of bad
economic times, the newly adapted building will hope-
fully be seen as a sign of ongoing recovery.
Owner
PMC Property Group, Philadelphia
Architect
Varenhorst Architects, Philadelphia
Structural Engineer
The Harman Group, Inc., King of Prussia, Pa.
General Contractor
Fastrack Construction, Fort Washington, Pa.
Steel Team
Fabricator and Detailer
Integrity Wall Panel/South Shore Iron Works,
Chicago (AISC Member/AISC Certified
Fabricator)
Erector
Quinco Contracting, Harleysville, Pa.
© Brian R. Tolbert (AISC Member)

AMERICA'S CENTER earn up to
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Incorporating the SSRC Annual Stability Conference and the

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April 17–19 2013

Learn. Meet. See.
Join more than 3,500 structural engineers, erectors,

detailers, educators and others involved in the
design and construction industry when they gather
this April at the NASCC: The Steel Conference,
incorporating the SSRC Annual Stability Conference
and the Technology in Steel Construction Conference.
One registration fee includes all three conferences.
Learn from more than 100 specialized sessions on

all aspects of steel building and bridge design and
construction. Meet with the nation's leading designers,
fabricators, and erectors. See the latest equipment and
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IMCA www.aisc.org/nascc
A Bridge
in Building’s Clothing BY TIMOTHY COSTELLO, P.E., AND MARK RAULLI, P.E.
A community college conceives a creative crossing to connect its campus.
THERE ARE A FEW WAYS to get over a gorge. nity organizations in need of performance venues, the new
One idea is to build a bridge. Another might be to build a building encourages an integrative approach to music by pro-
building. viding facilities for the entire music school, including adminis-
Onondaga Community College decided to do both—but in tration, production, teaching, research and support spaces. The
one structure—and is in the process of completing an $18.9 building also shares the Gordon Student Center’s loading dock
million, 45,000-sq.-ft “bridge building” across the foliage-filled and other support functions.
Furnace Brook Gorge, a 60-ft-deep fissure that divides its cam- Inside the addition, called Ferrante Hall Academic II,
pus in Syracuse, N.Y. The gorge was, in fact, previously spanned are a 150-seat music recital hall, a music resource center, a
by a bridge, but one that was open to wind, rain and snow. The 2,500-sq.-ft instrumental rehearsal room, an 1,800-sq.-ft
new building will provide a protected crossing over the gorge— choral rehearsal room, 20 practice rooms of various sizes, 16
particularly enticing during the area’s harsh winters. In addi- faculty teaching offices and eight classrooms. The recital hall
tion, the two-story structure makes use of otherwise unusable can accommodate a 110-piece orchestra with an 80-member
land. And by avoiding underground rerouting of elements such chorus, as well as another chorus at the stage end of the lower
as sewer lines and electrical conduits, which would have been balcony if needed.
required with the original proposed building location, it was Because limited excavation was needed to bury elements such
achievable within the college’s original budget. as electrical conduits and sewer lines, and because the building
The building is actually an addition to the school’s Ferrante taps into existing parking, loading, utility infrastructure and site
Hall and is also attached to the Gordon Student Center, uniting work, construction costs and environmental disruption were
the east and west campuses and connecting the campus spine considerably reduced, freeing up resources to attack the project’s
on the south with public, staff and student parking to the north. numerous engineering challenges. These included a constricted
Conceived as a teaching facility offering outreach to commu- work area, uneven loading, deflection and rock fragmentation.

Tim Wilkes Photography
The new "bridge building" uses 860 tons of structural steel in all.
➤ ➤
The final truss is installed.
Cannon Design
Ferrante Hall Academic II, which opens in May, adds

➤
45,000 sq. ft of building space to the Onondaga Com-

munity College campus.
➤ Installation of two of the 200-ft-long trusses for the
new building.
Timothy Costello is an associate vice president with Cannon

Design and can be reached at tcostello@cannondesign.com.
Mark Raulli is an engineer and estimator with Raulli & Sons,
Inc., and can be reached at mark@raulliandsons.com.

Over the Gorge incorporate some of the largest rolled steel elements avail-
Use of bridge construction materials and techniques was able (up to W14x665). With limited working room on either
essential in achieving the architectural vision, given the struc- side, the construction team built a temporary single-support
ture’s double life as a bridge and a building. Three two-story, steel tower in the middle of the gorge, allowing the trusses
200-ft trusses support the building and its range of interior to be erected in two halves and spliced in the middle; the
room types, and bridge bearings are used to transfer loads to largest half-truss was 70 tons. This piecewise approach facili-
the building’s foundations (called pot bearings, there were six tated field assembly of the trusses to occur in a smaller area
total, one under each end of each truss). On either side of the and enabled the use of a smaller crane. When unexpected
truss are link buildings (60 ft to 80 ft in length) that attach the rock fragmentation was discovered on one side of the gorge
addition to the existing structures on either side of the gorge. during excavation, drilled mini-piles and rock anchors were
The new building uses a total of 860 tons of structural steel. installed by a specialty contractor to supplement the founda-
To withstand structural forces, the 30-ft-high trusses tion’s original 7-ft-diameter caissons.

A Balanced Recital exposed concrete floors, the deflection of the trusses could
The recital hall posed a major structural challenge, due cause windows to pop out and the concrete to crack exces-
to its configuration in comparison to the rest of the build- sively. Construction was sequenced to take as much deflec-
ing. Because it was a two-story space on one side of the tion out of the trusses as possible prior to placing deflec-
building and the other side of the building was composed of tion-sensitive materials. The team considered two options:
two one-story layers, the load on the structure was unbal- preloading the trusses to neutralize deflections and sequen-
anced. While the north truss supported the weight of the tially unloading them as the building was completed, or
roof and two lower levels, the south truss only supported installing non-deflection-critical items first to help deflect
a roof and one lower level, and the center truss supported the trusses. A combination of the two was eventually chosen.
a two-story space on one side and two one-story spaces on As many materials as possible were installed prior to the cur-
the other. tain wall; once it was determined that enough deflection had
If trusses were loaded after placement of curtainwall or occurred in the truss, the curtain wall was installed.
Dave Revette Tim Wilkes Photography
Lift and installation of truss 1.

➤
➤
The construction team built a temporary single-support
steel tower in the middle of the gorge, allowing the
trusses to be erected in two halves and spliced in the
middle.
➤
A top truss cord gusset connection.

1" FULL DEPTH STIFFENER 1" FULL DEPTH STIFFENER
PLATE TYP EA SIDE OF WEB PLATE TYP EA SIDE OF WEB
TOP CHORD 1" FULL DEPTH CONNECTION
PLATE TYP EA SIDE OF WEB
CJP GUSSET PLATE
2 ROWS OF (3)1½" A490X

PIECE OF W BOLTS IN STANDARD
TO MATCH HOLES TYP
DIAGONAL
PIECE OF W
TO MATCH
DIAGONAL
TYP FLANGE
SPLICE BOLTING
DIAGONAL W
PLATES TO MATCH DIAGONAL W

VERTICAL TRUSS
FLANGE MEMBERS
TYP WEB VERTICAL W

SPLICE BOLTING
Cannon Design
¾"=1'0"
A detail of a top truss chord connection.

➤
Bolt Dilemma to manufacturing techniques used for the large bolts, a spe-
Besides the unique construction area and balance issues, cial lubricant was needed to achieve the required torque for
bolting also posed a challenge. During steel fabrication, them, as the friction would have been too great otherwise.)
the team learned that the 1½-in. A490 bolts specified in the When the new bridge building opens in May, Onondaga
design had a tendency to fail if they were installed by turn- Community College students, faculty and visitors will have
ing the head end of the bolt rather than the nut end. In the a new path across Furnace Creek Gorge, as well as a new
building’s design, however, the bolts were an architectural music building surrounded on all sides—including below—
feature specifically designed to be installed in one direc- by natural beauty.
tion—via rotation of the bolt head. And because the bolts Owner
were so large, they couldn't be installed any other way. (Due Onondaga Community College, Syracuse, N.Y.
A truss connection as a Revit model... ... and as-built.

➤
Cannon Design Cannon Design

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➤
The building sits above a 60-ft-deep fissure.

INFORMATION MODELING (BIM), GIRDER-SLAB COMPOSITE STEEL AND PRECAST
Lift and installation of truss 2.
➤
TECHNOLOGIES, AISC ERECTOR CERTIFICATION–AND MUCH MORE.

IF YOU WANT TO BE THE BEST, YOU CAN’T AFFORD TO MISS WHAT WE HAVE TO OFFER.
Architect and Structural Engineer

Cannon Design, Grand Island, N.Y.
General Contractor
Hueber-Breuer Construction Company,
Inc., Syracuse
Construction Manager
C&S Companies, Syracuse
Steel Team
Fabricator and Erector
Raulli & Sons, Inc., Syracuse, N.Y.
(AISC Member/AISC Certified
Fabricator and Erector)
Detailer
JCM and Associates, Ltd., Frankford,
Ontario, Canada (AISC Member)

The newest Chicago “L” station
sports its own look thanks to hundreds of curved hollow structural sections.
Ticket to Ride BY STEVEN C. STEFFENS
THE SKOKIE SWIFT is filling out. form to narrow to allow it to penetrate the lower bay of one
Until recently, the Chicago Transit Authority’s (CTA) Yel- of the tower structures. At this point, the passenger platform
low Line (the Skokie Swift’s official name) only had two stations transforms into a covered walkway that provides protection for
and served to connect suburban Skokie to the rest of the Windy patrons circulating between the north station house and the
City’s mass transit system (colloquially referred to as the “L”). passenger platform during inclement weather.
But this past spring it gained a third station, the first new
CTA station to be built in more than a decade. Located at the Clusters of Steel
intersection of Oakton Street and Skokie Boulevard, it puts the While a certain degree of uniformity exists through-
town’s downtown business district on the map—or at least on out the L system, the Oakton-Skokie station achieves its
the train map. own look via nearly 600 hollow structural sections (HSS).
The linear design concept for the new 65-ft-wide by The station’s structural framing consists of 72 columns,
1,100-ft-long Oakton-Skokie station is, of course, based on each comprised of eight round 6-in.-diameter round HSS
its function as a train stop. Passengers enter and exit via sta- arranged in circular clusters; 134 tons of structural steel
tion houses located at the north and south end of the site and were used in all. As the clusters rise toward the station
arrive and depart trains from a centrally located platform, a house roofs and platform canopy, the sections curve and
layout consistent with several of the CTA’s 145 L stations. interconnect with those of neighboring column clusters and
Existing high-voltage transmission towers traverse the mid- result in a superstructure that is at once Gothic, modern
dle of the site, which requires the width of the passenger plat- and organic. The pipe-to-pipe connections are made with

➤ ➤
Photos by John Merkle

➤
Structural framing for the station is provided by 72 columns,

➤
The station, before roof installation and paint application (top) and
each made up of eight round HSS members. complated (bottom).
¾-in.-diameter hex-head bolts. Subtractive iterations Steven C. Steffens was formerly direc-
of the cluster design resolve unique conditions that are tor of architectural design and construc-
created by the aluminum-glazed curtainwalls forming tion with McDonough Associates, Inc.
the perimeters of the station houses; by the expansion Engineers/Architects in Chicago, and
joints required between the station house roofs and was the senior project manager for the
adjacent canopies; and at the longitudinal terminations Oakton-Skokie CTA station project. He
of all of the facility’s canopies. is now with Globetrotters Engineering
The roofs of the station houses are held back laterally, Corp. in Chicago. You can reach him at
also by HSS, exposing sun-control louvers comprised of stevensteffens@yahoo.com.
steel channels (C15x33.9) that integrate with the structural
frame and enhance the organic quality of the design. The
louvers provide shade in the station houses during the sum-
mer and filter natural light into the occupied areas through-
out the remainder of the year.

McDonough Associates
➤ Top and side drawings of the column clusters. The pipe-

to-pipe connections are made with ¾-in.-diameter hex-
head bolts.
The structural steel elements were both hot-dip gal-

vanized (per ASTM A123/A153) and painted. The paint
system consists of a shop-applied 2-mil. prime coat of
polyamide epoxy (Carboline Carboguard 893SG Epoxy)
and a topcoat of Carboline Carbothane 133 HB Acrylic
Polyurethane.
Future Expansion
The station currently receives two-car trains and
the platform, as currently configured, can accom-
modate four-car trains. As the demographics of the
region increase, or if the branch line is extended, the
design allows for future expansion to accommodate a
maximum of eight-car trains. Piers installed on either
side of the covered walkway can accept future column
clusters, and the platform and canopy structures can

Inset: An early mock-up of a detail of one of the columns.

➤
The project uses 134 tons of structural steel.
be extended from the north face of the current platform/ Owner

canopy terminus to the south face of the north station Chicago Transit Authority
house. Any future expansion would require relocation of Architect and Structural Engineer
the existing high-voltage transmission towers, removal of McDonough Associates, Inc. Engineers/Architects, Chicago
the walkway roof and columns and the addition of con-
General Contractor
crete platform slabs on either side of the existing walkway.
Village of Skokie, Ill.
The local power company plans to upgrade and relocate
the existing transmission towers in the future. Once that Construction Manager
occurs, the expansion of the platform and canopy can take Riley Construction, Kenosha, Wisc.
place, and the ultimate design will be fulfilled. Steel Team
In its current and fully complete iterations, the Oakton- Fabricator, Erector and Detailer
Skokie station is more than just an addition to a major mass K & K Iron Works, LLC, McCook, Ill. (AISC Member/AISC
transit system. It creates a positive impact on the environ- Certified Fabricator)
ment, enhances the local economy by providing riders with Bender/Roller
direct access to Skokie’s downtown business district and Chicago Rolled Metal Products, Chicago (AISC Member)
vastly improves the local community’s connection to the
greater Chicago metropolitan area.

The great outdoors
OPERATING ONE SCHOOL—with a
come into capacity of more than 500 students—out of
two separate campuses isn’t an ideal situation.
the classroom— But it was long the reality for the Red-
ding School of the Arts in the northern
California community of Redding.
By the autumn of 2007, despite the best
efforts of the school to raise funds for a uni-
fied campus, prospects appeared dim.
Then, unexpectedly, a locally based
and sometimes philanthropic foundation stepped forward
with an offer to provide both land and the
the classroom funds to design and construct a new ultra-
green school.
goes outside— Once an agreement was reached to move
forward, Trilogy, the architect, approached
at the Redding the funder (the McConnell Foundation),
school administrators, parents and general
School for the Arts. contractor with this question: “What is the
single most important characteristic to you
for this new school to possess?”
This was not about figuring out how
many classrooms were needed or how large
the music rooms needed to be, but rather
about the very core of what the school
wanted to accomplish with its design.
One answer in particular resonated
with the designers: “Integrate indoors
with outdoors.”
Outside
Thus began design on a new campus for
this 77,000-sq.-ft K-8 public charter school
for the visual and performing arts, with the
goal that when complete it would serve as
both an environmental model for other
schools and an inspiring learning environ-
In
ment for its own students. Looking to break
away from traditional design patterns, the
design team conceived of a school where
more than half of the learning space would
actually be located outdoors.
Of course, northern California weather
isn’t always conducive to holding class
BY JAMES E. THEIMER, AIA, LEED AP BD+C
outside, but even in times of inclement
weather the school’s large glazing areas—
especially on the north side—help bring the
outdoors inside. And steel framing helps
facilitate this. Trilogy and Kibler & Kibler,
the structural engineer, chose a system of
interior structural steel braced frames—not
only to help maximize daylighting but also
because such a framing system was well-
suited to the building’s complex geometry;
Whittaker Photography
➤ Exposed structural materials are the norm

at the new Redding School of the Arts in
northern California.

Trilogy Architecture
➤
The new school brings together more than 500 students, initially
➤
steel was also deemed the most cost-effective solution for

both the vertical and lateral systems. at two separate campuses, into a state-of-the-art facility that
connects the indoors with the outdoors.
Creating a footprint for maximum daylight also pro-
vided an opportunity to alter the traditional rectangular
classroom shape into multi-purpose spaces, allowing for
arrangements conducive to teaching large groups as well as
break-out areas for smaller groups or individuals. Exposed
interior structural columns and braces are accented in
bright colors and provide a lesson on how buildings are
structurally supported.
The braced frames for the school were typically con-
structed with HSS5×5×5∕16 columns, W16×26 floor and roof
beams and HSS4×4×¼ braces. The braces were designed
as X-bracing to reduce the buckling length so the brace
size could be minimized. This significantly reduced the
requirements for the brace connections, as their design was
based on the tensile strength of the bracing. When pos-
sible, based on the frame size that could be readily trans-
ported to the site, the frames were completely fabricated
in the shop.
The building has a total of 40 different roof planes
and more than 140 structural corners, and required 102
braced frames (83 different geometries). Portions of the
second-floor exterior walkways are covered with fabric
tensioned-membrane roof supported by exposed HSS
Kibler & Kibler
beams. The connections for these beams were designed
so they could be fabricated and erected with the main
structure while allowing adequate access to install the James E. Theimer is the owner
exterior wall finishes and the roof membrane at later and principal architect of Trilogy
dates. Additional complications included a seismic "SDIJUFDUVSF t 6SCBO %FTJHO t
separation joint between the three wings that was offset Research and can be reached at
between the floor framing and roof framing levels, a jt@trilogyarch.com.
40-ft-tall tower, two levels of amphitheater seating,
rammed earth walls at the three stage areas and a variety
of sloped second-level floors.
Head Start
One of the most pressing restrictions of the project,
as with many projects, was a tight schedule. With the

➤
➤
The outdoor amphitheater, surrounded on all sides by cooperation of owner McConnell Foundation and general
the school. A 3D modeling approach allowed the lighting contractor Gifford Construction, shop drawings were begun
designer to conduct shading studies for the roof over
the theater. This roof, supported by W27×84 beams, even before final structural design was complete and before
cantilevers approximately 20 ft. the steel fabricator/erector had been selected. The building
was designed as three structurally distinct wings, each
seismically separated from the others, and the shop drawings
➤
were completed in three phases corresponding to the wings.

This “head start” on shop drawings was crucial in allowing the
project to move forward in a timely manner. As with the shop
drawings, the fabrication and erection of the structural steel was
➤
phased, allowing for other trades to begin work earlier in the

project. In addition, many of the two-story braced frames for
the lateral system were shop fabricated, which reduced the field
fit-up, welding and special inspections of the frames.
ArchiCAD software was used to model the structural ele-
ments in 3D and provided a continual verification of the design as
necessary structural revisions were made throughout the design
process. The 3D modeling approach also allowed the lighting
designer to conduct shading studies for the roof over the central
outdoor theater. This roof, supported by W27×84 beams, canti-
levers approximately 20 ft and extends over the adjacent wing.
The building has an unorthodox shape, meaning that there
would be very limited repetition among the structural members.
This precluded the use of concrete, where the unique formwork
required for each and every portion of the building would have
been cost-prohibitive; open-web steel joists were considered but
also rejected due to the same concern over the number of unique
elements required. In the end, cross-braced hollow structural
section (HSS) frames using conventional wide-flange horizon-
tal beams with HSS columns proved to be the most economical
Kibler & Kibler
structural system and also provided an additional advantage when
it came to connections. By using cross-braced HSS frames, the
➤
A RISA-3D structural model of the
school's south wing.
Kibler & Kibler
effective lengths of the bracing members were reduced, which the project team working toward LEED Platinum status, Tril-
allowed the connections in the special concentric braced frames ogy and the building systems team would need to be granted
to be designed for 36% less load than if standard braces had been maximum flexibility in designing their systems—without the
chosen. Also, the member sizes, welds and foundations were sig- structural system providing unnecessary constraints. To facili-
nificantly less than if a moment frame system had been chosen. tate this, the structural system was minimized at the building’s
The building uses 664 tons of sturctural steel in all. exterior, giving the team much more room to work with for
Another goal of the structural team was to allow the other the placement of windows and shading devices in the façade.
design disciplines maximum flexibility in their design. With In addition, using HSS columns (moslty HSS5×5) allowed for
USD
Something that is absolutely necessary.

Trilogy
A Rhino 3D model of the K-8 school.
➤
➤ A connection drawing of second-floor braced frames.
a less intrusive design, and the relatively thin floor and roof
beams (mainly W16s at the floor and W14s at the roof) allow
maximum daylighting on both floors.
Near Zero
The school was designed to be a model for future public
buildings by placing energy and budget responsibility ahead
of the popular notion of net-zero energy, and the school
generates about 70% of the energy it uses thanks to photo-
voltaics; plans to increase efficiency for the second year of
operation (the school opened in the fall of 2011) are being
instituted, with the expectation that the energy gap can be
reduced even further.
The green efforts have been recognized. In May, Redding
School of the Arts became the first completely new school cam-
pus to receive Platinum certification under the 2009 LEED for
Schools standards. It also won a 2012 Design Excellence Award
for Educational Facilities from the American Institute of Archi-
tects. The school is a living, learning laboratory that blurs the line
between the inside environment and the great outdoors.
Kibler & Kibler
Owner
The McConnell Foundation, Redding, Calif.
Architect
5SJMPHZ"SDIJUFDUVSFt6SCBO%FTJHOt3FTFBSDI 3FEEJOH
Structural Engineer
Kibler & Kibler Architecture and Engineering, Redding
General Contractor
Gifford Construction, Redding
➤ Maximizing daylighting in the classrooms was a major goal for

the project.

Get the latest
information on seismic design.
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NOW AVAILABLE
Order your copy today!
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Chicago, IL 60601
312.670.2400 www.aisc.org
Widening
the
Gap BY LANCE BORDEN
Courtesy of PCL Civil Constructors, Inc.
A bridge replacement and expansion project eases water and road traffic and
accommodates future growth in the Hampton Roads region of Virginia.
Courtesy of Modjeski and Masters
ONE OF THE WORLD’S largest natural harbors and Only 25 ft separate the Gilmerton Bridge from an adjacent railroad
➤
home to 1.7 million people, the Hampton Roads area in bridge.

southeastern Virginia, is known for its year-round ice-free
waterways, high concentration of military bases and ship-
yards, and miles of waterfront property. ing a new bridge on a separate alignment, then later demolishing
The Henry G. Gilmerton Bridge is one of five critical the original bascule span. However, it was determined that any
bridges connecting the region and carries approximately alternate alignment would further impact already tight navigational
one million travelers every month. In the late 1990s, tolerances at the site. The city turned to bridge engineering firm
nearly 70 years after the bridge was originally constructed, Modjeski and Masters for the complex design assignment—one that
the City of Chesapeake recognized the need to replace required the new bridge to be built on the exact same alignment.
the aging span to accommodate future growth in an area Doing so, however, would potentially create a significant disrup-
becoming increasingly congested both on the land and in tion of traffic. Military Highway is a critical artery in the Hamp-
the water. ton Roads region, carrying more than 35,000 motorists every day,
The original bascule span’s 11-ft clearance required
a large number of bridge lifts, making it the most
frequently opened bridge in Hampton Roads at 7,500 Lance Borden is a senior associate and
openings per year. It also carries Military Highway design project manager with Modjeski
over the Elizabeth River and thus needed to assist and Masters. You can reach him at
with expanding the highway to help facilitate the area’s lvborden@modjeski.com.
increasing motor traffic.
As such, the City of Chesapeake embarked on a $134
million replacement project. Early plans called for build-
➤
The new bridge's two main lift towers, 207 ft tall, were
erected directly over live traffic.

➤
The Gilmerton Bridge and railroad bridge, before construction.
Courtesy of the Virginia Department of Transportation
and any lengthy disruption to traffic could significantly impact vibrations from a typical freight train passage were greater than
travel and commerce. those produced from the installation of the shafts.
Laying the foundations also presented a challenge for the
Above and Below construction and design teams. The Gilmerton Bridge is located
The design team thus came up with a plan that involved in the Great Dismal Swamp, a marshy area on the coastal plains
building the bridge above and below the existing structure, with region with less than desirable soil conditions. To effectively
the original bridge remaining functional until the float-in of the support the new lift span, a total of eight 12-ft-diameter drilled
new span. The new bridge was originally proposed as a bascule shafts were needed. The drilled shaft foundations were designed
span, but was later designed as a vertical lift bridge to accom- to reach 120 ft below ground level, a feat that would require spe-
modate the necessary increase in bridge length and width. cial equipment and a team of industry experts. The contractor,
Construction of the new bridge began in late 2009, following PCL Civil Constructors, used a specially made massive oscillator
completion of final design, and it is scheduled to be completed to drill the foundations, and the project features some of the larg-
in 2014. As one of the challenges with the replacement project est drilled shafts ever constructed using the oscillating method.
was minimizing impact on the traveling public, construction Above ground, 207-ft-tall steel main span lift towers were
was not only coordinated around morning and evening rush erected directly over live traffic. The towers span from 38 ft from
hours but also around peak summer travel when both marine center of front column to center of rear column and are 89 ft
and motorist traffic are heavy. center to center, transversely, to match the lift span. The tower
With construction underway, the teams faced several chal- columns and horizontal braces are box shaped, with I-shaped
lenges, starting with the proximity of a nearby railroad bridge. The diagonal bracing members. The new steel towers exceed the
railroad bridge, which is owned by Norfolk Southern, is a primary required 135 ft of vertical clearance for the 250-ft long and 85-ft
route for the coal industry and is heavily used. With only 25 ft wide lift span, which ended up being one of the widest lift spans
between the Gilmerton Bridge and the railroad bridge—coupled ever designed. Due to the exceptional bridge width, four 15-ft-
with the necessity to create wider foundations for the new bridge— diameter sheaves, each carrying twelve 2¼-in.-diameter wire
setting the foundations, constructing the substructure and demol- ropes, were required on each tower to support the load of the lift
ishing the original bridge would need to be done in a way that did span and counterweights—twice as many as typically necessary.
not disrupt the railroad bridge or its foundations. The team used The front and rear tower columns incorporate jacking brack-
seismic instruments to monitor and identify potential settlement ets that allow the tower, with the full weight of the lift span and
impacts to the railroad bridge foundations during installation of counterweight, to be jacked and shimmed should there be any
the new drilled shafts. Fortunately, it was determined that the differential settlement of the drilled shafts. Finger shims will

➤ The new lift span has a vertical clearance of more than 35 ft in the
closed position, compared to the original bridge’s 11-ft clearance.
➤
A 3D Tekla Structures model of the bridge.
Courtesy of PCL Civil Constructors, Inc. WSP Mountain Enterprises
be placed under the tower bearings to bring the tower back to ing bridge carries four. Both outside lanes will be striped, allowing
vertical and at the correct elevation. them to operate as shoulders before the necessary expansion.
It is typical on a vertical lift bridge for the bottom panel of The float-in of the lift span is scheduled to take place early
the tower to be designed as a portal frame, because bracing can- this year, and the project is expected to finish later in the year.
not be used in order for the roadway to pass through the tower. The new six-lane bridge is 1,908 ft long and 85 ft wide, with the
On the Gilmerton Bridge the bottom panel is located where lift bridge portion measuring 335 ft long. The final lift bridge
the existing bridge passes through the tower and the second will use a total of 5,000 tons of structural steel and 650 tons of
panel is located where the new bridge roadway passes through miscellaneous steel. The new lift span has a vertical clearance of
the tower. Therefore, the two bottom panels of the tower are more than 35 ft in the closed position, compared to the original
designed as portal frames. To relieve the moments in the tower bridge’s 11-ft clearance. Increased clearance will lead to fewer
columns that are realized by wind loading, the front and rear annual lifts, easing the strains placed on this movable bridge
transverse floor beams were designed with full moment con- and facilitating maritime traffic flow by allowing more vessels
nections. In addition, the anchor bolts are post-tensioned in to pass without additional bridge openings. It is predicted that
order to provide a fixed support at the base. the new bridge will see 40% fewer openings each year, easing
Wind loads control many of the bracing members in the traffic and marine congestion alike.
towers. An aerodynamic study of the main span was performed Owner
during the design phase, which revealed that some of the tower Virginia Department of Transportation
bracing members may be susceptible to wind-induced vibra-
Structural Engineer
tions. To solve this problem the flat plates that would normally
Modjeski and Masters, Mechanicsburg, Pa.
make up the flanges of the I-shaped members were replaced
with channels in order to increase their out-of-plane stiffness. General Contractor and Erector
The bridge itself also needed to be designed and built in a PCL Civil Constructors, Inc., Chesapeake, Va.
way that would accommodate increased traffic and expansion of Steel Team
Military Highway. Again, proximity to the adjacent railroad bridge Fabricator
created challenges. A hard bend in the river south of the bridge Banker Steel Co., LLC, Lynchburg, Va. (AISC Member/
eliminated the possibility of expanding in that direction, so Nor- AISC Certified Fabricator/NSBA Member)
folk Southern’s willingness to yield some of its right-of-way was Detailer
the only way the wider bridge could be constructed. Ultimately, WSP Mountain Enterprises, Inc., Sharpsburg, Md.,
the new bridge is designed to carry six travel lanes, while the exist- (AISC Member)

news
INDUSTRY NEWS
As Construction Rebounds, More Skilled
Workers are Needed People and Firms
The construction industry’s slow climb out skilled workers once construction t D a n i e l R . D i M i c c o , c h i e f
of a long and deep recession will continue demand rebounds. He added that executive officer and executive
into next year, according to McGraw-Hill federal tax and spending uncertainties chairman of Nucor Corporation,
Construction’s 2013 forecast. Released at are making it difficult for firms to recently announced that current
the company’s annual Outlook conference encourage people to consider careers Nucor president and COO, John
recently in Washington, D.C., the report in construction. J. Ferriola, will replace him as
predicts construction starts to rise six The shortage comes at a particularly CEO, effective as of January 1.
percent to $483.7 billion. inopportune time, as the construction DiMicco will remain with Nucor
So what does the future hold for industry is projected to have one of the as executive chairman. DiMicco
construction jobs? According to a similar fastest U.S. industry job growths through has served as CEO for more
report issued earlier this month by the this decade and add nearly 1.3 million than 12 years and has led Nucor
Associated General Contractors of America new jobs by 2018. The industry needs through one of its most profitable
(AGC), construction employers added to attract about 185,000 new workers growth periods and an industry-
5,000 jobs between August and September, annually to keep up with the current leading total shareholder return
while the industry’s unemployment employment demand.
of 463.9%. He
rate hit 11.9%. AGC’s officials caution New worker recruitment is crucial
is also last year’s
that construction employment has been to avoid a net shortage of skilled
recipient of
relatively flat for more than a year, as construction workers in the coming
AISC’s Robert
growing demand for residential and some years. One of the challenges is that
P. Stupp Award
commercial projects has been offset by many students today don’t realize there
declining public sector construction activity. are advanced educational and training for Leadership
“Despite the slight uptick in programs and good-paying career Excellence,
construction employment for the past opportunities available in the trades. which gives
month, the industry is a bit smaller than One program hoping to tackle this s p e c i a l
it was one year ago,” said Stephen E. challenge is the Build Your Future recognition to
Sandherr, AGC’s chief executive officer. national educational and recruitment individuals who DiMicco
“It appears that for every rebounding campaign. Organized by the National have provided
market segment, there is another one Center for Construction Education unparalleled
that is shrinking.” and Research (NCCER), the program leadership
Sandherr also noted that more connects youth and displaced workers in the steel
than two million former construction with career opportunities in construction construction
workers have left the industry, either and includes resources for prospective industry. Ferriola
to retire or for other jobs in faster- ironworkers and welders. has stepped
growing sectors. As a result, the To learn more about the Build Your repeatedly
industry will have a hard time finding Future campaign, visit http://byf.org. i n t o ro l e s o f
increasing Ferriola
NASCC re s p o n s i b i l i t y
as part of Nucor’s succession
NASSC to Offer More than 100 Sessions planning. He joined Nucor in
The 2013 NASCC: The Steel very well known, while others may not be 1992 as manager of maintenance
Conference—the premier educational household names but still bring a distinct and engineering at the Jewett,
event for those involved in the design expertise to the program. Speakers range Texas, bar mill, and has served
and construction of fabricated steel from Will Jacobs on “Composite Floor as general manager at three
buildings and bridges—will take place System Design Techniques” to the always- divisions: Vulcraft Texas in
in St. Louis April 17-19, at America’s popular Cliff Schwinger on “50 Tips for Grapeland, the bar mill in
Center Convention Complex. Presented Designing Constructable and Economical Norfolk, Neb., and the sheet
by AISC, the three-day event will offer Steel Buildings” to Jerry Mathison on mill in Crawfordsville, Ind.
more than 100 sessions by top industry “Fixing Weld Quality Issues.” Attendees He was named Executive Vice
leaders, more than 200 exhibitors and can earn up to 24 PDHs (professional President in 2002, then COO of
ample networking opportunities. development hours). Steelmaking Operations in 2007.
Unlike other conferences that issue Registration is now open at www. In January 2011, the Board of
a general call for papers, The Steel aisc.org/nascc. Be sure to register early! Directors appointed him Nucor’s
Conference carefully selects topics of The rate increases $10 every week until
president and COO and elected
interest and then seeks out the top experts the conference opens, when the price
him to the Board.
and presenters. Some of the presenters are becomes $480.

news
CONTINUING EDUCATION
AISC Launches Night School Online Educational Program
Looking for an educational program P.E., Ph.D., emeritus professor at ➤ Session 7: March 11 –
that enhances your professional growth Virginia Polytechnic Institute and State Moment Connections, Part III
and accommodates your busy schedule? University, Blacksburg, Va. Murray ➤ Session 8: March 18 –
AISC offers “Night School,” an evening is a renowned specialist in structural Bracing Connections
curriculum of online courses focused steel research and design. He received Attendees can register for the course
on relevant structural steel design AISC’s prestigious Geerhard Haaijer in two ways: They can register for the
and construction topics. The first Award for Excellence in Education entire eight-session package and view the
course begins January 14, 2013 and in 2010 and an AISC Lifetime webinars live or recorded, one attendee
registration is now open at www.aisc. Achievement Award in 2007. per connection, earning up to 12 PDHs
org/nightschool. The first course consists of the (1.5 PDHs per session attended) and 1
“Night School’s integrated series following 1.5-hour webinar sessions: “EEU” certificate upon passing a series
of courses provides an effective and ➤ Session 1: January 14 – of eight quizzes and a final exam; or, they
economical means to learn the essentials Fundamental Concepts, Part I can sign up for individual webinars to
of designing and building with structural ➤ Session 2: January 28 – view live only, with an unlimited number
steel,” said Nancy Gavlin, S.E., P.E., Fundamental Concepts, Part II of attendees per connection, and earn 1.5
AISC’s director of education. ➤ Session 3: February 4 – PDHs per webinar.
Each course in the curriculum will Shear Connections, Part I For additional information about
consist of eight weekly webinar sessions ➤ Session 4: February 11 – A I S C ’s N i g h t S c h o o l p r o g r a m ,
on Monday evenings beginning at 7 Shear Connections, Part II registration details and pricing options,
p.m. Eastern Time. The first course ➤ Session 5: February 25 – visit www.ai sc.org/ n i gh t sch ool .
will focus on “Fundamentals of Moment Connections, Part I Registration for courses two and three
Connection Design” and will be ➤ Session 6: March 4 – in the curriculum will be offered in the
presented by Thomas M. Murray, Moment Connections, Part II spring and fall of 2013.
BRIDGES
FHWA Memo Promotes Safety by Clarifying Policy on FCMs
The Federal Highway engineers: load path redundancy, in-service inspection.
Administration’s (FHWA) Office structural redundancy and internal The memo is intended to clarify
of Bridge Technology has released member redundancy. For design and the FHWA’s position and promote
a memo to provide clarification of fabrication, the memo states that consistency in the application of
its policy for the classification and only load path redundancy may be appropriate design and inspection
treatment of fracture-critical members considered. For in-service inspection requirements. As a result, owners
(FCMs). Proper and consistent protocol, structural redundancy now have the opportunity to reassess
identification of FCMs is essential demonstrated by refined analysis their inventory of bridges with
to ensuring safety in the design and is now formally recognized and FCMs and optimize their allocation
management of bridges and to satisfy may also be considered. Internal of inspection resources. However,
the requirements of the Code of member redundancy is currently non-load path redundant tension
Federal Regulations. not recognized in the classification members in existing bridges that
There are two primary of FCMs for either design and were not fabricated to meet the
implications related to identifying fabrication or in-service inspection modern FCP, introduced in 1978,
FCMs in bridges: 1) specification (i.e., in order to prevent a scenario are not eligible for classification
of proper materials and testing for in which a cracked plate element in as SRMs and relief from fracture
design and fabrication as per the an important built-up member would critical in-service inspection based on
AASHTO AWS Fracture Control go undetected by routine biennial refined redundancy analysis. High-
Plan (FCP) and 2) application inspection for an extended time performance steel (HPS) and the use
of proper “hands-on” in-service period). of internally redundant detailing both
inspection protocol as per the Finally, this memo introduces have the potential to further improve
National Bridge Inspection Standards a new member classification: a the fracture propagation resistance
(NBIS). system redundant member (SRM), of FCMs and should be implemented
Redundancy is the fundamental which is a non-load path redundant where practical. The implications
quality that dictates whether a member that gains its redundancy by of such measures are the subject of
member will be classified as a FCM, system behavior. The SRM requires ongoing research efforts.
and there are three different types fabrication according to the AWS FCP, You can view the memo at http://
commonly understood by bridge but need not be considered a FCM for www.fhwa.dot.gov/bridge/120620.cfm.

news
PUBLICATIONS
New Seismic Manual Now Available
AISC has published the 2nd Edition assembled a group of industry
Seismic Design Manual. This new experts lead by Rafael Sabelli—the
edition includes hundreds of pages result of which is the 2nd Ed Seismic
of comprehensive design examples, Design Manual,” said Mark Holland,
including connections, updated for Chairman of the AISC Committee on
the 2010 AISC Seismic Provisions; Manuals.
side-by-side LRFD and ASD design “The Seismic Design Manual
methodologies for design examples; provides the industry with a practical
a new chapter on analysis; more resource for application of the
thorough examples on connection design requirements of the 2010
design, including panel zone detailing Seismic Provisions,” said Sabelli,
and brace-to-beam/column connection who is Chairman of the Seismic
design options; extended discussion Subcommittee. “In contrast to
and more economical design the Manual of Steel Construction, it
methodology for collector elements; typically follows a system-design
new examples for buckling-restrained format: Examples are organized
braced frames; and new chapters around the illustration of an
on composite moment frames and entire seismic system, with each
composite braced frames. example illustrating the design of a
Also included are two AISC seismic- representative element. Connection
related standards: the 2010 AISC Seismic design examples are presented for
Provisions for Structural Steel Buildings each system; in some cases alternate
(ANSI/AISC 341-10) and the 2010 connection designs are presented
AISC Prequalified Connections for Special to illustrate some of the range of
and Intermediate Steel Moment Frames for approaches that designers can take. is available for sale in both digital
Seismic Applications—with Supplement Th e S e is mic De s ig n M a n u a l thus and hard copy formats and can be
No. 1 (ANSI/AISC 358-10 and ANSI/ provides the industry with a useful purchased by members for $175 or by
AISC 358s1-11). collection of tools for addressing the nonmembers for $350. Order online at
“To produce a useful companion seismic design of steel structures.” www.aisc.org/bookstore or via phone
to the 2010 Seismic Provisions, AISC The new Seismic Design Manual by calling 800.644.2400.
BOOKS
2012 T.R. Higgins Award Winner Publishes Second Novel
Michel Bruneau, P.E., Ph.D., professor numbers, good wines and the meaning
in the Department of Civil, Structural of life, love and death.
and Environmental Engineering at the Bruneau says of his new novel, “In
University of Buffalo, N.Y., and the contrast to my previous novel, The
recipient of the 2012 AISC T.R. Higgins Emancipating Death of a Boring Engineer
Award, is also an award-winning fiction is an uplifting story with an upbeat
writer. And he’s recently published his ending, because it was written with a
second novel, The Emancipating Death of a pen of a different color.”
Boring Engineer. Print and e-book versions of the
Bruneau’s roots in writing fiction go novel can be ordered from online
back to his childhood, and in 1998 he retailers worldwide (Amazon, Apple’s
published his first book, a collection of iBookstore, Kobo, etc.) as well as
short stories written in French. Then, purchased at brick-and-mortar
in 2010, he published his award- bookstores. For more details on
winning novel, Shaken Allegiances. A Bruneau’s new novel and previous
fictional account of what ensues when a work, visit www.michelbruneau.com/
devastating earthquake strikes Montreal MB-Literature.htm.
Island in the dead of an icy winter, the Bruneau is featured in the
Kafkaesque tale was well-received by Februrary 2012 issue of MSC in our
readers and critics alike. monthly “People to Know” section.
His new novel is a fictional story To learn more about Bruneau, both as
about one engineer’s unconventional writer and engineer, visit his website:
journey, searching for significant www.michelbruneau.com.
news
JOISTS
Joist System Adds New Phase to Overload Scenarios
New Millennium Building Products, LLC, The concept for this new joist design adjacent joists. This is made possible by the
is hoping to bring some flexibility to the came almost by accident, say Heasley ductile behavior of each joist in the system
world of roof joists. and Pote. during an overload. If an individual joist is
The company has created Flex-Joist, “In performing quality assurance loaded in excess of the elastic limit, it will
a roof joist with a “bend but don’t break” testing on one of our joist assemblies, continue to sustain loads up to its plastic
design that provides an extra line of defense we made a rather fortunate discovery load capacity. Any loads added in excess of
against gravity overload conditions (but about the limit state,” says Pote. “While the plastic load capacity of the individual
isn’t designed to address lateral force attempting to make the joist fail by joist will be transferred to adjacent joists,
events, like seismic or high wind). pushing pistons into it as far as possible, while the individual joist continues to
“Most joists, when tested to we saw that it yielded slowly. We were sustain its own plastic load capacity.
destruction, will exceed the safe load- expecting a ‘snap’ but never got it. This The development of Flex-Joist reflects
bearing limit, then buckle,” says Joe Pote, was exciting because most light joist New Millennium’s steady expansion. The
director of research and development systems such as cold-formed channels, company is in the process of opening a
with New Millennium. “Flex-Joist loses light-gage trusses or wood I-beams don’t new deck line in Hope, Ark., and within
shape, but in a different way.” exhibit that level of ductility.” the last year began making its FreeSpan
The new joist introduces time delay When this behavior was noted on more line of castellated and cellular beams in its
into roof overload scenarios. While all joists than one occasion during QA testing, New Continental, Ohio, facility, using members
will eventually buckle if a load sufficiently Millennium decided to explore further and produced at Steel Dynamics, Inc.’s mini-
exceeds its carrying capability, Flex- commissioned a six-year research project. mill in Columbia City, Ind. (SDI is the
Joist is designed to flex before it buckles, The technology is currently being reviewed parent company of New Millennium.)
identifying an overload problem before it by the International Code Council “As we grow, we’ve placed an
gets to a crisis point. Strain gauges can be Evaluation Service (ICC-ES), which is emphasis on identifying new ways to
attached to the primary tension members working with New Millennium to develop design joists into projects,” says Heasley.
to measure ductile tensile yielding, and an appropriate acceptance criteria. Once the “We’re always pushing for new ideas, and
alarm can signal the level of overload; the acceptance criteria have been defined and Flex-Joist was one of them. It generated
alarm system can be set up as a standalone approved, an evaluation report will certify excitement with the engineers, and our
solution or integrated into a building’s that Flex-Joist meets all International customers believe this new product will
existing detection system. Since the system Building Code criteria. be well-received by owners.”
indicates the location and size of the The Flex-Joist manufacturing process
overload problem—whether the design and appearance are identical to traditional
load or the safety load has been reached— joists; the difference is in how the members
building management can determine are sized. Flex-Joist combines smaller
whether to evacuate, provide additional end webs and bottom chord with larger
roof shoring or simply remove the load compression webs and top chord, with
(such as snow) from the roof. weight comparable to a traditional joist.
“Flex-Joist is a natural extension of The design imposes relative strength
New Millennium’s growth strategy,” ratio criteria between the various joist
says Gary Heasley, president of New components and the joist primary tension
Millennium Building Systems. “Whether members (bottom chord and end webs).
it is improving on our Dynamic Joist This establishes a primary ductile tensile
building information modeling services yielding limit state that, in the event of
Informed of the location of an overload,
or expanding our new online joist an overload, causes the joist to gradually management can “see” the estimated sta-
specification tools, the company is growing deform and achieve extreme deflections. tus of the overload and make decisions as
by addressing market needs.” The system also shares loads between to evacuation, roof shoring or load removal.
INDUSTRY NEWS
Overall and Structural Steel Recycling Rates at All-Time High
The recycling rate for the world’s most The recycling rate for structural steel Waste, National Automobile Dealers
recycled material—steel—is at an all- has held steady at an all-time high of Association, Association of Home
time high of 92%, according to an 98% since 2009. Appliance Manufacturers and the Institute
announcement by the Steel Recycling Steel recycling rates are generally of Scrap Recycling Industries.
Institute (SRI) in celebration of America released up to 18 months following the Visit the Steel Recycling Locator at
Recycles Day late last year. end of the calendar year. They’re based on www.recycle-steel.org for additional
More than 85 million tons of steel data released from the American Iron and information. To learn more about
scrap was consumed by steelmaking Steel Institute’s (AISI) Annual Statistical structural steel and sustainability, visit
furnaces in 2011—an increase of nearly Reports, U.S. Geological Survey, EPA AISC’s sustainability page at www.aisc.
10 million net tons from the previous year. Characterization of Municipal Solid org/sustainability.
marketplace Search employment ads online at www.modernsteel.com.
Visit steelTOOLS.org AISC Quality Certification

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RECRUITER IN STRUCTURAL MISCELLANEOUS
OPENINGçINçTHEIRç'REELEYç#OLORADOçOFFICEçFORçANçEXPERIENCEDç STEEL FABRICATION
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TWOçYEARSçESTIMATINGçEXPERIENCEçFORçAçSTEELçFABRICATORçORçOTHERç
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#ONSTRUCTIONç-ANAGEMENTçORçEQUIVALENTçCOMBINATIONçOFçTECHNICALç or state in the United States. We communicate with
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STS STEEL, INC. Vice President Operations

STS Steel, an AISC Certified fabricator focusing on complex
(Structural Steel Fabricator)
buildings is recruiting for two positions: ,OCATEDçINç#ENTRALç7ISCONSINçNEARçPRIMEçOUTDOORçRECREATIONALç
AREASç-ERRILLç)RONçç3TEELçISçAçLEADINGçFABRICATORçOFçSTRUCTURALçSTEELç
Project Manager- Prospective candidates must have an 4HISçPOSITIONçREPORTSçTOçTHEç0RESIDENTçANDçISçRESPONSIBLEçFORçPROJECTç
MANAGEMENTçCONTRACTçADMINISTRATIONçANDçPURCHASINGçFUNCTIONSç
engineering degree (PE preferred) and at least 10 years 3UCCESSFULçAPPLICANTçMUSTçDEMONSTRATEçAçMINIMUMçOFççTOççYEARSçOFç
experience in all phases of project management at an AISC RELEVANTçSENIORçMANAGEMENTçEXPERIENCEçPLUSçSEVERALçYEARSçOFçPROJECTç
MANAGEMENTçEXPERIENCEçANDçHAVEçAççYEARçENGINEERINGçDEGREEç
certified fabricator. 3PECIFICçRESPONSIBILITIESçINCLUDEçREVIEWINGçANDçINTERPRETINGçCUSTOMERç
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complex buildings. PRICINGçAREçDONEçINçAçTIMELYçMANNERç%XCELLENTçCOMPENSATIONçWITHçBONUSç
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TYOUNGWITH MERRILLIRONCOMçORçMAILçYOURçRESUMEçTO
history to glennt@stssteel.com.
$IRECTORçOFç(UMANç2ESOURCESç-ERRILLç)RONçç3TEELç)NC
We are an Equal Opportunity Employer ç!LDERSONç3Tç3CHOFIELDç7)ç
Zalk Josephs Fabricators has an immediate need for a Senior Estimator

Structural & Misc. Steel Fabrication TOçWORKçINçOURç3TOUGHTONç7ISCONSINçFACILITYçSUPPORTINGçAçFASTçPACEDçMANUFACTURINGç
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Fabricating industry for over 20 years. Current positions include: APPLY online at jobs.heicocg.com
s3URMHFW0DQDJHr s*HQHUDO0DQDJHUs4XDOLW\&RQWURO
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s&KLHI'UDIWVPDQ s&KHFNHUV EXPERIENCEDçCOMMANDçOFçCONSTRUCTIONçCOSTçESTIMATINGçSOFTWAREçANDç4AKEOFFç3YSTEMSçALONGç
Please send resume to: WITHçAçTHOROUGHçKNOWLEDGEçANDçUNDERSTANDINGçOFçGENERALçANDçSUBCONTRACTçDOCUMENTSç
Richard Stauffer DRAWINGSçSPECIFICATIONSçCONSTRUCTIONçMEANSçMETHODSçANDçMATERIALS
United Employment Associates, 232 Main Street, Emmaus, PA 18049
phone: (610) 437-5040 fax: (610) 437-9650 :ALKç*OSEPHSç&ABRICATORSçOFFERSçAçCOMPETITIVEçSALARYçANDçAçCOMPREHENSIVEçBENEFITçPACKAGE
e-mail: rstauffer@unitedemployment.com www.unitedemployment.com Zalk Josephs Fabricators is EEO.
To advertise, call 231.228.2274 or e-mail gurthet@modernsteel.com.
people to For Christian Colombo, coming home to
know work for the family business offered bigger
GOING GLOBAL opportunities than he expected.
LIKE MANY EUROPEANS, Christian Colombo speaks Barcelona, working as a consultant for industrial process opera-
more than one language. tions and specializing in discrete simulation.
But he might be considered somewhat of an overachiever After a while, though, Varese—and Ficep—began to beckon,
even by European standards, as he is fluent in not two or and so he returned home with the idea that he’d give the family
three, but six languages: English, Spanish, Portuguese, French, business a try for a year. Before going back to Varese, though,
Catalan and his native Italian. he spent nine months at the company’s subsidiary in France, in
“My mom is Scottish and my father is from Northern Italy, the after-sales and assembly shop. Sixteen years later, he remains
so we always spoke both English and Italian at home,” he says. with Ficep and is raising his family (he has two boys) in the town
He honed his Catalan and Spanish while attending uni- where he grew up. “My kids even go to my old school,” he laughs.
versity in Barcelona, Spain, where he studied industrial engi- Returning to Varese and starting work with Ficep was also
neering, and his French while working in Bordeaux. And he an educational experience for Colombo. In the beginning,
studied Portuguese while working in both Brazil and Portugal. drawing from his industrial engineering background, he worked
Colombo grew up in Varese, Italy, about 35 miles north of primarily with servicing machines. From there, he moved on to
Milan. Located at the foot of the Italian Alps, the town is home sales and business development and credits his evolution and
to Ficep, a manufacturer of steel fabrication equipment, which success at Ficep to his mentors.
Colombo’s great-grandmother started in 1930. The company is “I have direct access to the industry’s most knowledgeable
also heavily invested in software; it was one of the first companies people,” he explains. “I’m very lucky to have had two great men-
to combine software and steel fabrication equipment and created/ tors on different sides of the business. One was our technical
installed its first CNC line in the 1960s. Ficep also owns 100% of director, Giorgio Frigerio, and the other is our sales director,
Steel Projects, a product life-cycle software company for the steel Edoardo Fusi. No one knows the world of steel like him.”
fabrication industry, fully oriented to BIM-based fabrication. In addition to the professional development experience he’s
And the company has stayed in the family throughout its gained, coming back home has, perhaps ironically, also allowed
history. All four of Colombo’s great-grandmother’s children Colombo to see even more of the world. He travels extensively,
worked there, his grandfather became president, his father is looking for new markets, setting up subsidiaries and building
the current chief of the executive committee, his sister is the awareness of the Ficep brand. He enjoys the travel, although he
chief financial officer and Colombo himself is the vice president notes that he rarely has time to get out and truly take advantage of
of operations. Ficep currently employs around 550 worldwide, the surroundings when traveling for work. The U.S. tops his list in
approximately 360 in Italy. terms of business culture. “There is more of an emphasis on return
Over the years Colombo has developed a passion for steel fab- on investment there as opposed to just first cost,” he says.
rication management software. It started during his thesis work When he is able to travel for pleasure, Spain, South America,
at university, for which he presented a project on “Simulation of Australia (where his wife is from), Japan and the U.S. are some of
Steel Fabrication Shops.” But despite his interest in fabrication his favorite destinations. He loves Colorado and Utah for heli-ski-
and his family connection to Ficep, joining the company wasn’t ing, a sport he has always enjoyed—even if nowadays, since his kids
a given for him. “At first, I didn’t want to join the family busi- were born, opportunities are more rare. Brazil and Central America
ness,” he recalls. He was more interested in striking out on his are his favorites for the summer. The weather, surroundings and
own path and getting away from home. So he spent some time in culture are nice—and he can practice his Portuguese.
➤
Colombo, dressed
for business—and the
elements, with his wife,
Catriona, at Mont Blanc.

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Bentley’s new Passport Subscriptions for structural engineers provide access to O Structural Drawings and Details
the full range of structural software (including upgrades) and training documents
and information that most projects require. These options are available as an … all easily coordinated with the
affordable alternative to traditional licensing. Architect and other team members and
their design applications – such as
Contact us to learn more. AutoCAD, Revit, MicroStation® and more.
www.bentley.com/Structural
© 2010 Bentley Systems, Incorporated. Bentley, the “B” Bentley logo, MicroStation, RAM, and STAAD are either registered or unregistered trademarks
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MODERN STEEL CONSTRUCTION

F1852 & F2280

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Figure 1: Weld in Shear Figure 2: Plate Girders

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A fillet weld substitution can often be made for CJP groove

W Figure 3: Weld in Tension

18 MODERN STEEL CONSTRUCTION JANUARY 2013

FreeSpan™ castellated and cellular beams

Table 1: Two-Sided Fillet Weld Size to

tion of the 5∕8t requirement, see the article

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