Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By:...

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Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University of Balamand, Lebanon www.balamand.edu.lb World Congress and Exhibition on Steel Structure, Dubai November 15 - 17, 2015

Transcript of Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By:...

Page 1: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges

By: Antoine N. Gergess, PhD, PE, F.ASCEProfessor, University of Balamand, Lebanon

www.balamand.edu.lb

World Congress and Exhibition on Steel Structure, Dubai

November 15 - 17, 2015

Page 2: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Horizontal Curves

Page 3: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Heat Curving

Continuous heat V heat (R > 300m)

Page 4: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Drawbacks

Procedure is complex Numerical computations have to account for material and

geometric non-linearity Temperature distribution along the flange width are not

exactly uniform Analysis has to account for the girder behavior during

heating and during cooling (natural cooling). During heating, heated zone elongates to form a larger

outer radius During cooling, the heated portion shortens to form a

reverse curvature

Page 5: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

0 135 270 405 540 675Temperature, C

0.2

0.4

0.6

0.8

1.0R

ati

o

Yield StressModulus of Elasticity

Material Properties

E/E

Fy/Fy

Page 6: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Cut-Curving

Flange

Scrap

Flange

Flange

Flange

WebPressure Applied During Fit-up

Fitting Jig

Flange

Page 7: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Too costly because of excessive waste

Too much scrap for sharp curvatures

Used for mild curvatures (R 300m)

Fit-up operation too complicated

Draw-Backs

Page 8: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

3-ROLLERS BENDING

Mainly used in buildings

Fit-up difficult for larger

size bridge girders

Perfect curve

Page 9: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

118

OTHER IDEAS?

Page 10: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

COLD BENDING

Page 11: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

χL3

btFP

2ffy

= a’/L; = x2/a’

Analysis

yfp F

E0.255bL (lateral bracing limit)

y2

fflange Ft75.3P (limit state of flange local buckling)

Page 12: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Stress-strain curve

Page 13: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

0

0.025

0.05

0.075

0.1

0.125

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

re

s(m

)

Distance x (m)

a' = 0.333L a' = 0.25L Circular a' = 0.1L

Idealization

a

Page 14: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.
Page 15: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Residual Stresses Flexural stiffness is reduced by the presence of

cold bending residual stresses.

ROLLED BEAMS WELDED SHAPES

Page 16: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Influence of Residual Stress on Average Stress-

Strain Curve

Page 17: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Tampa Steel ConceptApply smaller loads at uniform intervals to achieve desired curvature

Page 18: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Idealization of Curve

8R

2

max

L

1 2 3 4 5 7 6

2

3 5

6

max = 4

x

22max xRRδδ

Page 19: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

SS

Li

Load P

Page 20: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

OFFSETS ii, ij

26 3646 56 66

55

1 2 3 4 5 6

22

23 33

24 34 44

45

Load: 4

25 35

7

Load: 3

Load: 2

Load: 5

Load: 6

max

Page 21: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Test Girder

Page 22: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Loading Details

Page 23: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Test Girder after Curving

Page 24: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Idealized Stress-Strain Curve

STRAIN

ST

RE

SS

y

Fy

max 10 y

1.5 yresidual 8.5 y

R = 255 m

1.89y

r 0.39y

r 0.77y

R = 115 m

2.27y

Page 25: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

FORMULATION

PARAMETERS:

Load Frame Spacing S

Bending Loads Ptf, Pbf

Deflection within span S

Segment Length Li

Number of Segments n

Offsets

S

Ptf

Li

Page 26: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

LOAD FRAME SPACING (S)

Based on lateral bracing limit:

S = 14.4c for Grade 250 steel

S = 12.2c for Grade 345 steel

For unsymmetrical sections use ctf

Load P

Comp. side

Flange

S = Lp

Fla

ng

e W

idth

2c

yt F

E1.76rS

Page 27: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

BENDING LOADS (Ptf, Pbf)

From simple beam plastic load analysis:

S

ct4FP

2fy

Mp = Fytfc2

Fytfc

4

PSM p

P

S

c

c

Fytfc

Constant

Top Flange: Ptf based on ttf, ctf

Bot. Flange: Pbf based on tbf, cbf

Page 28: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

DEFLECTION

216Ec

S13FΔ

2y

Load P

S

Plastic Hinge

tf

bf

ctf cbf

Ptf Pbf

tf bf

set = cte = tf

bf ???

P Pbf

(on-going research)

Set P = Pbf,

Load in cycles

m=tf/bf

Page 29: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

SEGMENT LENGTH Li

S

4RΔLi

2Li

Radius R

S

[m-1][m+1]

[m]

S

L2 iConstant

tf

8R

l2

2Li2Li/S

Page 30: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

NUMBER OF SEGMENTS

iL

S-Ln

n

S)-(LLi

Round-down to the nearest even integer

nLi

1 2 3 4 5 n+1 n

Length L

a a

Line of symmetry

adjust

Page 31: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.
Page 32: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Challenges ?

Cracking, Fracture

Flange Upsets

Dimples

Web Crippling

Page 33: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

- Effects on Steel mainly fracture

characteristics

- Does it lead to a permanent reduction

in the ductility and fracture resistance of

steel?

- Effects if steel is loaded beyond plastic

limits

- ANSWERS ? Specific need for full-scale

testing.

Challenges ?

Page 34: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

How could it be assessed - 1?

• Perform visual inspection using NDT techniques

• Instrument to measure loads, offsets, strains and web movement

Page 35: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

How could it be assessed - 2?

Perform in-depth material testing of the bent zone, e.g.

Charpy V-notch test

Fracture sensitivity

Tensile strength Brinell hardness

Page 36: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

How could it be assessed – 3?

Property ASTM A709

Grade 345

ASTM A709

HPS 485W

Plate Thickness up to 5 cm (2 in.) up to 10 cm (4 in.)

Yield Strength 345 MPa (50 ksi) 485 MPa (70 ksi)

Tensile Strength min. 404 MPa

(min. 58 ksi)

620 – 758 MPa

(90 – 110 ksi)

Min. Elongation

5 cm (2 in.) 21% 19%

Toughness: CVN

Fracture Critical

Zone 3

35 m-N @ -12C

(25 ft-lbf @ 10F)

6.35 cm (to 2.5 in.)

47 m-N @ -23C

(35 ft-lbf @ -10F)

6.35 cm (to 4in.)

Check for compliance with AASHTO Requirements

Page 37: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Results of FHWA Tensile Tests on HPS 485W Specimens.

Wright W, Candra H, Albrecht P. “Fracture Toughness of A709 Grade HPD -485W Steel”. Draft FHWA Report, Washington, D.C, 2005.

HPS 485W

Page 38: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

How could it be assessed – 4?

3D Finite Element Modeling

Page 39: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Specifications

Develop criteria and specifications for consideration by AASHTO

Limits on strainLimits on applied loadLimits on minimum radius

Guidelines for localized damage repair Guidelines for inspection Fabrication aids

Page 40: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Acknowledgment Dr. Rajan Sen, PhD, PE, F.ASCE, Samuel and Julia Flom Professor,

University of South Florida, Tampa

Tampa Steel Erecting Company, Tampa, Florida

Page 41: Cold Bending Steel Beams: a State-of The-Art Engineering Solution that Meets Industry Challenges By: Antoine N. Gergess, PhD, PE, F.ASCE Professor, University.

Thank You!www.balamand.edu.lb