Parametric Studies of Steel Cold-Formed Section Beam to

Column Moment Connections with Self-Drilling Screws

M. T. HANNA1, MOHAMED M. EL-SAADAWY1, EHAB H.A.H. ALY 1

AHMED MOHAMED MASSOUD 2
1Professor, Structures and Metallic Construction Research Institute, Housing and Building
National Research Center (HBRC), Giza.

2Teaching Assistant, Civil Engineering Department, British University in Egypt (BUE), Cairo.

ABSTRACT
Strength of frames made of steel cold formed sections depends to large extend
on the behavior of beam to column connections. Such connections suffer
different modes of failure that arise because of the small thickness of these
sections. These modes of failure can be summarized as fastener tilting, shear
and bearing. This research introduces proposed numerical model for predicting
the behavior and strength of such connections. The response of two types of
cold-formed section beam to column connections are studied. In the first type
of connection, the beams are connected to the column with a flat gusset plate
(tapered and rectangle) attached to the web of the beam and column sections
with a group of self-drilling screws. In the second type, in addition to the
gusset plate there is a plate connecting the flanges of the beam and column on
the tension and compression sides. Lipped channel sections are considered
with dimensions of 200 mm for the web, 60 mm for the flanges, and 20 mm for
the lip. In the non-linear finite element model, the cold-formed sections are
modeled using shell elements while the self-drilling screws are modeled using
beam elements. The parametric study carried out covering different
parameters such as the thickness of the main elements and the connecting
plates as well as the screw diameter. Results reveal that connections with
tapered gusset plate reaches about 80 % of the beam section flexural capacity.
Finally, the numerical results are compared with that predicted by AISI.

KEYWORDS: Steel Structures, Strength, Cold Formed Sections, Connections,

1. INTRODUCTION:
The use of steel CFS for columns and rafters of short and moderate span portal
frames could be an economic alternative to conventional hot rolled or built up
sections. The design of such frames will depend largely on the nature
(rigid/semi-rigid) of the connection between the rafter and the column. A few
researchers studied the behavior of cold formed sections rigid frames. Colin
Jackson et.al., (2012) demonstrated that CFS frames designed based on the
assumption of rigid and full strength joints to satisfy the gravity load case can
potentially be unsafe by as much as 60%. Moreover, Andrzej M. Wrzesien et.
al., (2012) revel experimentally that the stressed skin effect can significantly
reduce horizontal deflections of CFS frames. Hanna, (2014), developed a
nonlinear finite element model to study the behavior of portal frame made of
single lipped channel CFS.The model showed that the frames failed in the
interactive sectional-overall buckling mode. Moreover, Chung and Lau (1999),
Lim and Nethercot (2004), Elkersh (2010), and Öztürk and Pul (2015) have
shown that the main problem with using CFS in portal frames is the semi-
rigidity of the connections due to bolt hole elongation. This reduces the
moment carrying capacity of the connection. The behaviour of eave and ridge
joints of CFS portal frames was also studied by Dubina et al. (2004) and the
study was extended to an experimental testing of full scale portal frames,
Dubina et al. (2009).

2. CASE STUDY:

Figure 1: Details of the tested connections

Cantilever beam connected to vertical column and subjected to vertical load as

shown in Fig. 1 has been studied. The column height, and beam length equal
to 1m; respectively. The beams are connected to the columns by screw
fastened connections. Two main configurations are examined. In the first
configuration, TG, the beams are joined to the column by a tapered gusset
plate connected to the web of each member. An equal angle with dimensions
40x40x4 mm is welded to the inclined part of the tapered connecting plate to
prevent local buckling in this part. However, in the second configuration, RG,
beams and columns are connected by rectangle gusset plate having width
equal to the height of the column web. Additional plates connecting the tension
and compression flanges of the beam and columns are used. Hex washer head
screw with diameter of 5mm is assumed in the connection. Note that, strength
of the connection determined first using the connecting gusset plate only, then
considering the connecting flange plates in-addition to the gusset plates. The
cross section dimensions of the beam and column sections are similar, and
equal to 200mm, 60mm, 20mm for the web height, flange width, and lip depth;
respectively. Two thicknesses are studied for the channel section, t1 = 1mm,
2mm. However, thickness of the gusset plate are t2 = 1, 2, 3, and 4mm.

3. Nonlinear Finite Element Model:

The connections are modeled numerically by the isoparametric shell element

"Shell 181" that is available in ANSYS finite element package. This element
allows for both the geo-metric and material nonlinear behavior. Figure 2
demonstrate the finite element model developed for the study. The meshing
density is chosen so that the element aspect ratio on average equal to one. In-
addition, BEAM4 element was used to model the screws that connect beam
and column cross sections to the gusset plate. The base conditions for the
column elastic line were treated as fixed condition. Therefore, all joints at the
column base were prevented from translation along X, Y, and Z axis.

Figure 2: Finite Element Model

Due to the presence of lateral restraints at the beam mid length section as well
as beam free end section, joints of the flange web and flange lip juncture of
these sections are prevented from translation along Z-axis (out of plane
direction). In addition joints of the web at the beam end section where loads are
applied are prevented from translation along Z axis to represent the presence
of the vertical stiffener at this section. To prevent the crippling of the web, loads
are distributed along the web joints at the beam free end. ANSYS classical
metal plasticity model was used to include the material non-linearity effects.
This model implements the von-Mises yield surface to define isotropic yielding
and associated plastic flow theory. A perfect plasticity model based on a
simplified bilinear stress-strain curve without strain hardening was assumed.
Newton-Raphson iterative technique along with tangential stiffness matrix was
implemented to solve the set of non-linear equations at each load increment.
The mechanical properties of the CFS used in the specimens were determined
according to the ASTM-A370 specifications. Three specimens were tested, and
results revel that the steel is high strength steel with yield stresses and Young’s
modulus equal to 450MPa, and 210000 MPa; respectively. The connection was
done using a single hex-washer head, # 10 (4.8 mm) diameter screw.
Moreover, to determine the shear strength of the screw, three single shear
specimens were tested. All the three specimens were failed by shear in the
screw at stresses equal to 720 MPa. In this specimen, the connecting plate
thickness were 4mm.

4 Verification of the Numerical Model

Results of the numerical finite element model have been verified by comparing
its results with the experimental results in Hanna et.al. (2014). This study
involves tests of ten specimens, with dimensions similar to those shown in
Fig.(1).

Figure 3: Test Setup

The specimens were fixed in a reaction frame through thick base plate. Two
vertical stiffeners with thickness of 10mm each welded to the specimen in the
section where the load was applied to prevent crippling in this zone. To prevent
the out of plane deformation of the specimens, lateral restraints attached to the
specimens at the tip of the horizontal beam below the load application, and at
the mid span of the cantilever beam. Hence, this configuration allows the
vertical in plane displacement of the specimen beam, and prevent the out of
plane deformations. Test setup is illustrated in Fig. 3.

The in plane deformations of the specimens were measured through linear

variable displacement transducers (LVDT) with accuracy of 0.01 mm. The
measured points were the vertical displacements of the beam end section
below the load application (LVDT 1), as well as the beam mid-length section
(LVDT 2). In addition, the horizontal displacement of the mid-height section of
the column was recorded (LVDT 3).

a) Connection with tapered gusset plate, b) Connection with rectangle gusset

t2 = 3mm plate, t2 = 3mm
Figure 4: Load displacement relationship for connections with tapered and rectangular gusset
plates (comparison between numerical and experimental results)

Figure 4 illustrate the relation between the applied forces and the
corresponding deformations of the two connection configurations. The applied
loads are represented in the normalized ratio of the acting moments, Mu, to the
moment capacity of the cross section, Ms. The acting moments, Mu, are
calculated as the result of the multiplication of the applied load, P, and distance
between the load and the center of the screws that connect the gusset with the
web of the beam section. However, the section flexural capacity, Ms, is
calculated using the direct strength method, DSM, in which the flexural strength
will be the minimum of the local, distortional, and the overall buckling strength.
This method requires the calculation of the elastic critical local and distortional
buckling stresses, these values have been determined using CUFSM computer
program.
It is obvious that the relations are almost linear at the early stages of loading,
then near failure the structural response become nonlinear and the stiffness
decreases continuously. In addition, the numerical finite element results are
plotted in the same figure for point 1. It is clear that there is good correlation
between numerical and experimental results.
5 Load Displacements Relationship and Failure Modes :

Figure 5: Load-Displacements relationship for connections with section thickness, t 1 = 1mm

In this section, the structural response of the studied connections was

evaluated by examining their load deformation history. The normalized ratio of
the acting moment, M, to the moment capacity of the cross section, Ms, are
plotted as function of the vertical displacements of the beam free end. These
relations are depicted in Fig. 5 for connections with section thickness, t 1 =1mm,
and connecting gusset plate thickness, t2 = 1, 2mm.

In connections with tapered gusset plate, Failure happened in the cross

section, therefore the capacity reaches the moment capacity of the cross
section. Also, increasing the thickness of the gusset plate does not affecting the
stiffens of the connection. However, in connection with rectangle gusset plate,
the connection failed at 60% of the section flexural capacity when thickness of
the gusset plate, t2 = 1mm. This capacity increases significantly by in-creasing
the thickness of gusset plate, t2, and also adding the plates that connect
tension and compression flange.

Connections with section thickness, t1 = 2mm, failed when zones around the
screws reaches the yield stresses. Similar to that observed in the experimental
results Maged, et al (2014) where failure happened by tilting in the screw and
bearing in the beam web. Consequently, all connections failed at strength lower
than that of the section, Ms. The relation between the normalized ratio, M/Ms,
and the vertical displacements of the cantilever end for connections with
section thickness, t1 =2mm, are plotted in Fig. 6 for connection with tapered
gusset plate, and in Fig. 7 for connection with rectangle gusset plate.
 Figure 6: Load-Displacements relationship for connections with Tapered Gusset Plate,
t2 = 2m

Results reflect that, for both types of connections, strength increases by

increasing thickness of gusset plate. Connections with tapered gusset plate the
ratio Mu/Ms ranges from 0.6 to 0.8, while for connections with rectangle gusset
plate this ratio rages from 0.2 to 0.8. Moreover, there are significant increase in
the connection stiffens when the thickness of gusset plate, t2, become larger
than that of the section thickness, t1, especially for connection with tapered
gusset plate. To add on, adding plates connecting tension and compression
flanges improve significantly connections with rectangle gusset plate.

Figure 7: Load-Displacements relationship for connections with Rectangle Gusset Plate,

t2 = 2mm
 Figure 8: Finite element model

6 Comparison with Design Codes

For the sake of comparison, Strength of connections have been determined

using E.4 provision in AISI-2017. Shear screw connections can fail in several
modes like screw shear, tilting, pull-out of the screw, bearing of the joint
material or edge tearing. However, this provisions focused on bearing and
tilting failure modes which are the failure modes observed in the studied cases.

Pns
r1 Pns d
MTG MU = M TG + M FP
MFP P r2
Pns MTG = nsr
1

MFP = 2 Pns d

Figure 9: Calculations of connection strength according to AISI-2016

The nominal shear strength of the screw, Pns, are determined first, then used to
calculate the connection moment strength, Mu, as the summation of the
torsional moment for the group of screws connecting beam web to the gusset
plate, MTG, and the moment developed by screws connecting beam flanges to
the additional plates, MFP, Fig. 9.

The second term, MFP, are neglected in the connections that have no additional
plates, and connections with tapered gusset plates where these additional
plates have no significant contribution to the connection strength as depicted in
the results. The moment strength according to FEM, and AISI-2017 are
designated as MU-FEM, MU-AISI; respectively. Note, the partial safety factors, c,
are not included when calculating the design moments. Results of this
comparison are listed in Table 1,

Table 1. Comparison between Finite Element and AISI-2016 Results.

Connection t1 t2 MU-FEM MU-AISI MU-AISI /
(mm) (mm) (KN.cm) (KN.cm) MU-FEM
TG21 2 1 6.88 6.22 0.9
TG22 2 2 10.3 12.4 1.2
TG23 2 3 13.7 12.4 0.9
TG24 2 4 14.5 12.4 0.85
RG21 2 1 5.58 2.45 0.44
RG22 2 2 7.4 4.9 0.66
RG23 2 3 7.4 4.9 0.66
RG24 2 4 11.5 4.9 0.43
RGP21 2 1 5.76 4.7 0.82
RGP22 2 2 9.1 9.5 1
RGP23 2 3 10.06 9.5 0.94
RGP24 2 4 15.3 9.5 0.62

Comparison revels that, generally, AISI-2017 code is very conservative

especially in the connections with rectangle gusset plates only. However, for
connections with tapered gusset plates, the strengths predicted by AISI code
are close to that of the finite element results. Moreover, for connections with
gusset plate thickness greater than 1 mm, moment capacity predicted by AISI
code are almost constant and are not affected by increasing the gusset plate
thickness. On the other hand, the finite element results increase by increasing
the gusset plate thickness.
7 CONCLUSIONS:
In this study experimental and numerical investigation are carried out for the
behavior of beam to column single lipped channel cold formed section screw
fastened connections subjected to major axis bending moments. Group of
connections were done using tapered gusset plates, while in the other group
the tapered gusset plate are replaced by rectangle one. Results revel that the
numerical and experimental ultimate loads as well as failure modes are
comparable. Moreover, specimens with tapered gusset plate reaches about
80% of the beam section flexural capacity. However, for specimens with
rectangle gusset plate this ratio become 60 %. Further, the longitudinal strains
are transformed from the beam section to the columns section through the
tapered as well as the rectangular gusset plates. For the two types of
connections changing thickness of the gusset plate does not significantly
change the ultimate capacity, but it reduces the displacements at the ultimate
loads. Also, using plates connecting tension and compression flanges improve
the performance of the connections with rectangular web.

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