Segmenting

Segmented members are fabricated by splicing several

straight members together, typically using miter joints at
discrete locations to approximate the geometry of a curved
member. This curving method is rarely used due to the segmented
appearance, the high fabrication cost, and the local
stress concentrations that are inevitable where the member
changes directions at the miter joints.
Cutting to Curve
Built-up shapes can be fabricated of two or more elements
that are either cut to the final shape or bent to the final shape
before assembly. Prior to assembly, cross-sectional elements
requiring strong-axis curvature are cut to shape, and elements
that are curved in the weak direction are bent to shape.
For horizontally curved members, the flanges are cut to the
curved shape and fitted to the web, which has been bent to
the curved shape. For vertically curved members, the flanges
are bent and the web is cut to the required radii. Cambered
plate girders can usually be fabricated without pre-bending
the flanges because bending under the self-weight of the
flange plate is often adequate to bring the flange-to-web
interfaces into contact.
This method is often used to camber large plate girders
that exceed the capacity of available bending machines; however,
the primary advantage may be the out-of-plane dimensional
stability of slender webs which can distort when other
curving methods are used. When very small-radius bends are
required, cutting to curve may be the best option; however, a
considerable amount of scrap is often generated. Other disadvantages
include the requirement of special jigs for fitting
the member and ensuring the proper curvature and the
need to recheck the curvature after welding because the weld
shrinkage distortion can alter the as-fit curvature (Thatcher,
1967).
Bending
Several methods are available for bending steel members:
pyramid roll bending, incremental step bending, induction
bending, rotary draw bending, and other processes. Some
methods are more common in the steel construction industry,
while others are used more in the forming of parts for
automobile, piping and other industries. Members of almost
any shape can be curved by bending, including rolled open
shapes, welded built-up shapes, and closed shapes.
Cold bending, where the member is bent at room temperature,
is usually more economical than hot bending or induction
bending; however, there are cases where the required
geometry cannot be formed by cold bending. The primary
advantage of hot bending is that the material yield strength
is lower compared to the room temperature value, requiring
smaller forces to be exerted by the bending machine.
Each bending method has advantages and disadvantages,
and each bender/roller company has developed unique bending
methods and often use one-of-a-kind, patented machines.
Developing proper bending techniques that ensure accurate
and consistent dimensions requires significant judgment and
experience. Due to differences in equipment, technique and
personnel, the capabilities of each bender/roller vary significantly.
For example, one shop may have the capability
to bend heavy members the hard way, another shop may