Cold-Formed Steel Structures Around The World: A Review of Recent Advances in Applications, Analysis and Design
Cold-Formed Steel Structures Around The World: A Review of Recent Advances in Applications, Analysis and Design
Schafer
DOI: 10.1002/stco.201110019
2.1 Framing
For many engineers, their first reaction to CFS framing is that it can only be a low-rise solution. Views of lowrise structures framed from CFS are superficially similar to timber construction, and thus the general presumption is that CFS framing will only be competitive in countries with timber framing traditions, and then only for one, or maybe two, story structures. Thus, the increasingly common use of mid-rise CFS framing in the United States, even in seismically active areas, can be a surprise for some. Fig. 1 provides an example of a six story mid-rise CFS structure constructed in the United States [8]. Many mid-rise CFS structures utilize ledger framing
1 Introduction
Today, cold-formed steel (CFS) structures enjoy widespread use in many countries and design specifications, e.g., [1] and [2] are well established, even if they are ever changing! Extensive reviews of the CFS literature are available [3], [4] and more targeted research reviews also exist: [5], [6] and Chapter 13 of [7]. However, even in the last five years significant progress has been made, particularly in analysis and design. Further, the state of the art in cold-formed steel applications, both structures and members, has not been detailed. This brief review paper provides an overview of recent advances in CFS structural applications, members, analysis, member design, system design, and seismic design. The selected
Selected and reviewed by the Scientific Commitee of the 6th European Conference on Steel and Composite Structures, 31 August to 2 September 2011, Budapest, Hungary
topics and discussions have two strong biases that must be recognized from the outset: (1) many of the applications are focused on North America, where the author resides and has the greatest interaction with the practice, and (2) the selected topics largely reflect areas where the author has been involved in one form or another (through direct research, committee work in the development of codes and specifications, or international collaborations). Given these biases, it is without a doubt that, novel applications and important research will be missed, for these shortcomings the fault is that of the author alone, and apologies are extended.
2 Structures
The three primary areas of load-bearing CFS applications are: framing, metal buildings, and racks. Each of these areas is briefly reviewed here with an emphasis on recent advances in applications, and in targeted research on these applications.
Ernst & Sohn Verlag fr Architektur und technische Wissenschaften GmbH & Co. KG, Berlin Steel Construction 4 (2011), No. 3
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are typically designed as an entire system. In some cases panelized CFS framing construction is extended to metal buildings (e.g. Nunconsteel in the United States provides such a system). However, even in the last five years, interesting efforts exist: in Australia with frames relying only on stiffened sheeting [10], in Hungary [11] and Poland [12] with frames using utilizing novel built-up sections and connections, and in the UK with a long term research effort employing cassette walls for the structure [13].
2.3 Racks
CFS storage racks are remarkably efficient structures that have long used novel cross-sections and connections in their design. Although the members and connections have not changed significantly in the last five years understanding of behaviour and translating that understanding into improved designs has been very active. Significant new testing has been conducted on uprights [14], [15] upright to shelf beam connections [16], [17] and base plates [18]. Testing protocols have advanced and become formalized [19], as well as analysis protocols particularly in the use of second-order analysis [20], [21]. Contemporary concerns such as impact forces [22], [23] and progressive collapse [24] have also seen recent study. Standards organizations supporting the CFS rack industry are active, and in many instances quite progressive due to the complicated nature of rack structural performance. For example, the forthcoming Australian rack standard (AS 4084) will provide complete codified guidance on performing geometric and material nonlinear analysis on the imperfect structure (GMNIA), similar in spirit to Eurocode for shell structures.
as opposed to platform framing. In ledger framing the building is constructed story-by-story, but the floors are hung from the studs using rim track, see Fig. 2. Mid-rise CFS construction requires technical expertise on the part of the engineer/designer, and the development and support of applicable code provisions. An entire family of CFS standards specifically for framing have been developed in North America (e.g., [9]) and form the basis for the adoption of these systems in building codes. In addition, many companies working in this market are panelizers, and thus perform significant construction offsite. In North America, the pre-engineered truss industry provides a model for this form of construction; and indeed pre-engineered metal trusses are used extensively in North America today.
3 Members
CFS members in common use in North America include the C (with and without lips), the Z (typically with sloping lips), and a variety of generally hat-shaped deck sections. Specialty cross-sections are also used in the CFS rack industry for both uprights and beams. All of these conventional sections have been in regular use for numerous years. In the past
five years cross-section innovation has begun to take greater advantage of manufacturing technology, and begun to seriously push the boundaries of available design methods. North America has long neglected cross-section innovation, preferring a more commodity-based approach, but this is changing as evidenced by Fig. 3. For example sections are now available in North America (Fig. 3a), though the longspan deck sections in use in many parts of Europe are still yet to be utilized here. The most significant crosssection innovations occurring in North America are associated with proprietary, pre-engineered, solutions. In particular, several truss companies in North America use novel sections with narrow webs, wide flanges, intermediate stiffeners, and return lips as chords in their trusses (Fig. 3b and c). The CFS framing industry has also introduced a variety of novel variations on typical C sections for use as studs, headers, jambs, distribution members, and even bracing. One of the most popular versions of these advanced sections uses stiffened holes in the webs of joists to provide room for services, the evolution of this idea is the creation of a hybrid between the bar joist and the CFS floor joist as exemplified by products such as that of Fig. 3d. For non load-bearing applications sections cold-formed from knurled steel have been developed (Fig. 3e) with the primary advantages coming from improved fire/thermal and acoustic performance, Any discussion of new CFS members would be remiss if it did not include the highly researched: LiteSteel Beam (Fig. 3f). By using closed tubular sections for the flanges of a channel this section is able to provide capacities more typically associated with hot-rolled, than cold-formed steel [25], [26]. However, as the researchers have shown high torsional rigidity concentrated in the flanges, while overall extremely beneficial, does lead to unique behaviour and interactions most-notably lateral-distortional [27]. The Australian CFS Specification provides the most up to date treatment of this unique CFS building product. A number of even more unique CFS cross-sections, that stretch the boundaries of what it means to rollform a section, and combine multiple
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(b)
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Fig. 3. Example of recently developed CFS members in use in North America; (a) TSNSigmaStud, (b) TrusSteel Dyna Truss Chord, (c) Nuconsteel NUTRUSS Chord, (d) SteelForm DeltaStud, (e) ClarkDietrich UltraSteel Stud, (f) LST Lite Steel Beam
manufacturing technologies, exist in various stages of product development. The desire to achieve even lighter, greener structures, and minimize material cost and impact will aid in bringing many of these ideas to market. The challenge remains for researchers, design methods, and design specifications/codes to keep up with these innovations and be vehicles for progress instead of impediments to new technology in CFS applications.
4 Analysis
Analysis of CFS members presents a unique challenge in civil engineering. At one end of the spectrum GMNIA analysis with shell finite elements provides a compelling multi-purpose simulation tool, even if sensitivity and knowledge of the required inputs can be a challenge [28], [29]. While at the other end of the spectrum typical CFS practice either uses no formal computational structural analysis, or when analysis is employed it is linear elastic with frame elements. Frame elements in typical use do not properly include torsional-flexural coupling in unsymmetric members (such as the CFS C-section), and are completely incapable of including cross-section deformations associated with local or distortional buckling. However, currently frame elements are the only solution that is computationally efficient enough to be used on large-scale civil systems for linear and nonlinear analysis, and under the multitude of necessary load cases. Given this situation CFS analysis has always been a vibrant area for
alternatives from conventional civil engineering analysis. Most notably, the finite strip method (particularly on the member level) has been demonstrated to provide a useful compromise between the power of shell finite elements and the needed efficiency of frame finite elements. In fact, the signature curve generated by a stability member analysis using the classical finite strip method [30] provides the organizing principles that much of the design advances of the last thirty years have been based upon. Recent advances in the finite strip method include the continuing development of open source tools [31], extensions to
general boundary conditions for stability analysis [32], the constrained Finite Strip Method (cFSM) which enables modal decomposition and identification [33] to [36], and the development of finite strip-based modal identification tools for general purpose shell finite element analysis [37]. Efforts are underway to enrich frame finite elements with cross-section finite strip analysis; however, more elegant approaches with Generalized Beam Theory (GBT) exist. GBT, which is predicated on an enriched Vlasov beam theory, is ideally suited for the needs of frame element-based civil engineering system
Fig. 4. Comparison of member stability analysis by GBT and cFSM, adapted from [38]
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analysis. In theory, if only classical modes are contained in the model then traditional framework finite element results will be obtained. However, as cross-section deformation modes are included: local-plate, distortional, shear, transverse extension, then the frame element takes on the mechanics of a typical shell finite element but with the advantage that the deformation fields are separated and known a priori in the analysis. The cFSM approach was derived based on the mechanical assumptions underlying GBT and as [38] and Fig. 4 show, they provide similar solutions. Recent GBT research demonstrates that geometric and material nonlinear analysis on the member level [39] and GBT-based frame elements for system analysis even including local loads and load height effects are possible [40], [41]. Further GBT, and its ability to identify and isolate the participation of a given deformation mode, has been shown to provide new insights on difficult problems in CFS behaviour [42]. Tools even exist for engineers to experiment with GBT analysis on their own [43]. Nearly all of the work for a fully nonlinear GBT frame element appropriate for CFS structures is in place, and the potential impact of this advancement on the analysis of CFS systems cannot be overstated. With either shell finite element analysis or advanced models based on cFSM or GBT, GMNIA based procedures for CFS are possible. However, before they can enjoy widespread use,
it must be recognized that CFS members have significant sensitivity to geometric imperfections, residual stresses and strains, and modelling parameters [28]. Thus, characterization of the inputs to GMNIA analysis remains an important area of research for CFS members and structures. Progress has been made in statistical characterizations of manufacturing imperfections [45], and in residual stresses and strains from the roll-forming process [46], [47], but significant work remains.
5 Design: member
Member design for CFS is complicated by the existence of local, distortional, and global buckling modes. In addition, the fundamental modes may interact with one another as well as with material yielding. Of course member-system interaction through secondary bracing, or through the primary framing (e.g., second-order effects) also must be considered. The primary design philosophy used in codes and standards for CFS member design is the Effective Width Method, e.g., in [1], [2]; however the Direct Strength Method (DSM) as provided in Appendix 1 of [1] and fully reviewed in [48] has been developed as an alternative approach. DSM has been formally adopted in many countries for CFS design, e.g.: Australia, the United States, Canada, Mexico, and Brazil. Under Eurocode the Direct Strength Method is best understood as falling in the family of general methods (e.g., see [49] for more on general methods). DSM combines linear eigenvalue analysis (i.e., elastic buckling analysis) with material nonlinear analysis to provide a prediction of the strength. From the users standpoint DSM is more formalized/simplified than the Eurocode general methods in that the strength curves to connect linear eigenvalue analysis with material nonlinear analysis in local, distortional, and global buckling have already been established. Regardless, the philosophy and implementation are in essence the same. Significant new work in the development of DSM has been completed in the last five years. CFS members commonly include holes, but until recently DSM provided no guidance on this situation. Recent work provides tools for under-
GBT Pcr = 48.46 kN GBT frame element DOF: order 100 ANSYS Pcr = 48.03 kN Shell elements DOF: order 10,000
Fig. 5. GBT frame stability and comparison with shell elements, adapted from [44]
standing and modelling the impact of holes on cross-section buckling modes from plates [50] to members [51], see Fig. 6a. Using a combination of new testing [52] and nonlinear finite element collapse analysis correct implementation of the DSM strength curves was also established; this included the use of net section yielding properties and modifications in the inelastic buckling regime for distortional buckling failures [53], [54], to handle transitions like Fig. 6b. This work is currently under ballot for North American CFS design in [1]. Additional progress has been made on a general/DSM method for shear, and shear and bending interaction. Current design provisions essentially only include shear buckling of the webs, and further presume the webs are flat. The newly proposed methods treat shear buckling as a cross-section buckling mode, similar to compression and bending. The impact of the flange on the solution is explicitly considered, as is the impact of other cross-section details such as rolled-in longitudinal stiffeners [55] to [59]. Research continues to determine the proper analogs to local, distortional, and global buckling for shear; meanwhile proposals are under ballot in North America to integrate the improvements already established [60], [61]. In North America fire analysis of CFS is typically completed experimentally on a given (wall or ceiling) assemblage. However, recent work has shown that available DSM expressions can properly predict the reduced strength of members, and even the switching between controlling buckling modes that occurs due to the temperature dependence of elastic buckling and yielding properties [62] to [65]. Integration of these degraded strengths with a true fire analysis is not yet completed, but is certainly on the horizon. As implemented DSM covers beams and columns explicitly, but relies on interaction equations for beamcolumns. Such an approach is not in the spirit of the general methods or of DSM. Instead the cross-section stability: local, distortional, and global should be assessed under the actual applied loads (at least axial plus bending). Section yielding may also be determined under the actual applied
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(b)
Fig. 6. Modeling and design method development for members with holes, adapted from [54], (a) stability analysis with and without holes, (b) transition from distortional buckling to net section failure as hole size increases
loads. Preliminary work [66] demonstrates that extension of DSM in this manner is possible and desirable in many cases provides significant improvements over current design. One shortcoming of DSM, as implemented, is that the buckling mode interactions that are considered are not cross-section dependent. So, for example a lipped channel with intermediate stiffeners in the flange and web has been experimentally shown to have meaningful distortional-global interactions [67], [68], but DSM only includes local-global interaction and assumes distortional buckling modes do not interact with other modes. This assumption was validated for lipped channels [7], but intense interest ex-
ists in explaining and determining the best way to handle these interactions in the future [42], [69] to [72]. One approach may be to evolve DSM further, recently the author explored the use of the strain energy distribution of the cross-section buckling modes as a means to determine an effective thickness in the cross-section [73]. In addition, work towards true nonlinear analysis (GMNIA analysis in Eurocode parlance) may be the best final direction for CFS member design. Indeed, recent efforts lead by Rasmussens research [17], [18], [22], [23] and codified in the Australian CFS rack standards (AS 4084) provide a pioneering example of such an approach in CFS member design.
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Fig. 7. Performance of CFS sheathed walls in compression, adapted from [75], (a) P- response of full scale walls in compression, (b) OSB-Bare Failure (flex-tors), (c) OSB-Gyp failure (local), (d) OSB-OSB failure (local)
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the key step for integrating the system behaviour into the DSM method of design, namely, if the stud-to-sheathing fastener stiffness and sheathing diaphragm stiffness are tested or calculated these may be integrated into the cross-section stability analysis (as spring restraints) and thus provide member local, distortional, and global buckling loads that reflect the systemlevel bracing behaviour. This was completed and the conventional DSM expressions used for strength prediction are shown to agree well with tests [74] when the elastic buckling loads were suitably updated to include the system-level bracing. As another example of the evolution of system-level design the DSM methodology was also extended to the design of continuous roof purlins, where the entire multi-span beam and all its possible limit states are treated together for the stability analysis and for the strength prediction, instead of reducing down to the cross-section as in traditional design [78]. System-level analysis methods like these hold particular promise for predicting efficiencies in repetitively framed structures such as those commonly used in CFS framing.
7 Design: seismic
Seismic engineering and design is an area of high research activity throughout structural engineering, and CFS is no different. In North America CFS seismic design is not codified in one standard, forcing engineers to work across multiple standards to achieve their designs. Nonlinear time history analysis, which forms the computational engine for modern seismic design philosophies such as performance-based design, must be grossly simplified for CFS structures due to limitations in modelling (as discussed in Section 4). System-level seismic design of CFS is still in its infancy, currently the governing philosophy is to drive all energy dissipation into pre-identified discrete elements, such as prescriptively designed shearwalls. The primary lateral force resisting system in CFS framing is the shearwall, and testing on this system continues worldwide, with recent (in the last five years) contributions from Italy on wood sheathed walls [79],
from Canada on strap-braced walls [80], from Canada and the United States on steel sheet shearwalls [81], [82], from China on corrugated steel sheet shearwalls [83], and from the United States on wood sheathed walls with pins [84] and adhesives [85]. Research on the translation of CFS shearwall test data into seismic design also continues worldwide [86] to [89]. In North America, all CFS shearwall design criteria have recently been brought together into a single design specification [9]. In the broader seismic engineering community significant research effort has been expended in developing systems that concentrate inelastic energy dissipation into replaceable fuse elements. This concept has been recently extended to CFS shearwalls by Japanese researchers with a remarkably innovative system that integrates a ductile fuse into the holddown [90]. As demonstrated experimentally, the resulting shearwall system has stable loops in cyclic testing, with little if any degradation. Analytical modelling indicates an energy dissipating performance that is far and above what is available today in CFS shearwalls. As an alternative to shearwalls a novel seismic system using hot-rolled steel tube columns bolted to CFS beams was successfully developed and approved for use in seismic design in the United States [91], [92]. The systems original use was for mezzanine structures in industrial buildings, but in the United States the system has spawned commercial framing products for the residential market (e.g., BlueSky FrameTM). Current CFS seismic research projects that the author is aware of as being underway, but not yet represented fully in the literature, include cyclic tests on CFS members, shake table tests on multi-story shear walls, diaphragms, and even full-scale buildings. The authors recent work in CFS seismic design is summarized in [93]; clearly, much work remains.
important structural domains and continues to expand into new areas, such as mid-rise construction. Coldformed steel members have definitively evolved to include numerous optimized shapes beyond the conventional cross-sections. Analysis advances in the Finite Strip Method and Generalized Beam Theory provide unique capabilities for modal decomposition and identification of thin-walled members, but important work still remains to provide efficient tools that can be readily integrated with conventional structural analysis. Member design has advanced significantly due to the flexibility afforded by the direct integration of computational cross-section stability in the Direct Strength Method. New tools for system design are aiming to duplicate that success for cold-formed steel systems. Finally, a rich array of work is underway in coldformed steel seismic design. Taken in total recent advances in cold-formed steel structures indicate that significant potential continues to exist for this versatile thin-walled building material.
Acknowledgments
This paper came about through discussions with Laszlo Dunai, and I would like to thank him for the opportunity to provide this review. I would also like to thank the members and staff of the American Iron and Steel Institute Committee on Specifications and Committee on Framing Standards, many of the big picture viewpoints shared in this review were developed though my participation in those committees. I would also like to thank Dinar Camotim who provided me with the insight and parallels between the Direct Strength Method and Eurocode general methods; however any misinterpretations of Eurocode still remain my own. I would also like to thank the numerous collaborators and students who informed the research that is so briefly summarized here. Finally, I would again like to apologize for those in the cold-formed steel research community who are not detailed herein; due to the topics I have chosen, a lack of space, and most importantly my own ignorance, I am sure I have missed important contributions, for this I am truly sorry.
8 Conclusions
This paper provides a review of the state-of-the-art in cold-formed steel structural applications, members, analysis, and design. Cold-formed steel enjoys widespread use in a number of
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tures, Vol. 32, No. 6, pp. 15221529, 2010. [83] Li, Y. et al.: Shear behaviors of lightgauge composite walls under monotonic and cyclic loading, 2010. [84] Serrette, R., Nolan, D. P.: Reversed cyclic performance of shear walls with wood panels attached to cold-formed steel with pins. Journal of Structural Engineering, Vol. 135, No. 8, pp. 959967, 2009. [85] Serrette, R. et al.: Cold-formed steel frame shear walls utilizing structural adhesives. Journal of Structural Engineering, Vol. 132, No. 4, pp. 591599, 2006. [86] Serrette, R.: Seismic design strength of cold-formed steel-framed shear walls. Journal of Structural Engineering, Vol. 136, No. 9, pp. 11231130, 2010. [87] Dubina, D.: Behavior and performance of cold-formed steel-framed houses under seismic action. Journal of
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nal of Structural Engineering, Vol. 136, No. 8, pp. 953960, 2010. [93] Schafer, B. W., CFS-NEES: Advancing Cold-Formed Steel Earthquake Engineering. [cited 2011 June 21]; CFSNEES Project Page]. Available from: http://www.ce.jhu.edu/cfsnees/. 2011. Keywords: cold-formed steel; constrained Finite Strip Method; Direct Strength Method; review
Author:
Prof. Benjamin W. Schafer Johns Hopkins University, Dept. of Civil Engineering, USA schafer@jhu.edu
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